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31

Additional Modes 

PI-Speed
Controller

MOSFET
Power
Amplifier

EC-Motor

Armature
Position
Calculation

Phase A

Phase B
Phase C

Hall Sensor A
Hall Sensor B

Hall Sensor C

Speed
Calculation

I

2

t - Current

Limiting

R

S

GND

V7

Microcontroller

RS-232
Communication
and Configurations
Module

+ 24V DC

V6

U

B

PC TXD

PC RXD

GND

n

act

V2

V1

RXD

TXD

I

act

Position
Controller

RS-232
Interface

3 Phase
PWM
Sine Wave
Commutator

ϕ

h

(t)

n

com

∆ϕ

U

a

Protection:

Current Limit

Overtemperature

Overvoltage

Undervoltage

5V- Regulator

VCC

Signal GND

Evaluation
Input 3

Input 3

V8

M8

M7
M1

M2

M5

M6

M3

M4

brown

orange
yellow

green

blue

grey

red

black

+5V

V4

Fault
Output

V5

V3

Position
Calculation

10k

E

xam

ple:

Lim

it S

w

itch

REFIN

Evaluation
Limit Switch

Analog
Input
AGND

Encoder

VDD

ChA

ChB

2,7k

2,7k

Command
Position

ϕ

e

(t)

Diagram 11: External encoder a position and speed signal source

Command Function

Description

Example

ENCMOD*)

Encoder 

Switches to encoder mode. 

ENCMOD

Mode

Position is registered by an 
external encoder. 

HALLSPEED*) Hall Sensor as Speed registered by the 

HALLSPEED

Speed Sensor Hall Sensors.

ENCSPEED*) Encoder as 

Speed registered with an 

ENCSPEED

Speed Sensor encoder signal

ENCRES*)

Load Encoder  Loads the encoder resolution 

ENCRES

Resolution

to the motor. From 0 to 65535 

2048

(4 x Pulses/Revolution)

GENCRES

Get Encoder  Calls up current encoder resolution.GENCRES
Resolution

➔

2048

Default Setting: ENCRES2048

Important: 

Because four edges are measured for every pulse, the pulse
number programmed with the ENCRES command must be 
multiplied by four. That means, for example, that an encoder
with a resolution of 1024 pulses translates to 4096 “steps” per
revolution and maximum resolution can be given with the
command, ENCRES4096.

The maximum position, which
is set with the LL command,
can range 
from 0 to +2,000,000,000 
and in the negative, 
0 to –2,000,000,000.

Input:
Maximum Input Frequency:
150 kHz 
Level: low 0 ... 0.5 V / 

high 4 ... 30 V

Summary of Contents for MCDC2805 series

Page 1: ...Serie MCDC2805 Motion Controller with Sine Wave Commutation for EC Motors Series MCBL2805 Instruction Manual ...

Page 2: ...s 12 Changing the Baud Rate 12 Setting the Node Address 13 Choosing the Motor Type 13 Optional Motor Types and Parameters 14 Configuring the Velocity Control 15 Sources for Velocity 15 Fine Tuning the Digital Filter 19 Position Control 20 Standard Positioning Sequences 21 Combined Motion Profiles 21 Setting the Digital Filter 21 Evaluating the Homing Points and Limit Switch 22 Direct Programming w...

Page 3: ...play 33 The Error Output as a Digital Output 34 Pulse Output 35 Saving and Running Programs 36 Controlling a Program Sequence 37 More About Commands and Functions 38 Technical Information 40 Commutation with a Sine Wave 40 Current Controller and Current Limiting 40 Overtemperature Protection 41 Undervoltage Supervision 41 Overvoltage Protection 41 Appendix 42 Electromagnetic Compatability EMC 42 T...

Page 4: ...ications and to relieve the host PC Inputs and Outputs Command Value Input For inputing command speed values in digital or analog form This input can also interpret a reference mark signal Depending on the Mode a frequency signal or a incremental encoder can be connected at this input Fault Output Open Collector This output can also be programmed as a direction of rotation input a digital input or...

Page 5: ...put No 3 SUB D Connector No Function 2 RS 232 RXD 3 RS 232 TXD 5 GND Motor Side No Function Color M1 Phase C yellow M2 Hall Sensor A green M3 VCC 5V red M4 Signal GND black M5 Hall Sensor B blue M6 Hall Sensor C grey M7 Phase B orange M8 Phase A brown Connections Options FAULHABER offers the optional Multiplexer Board to operate multiple motion controllers from one RS 232 port To accomadate our cu...

Page 6: ...r Switched to GND Programmed as an input low 0 0 5 high 4 UB V Input No 3 Logic Level low 0 0 5 high 4 30 V Port RS 232 9600 1200 2400 4800 19200 Baud Memory for Programs Serial EEPROM 7936 Bytes Operating Temperature Range 0 70 C Storage Temperature Range 25 85 C Weight 110 g 1 Can be set over the RS 232 port Factory configuration Command Analog Velocity 2 Preset value Can be changed over the RS ...

Page 7: ...el B RS 232 Connections The RS 232 hardware cabling consists of the TXD RXD and Supply GND connectors The built in RS 232 port allows for a direct connection to the host PC Fault Output The system is outfitted with a fault output through which system errors are signalled Fault Output Characteristics Switch to ground open collector Output Resistance switched through low level 47 Ohms open high leve...

Page 8: ...rrent Controller and Current Limiting Page 40 When operating the MCBL2805 in one of the Additional Modes please read the corresponding chapters carefully In particular the folllowing Operating Mode Using an External Encoder to Measure Actual Position Interfacing the external encoder Command ENCRES Setting the Fault Output as an Input Use the command REFIN or DIRIN and then EEPSAV before a signal i...

Page 9: ...Wave Commutator ϕ t ncom ϕ Ua Protection Current Limit Overtemperature Overvoltage Undervoltage 5V Regulator VCC Signal GND Evaluation Input 3 Input 3 V8 M8 M7 M1 M2 M5 M6 M3 M4 brown orange yellow green blue grey red black 5V Analog Input AGND V5 V3 _ 10V GND The standard MCBL2805 is layed out as a Velocity Controller The command velocity is given as a voltage signal at the analog input In this o...

Page 10: ... due to the changes in voltage at the TXD connector The RS 232 port cannot be used Diagram 3 shows a more precise circuit but note the following The analog GND is separate from the supply GND The RS 232 is available Some Comments about the Input Circuit The input circuit at the analog input is layed out as a differential amplifier If the analog input is open there is already a voltage of 2 V That ...

Page 11: ...l time graphics generation for values like actual speed and position Building blocks of the ASCII Commands 1 Node Address option just necessary in a network 2 Command word a character string letters only 3 Number in many cases the command word is followed by a number 4 The conclusion is always a carriage return In a terminal program for example the enter or return key Example V 500 enter Switch to...

Page 12: ...p can be lost in the case of a loss of power during programming Comments about the command table Commands that are marked in the instruction manual with a will be saved with the EEPSAV command Diagram 4 The operation of the EEPROM Changing the Baud Rate The baud rate can be set to the following values 1200 2400 4800 9600 19200 Baud Command Function Description Example BAUD Select Baud Rate Sets th...

Page 13: ...y one motor may be connected at the time of addressing Otherwise multiple motors will receive the same node address Careful when hosting multiple motors If commands are sent without a node address all the motors in the network will receive the command If one calls up the status of a motor without entering the node address an error will occur because all the motors will attempt to answer at the sam...

Page 14: ...6 5 3000 480 5 2444S024B K1155 4 15 5000 1370 6 3056K012B K1155 6 10 7000 1940 7 3056K024B K1155 12 12 3000 930 8 3564K024B K1155 8 20 8000 2800 These parameters can be individually changed or reset to the default parameters of the individual motor with the command RN Important By setting the Motor Type other internal parameters will also be changed Therefore it is important when changing motor ty...

Page 15: ...ings apply to all modes GSP Get Maximum Calls up maximum speed GSP Speed 2500 Example SP5000 return The maximum velocity is set to 5000 rpm That means that 10 V at the Analog Input represents a command velocity of 5000 rpm Default Setting SP10000 Setting the Minimum Velocity The lowest possible velocity at minimum analog voltage can be set Command Function Description Example MV Minimum Sets the m...

Page 16: ...necessary minimum starting voltage The motor will not turn if the voltage ranges from 99 mV to 99 mV Default Setting MAV25 Advantages While 0 mV at the analog input is normally very difficult to achieve 0 rpm can not be accurately set Setting the minimal analog voltage 0 prevents this from being a problem The resulting dead zone is also useful because the motor will not start up when small disturb...

Page 17: ...50 Rotation Right Pulse Duty Ratio 50 Rotation Stop Pulse Duty Ratio 50 Rotation Left The commands SP MV MAV ADL and ADR can also be used in this mode c Command Velocity at the RS 232 Port Command Function Description Example V Select Activates velocity control mode V2000 Velocity and rotates with the given value Mode GV Get Velocity Calls up the command velocity GV 500 Directly following the SOR0...

Page 18: ... Description Example DIRIN Direction Sets the fault output to function DIRIN Input as a direction of rotation input activates the limiter switch function Level and Direction Low 0 to 0 5 V Rotation Left High 4 to Supply Voltage Rotation Right The logic level at the direction of rotation input is dominant to changes made with the ADR and ADL commands When the Fault Output is used as a Direction of ...

Page 19: ...er Velocity jumps from 2 3 to 1 3 the Maximum Application Speed only an example value 5 Repeat steps 2 4 until the controller becomes unstable Then reduce the Proportional Term until the stabilty is achieved 6 Repeat steps 2 5 with the Integral Term Fine Tuning the Digital Filter The digital filter parameters can be adjusted to improve the dynamic performance These parameters should be carefully c...

Page 20: ...tch at the analog input The following Command Sequence is necessary to switch from Speed Control Mode factory setting to Positioning Mode SOR0 enter Switches to RS 232 Communication in Speed Control Mode LR0 enter Load Relative Position 0 M enter Switches to Positioning Mode Positioning commands Command Function Description Example M Initiate Motion Activates positioning mode and starts positionin...

Page 21: ... other positions one after the other Combined Motion Profiles Through well chosen values Maximum Velocity Acceleration end Position entered during a positioning sequence one can create complex motion profiles After any values have been changed during a positioning sequence a new motion start the M command must be initiated The commands NP notify position and NV notify velocity can be used to aid i...

Page 22: ... of that input A 0 deactivates that input Example HA0 Deactivate Home Arming at all Limit Switches HA1 Activate Home Arming at Analog Input deactivate all others HA2 Activate Home Arming at the Fault Pin deactivate all others HA3 Activate Home Arming at both the Fault Pin and the Analog Input HA4 Activate Home Arming at Input 3 HA5 Activate Home Arming at Input 3 and the Analog Input HA6 Activate ...

Page 23: ...n trigger edge is triggered The programming can be changed with a new command before triggering at an edge In the event of a power loss the HA HL and HN programming is erased and all limit switches are inactive Command Function Description Example HA Home When edge triggers the position is set to 0 HA1 Arming 1 activate 0 deactivate HL Hard When edge triggers the motor stops HL3 Limit 1 activate 0...

Page 24: ...her configuration commands if necessary 5 Save the commands to the EEPROM with the EEPSAV command The commands in the intermediate memory will be tranferred as well To make changes in the Homing Sequence repeat steps 1 5 with the new values POHOSEQ0 Power On Homing Sequence Inactive deactivates the Homing Sequence in the event of POWER ON Save the settings to the EEPROM with the EEPSAV command Com...

Page 25: ...s or deactivates hard HB3 blocking at a given limit switch 1 activate 0 deactivate HD Hard Direction Sets which direction will be HD2 blocked 1 Blocked right 0 Blocked left The logic level high low of the limit switch is set with the HP command The hard blocking function can be simultaneously active with the other limit switch commands Hall Indexing Sequence The motor will run to the Hall Zero Poi...

Page 26: ...C Motor Armature Position Calculation Phase A Phase B Phase C Hall Sensor A Hall Sensor B Hall Sensor C Speed Calculation I 2 t Current Limiting RS GND V7 Microcontroller RS 232 Communication and Configurations Module 24V DC V6 UB PC TXD PC RXD GND nact V2 V1 RXD TXD Iact Position Controller RS 232 Interface 3 Phase PWM Sine Wave Commutator ϕ t ncom ϕ Ua Protection Current Limit Overtemperature Ov...

Page 27: ... at the frequency input STN step number number of steps per revolution STN and STW range 0 to 65535 Command Function Description Example STEPMOD Stepper Switches to STEPMOD Motor Stepper Motor Mode Mode STW Load Step Sends the step STW1 Width width to the motor STN Load Step Loads the number STN1000 Number of steps per revolution GSTW Get Step Calls up the GSTW Width current step width 1 GSTN Get ...

Page 28: ...2 M5 M6 M3 M4 brown orange yellow green blue grey red black 5V V4 Fault Output V5 V3 Command Position Calculation 10k Example Limit Switch REFIN Evaluation Limit Switch Analog Input AGND Encoder VDD ChA ChB 2 7k 2 7k Diagram 9 Gearing Mode with a reference point at the Fault Pin The reduction ratio is calculated just as in Stepper Motor Mode Command Function Description Example GEARMOD Gearing Mod...

Page 29: ...ignal GND Evaluation Input 3 Input 3 V8 M8 M7 M1 M2 M5 M6 M3 M4 brown orange yellow green blue grey red black 5V V4 Fault Output V5 V3 Command Position Calculation 10k Example Limit Switch REFIN Evaluation Limit Switch Analog Input AGND _ GND 10V Diagram 10 Position control with an analog voltage Command Function Description Example APCMOD Analog Position Switches to analog APCMOD Control Mode pos...

Page 30: ... the armature has only moved within one revolution With the following commands it is possible to position the motor inside one revolution with a voltage ranging from 0 10 V even after the power has been turned off and then on again Using an External Encoder to Measure Actual Position A processed signal from an external encoder can be used to precisely measure actual position The positioning resolu...

Page 31: ...ource Command Function Description Example ENCMOD Encoder Switches to encoder mode ENCMOD Mode Position is registered by an external encoder HALLSPEED Hall Sensor as Speed registered by the HALLSPEED Speed Sensor Hall Sensors ENCSPEED Encoder as Speed registered with an ENCSPEED Speed Sensor encoder signal ENCRES Load Encoder Loads the encoder resolution ENCRES Resolution to the motor From 0 to 65...

Page 32: ... motor than functions as a power amplifier It is important to keep in mind that the sampling frequency of the regulator is 1 866 ms and the resolution at the analog input is 10 Bit Voltage Regulator Mode The controller can be configured with the VOLTMOD command to serve as a voltage regulator The motor voltage is proportional to the input voltage at the analog input The current limiting remains ac...

Page 33: ...grammed GDEV degree of deviation 200 Default Setting DEV30000 This degree of deviation cannot possibly be reached It represents the deactivation of deviation error display The standard error functions and the way that these errors can be rectified are described in detail in the chapter Technical Information Aside from these error functions which serve mainly to protect the motor from being dama ge...

Page 34: ...Clear Output Sets digital output to logic CO level LOW SO Set Output Sets digital output to logic SO level HIGH The last setting will be saved with the EEPSAV command Command Function Description Example DCE Delayed Current Delayed activation of the DCE100 Error error display for current limiting over voltage protection and deviation error Given in 1 100th seconds GDCE Get Delayed Calls up the del...

Page 35: ...ecause the output has only one channel the direction of rotation cannot be registered Command Function Description Example LPN Load Pulse Number Sets pulse number LPN16 with a range of 1 to 255 GPN Get Pulse Number Calls up current GPN number of pulses 16 ERROUT Error Output Switches to ERROUT Fault Output Mode ENCOUT Encoder Output Switches to ENCOUT Pulse Output Mode Example LPN64 Sets 64 pulses...

Page 36: ... command END defines the end of the program All commands given after the END will be immediately carried out by the controller GPROGSEQ Get Program Calls up the program sequence GPROGSEQ Sequence at the host PC Program ENPROG Enable Starts the program This ENPROG Program command can also be saved with the EEPSAV command and the program will then run directly after turning the power to the controll...

Page 37: ...TIMEOUT5 commands are being carried out and then the asynch o sequence will continue Arguement 1 100th of a second Range 0 to 65535 An answer of o at the RS 232 host means that the notify requirements were not met The command can also be programmed with the RS 232 JMP Jump Jumps to a given address The command JMP5 can also be programmed with the RS 232 JPH Jump if Hard Input Jump to a given addres...

Page 38: ... jump command can also be used while connected at the RS 232 port This becomes useful when different programs are to be called up on the computer Example PROGSEQ A1 JMP1 continuous loop A2 Program sequence 2 can only be called up with the JMP2 command at the RS 232 LA10000 NP M JMP1 jumps back to continuous loop A3 Program sequence 3 can only be called up with the JMP3 command at the RS 232 LA 100...

Page 39: ...n reached In order to be able to use the GOHOSEQ command effectively during a program the HN command must be set correctly in the Homing Sequence This is especially important when a Power On Homing sequence is to be run POHOSEQ1 About the Notify Commands With the Notify commands it is possible to create very complex motion profiles Example LA10000 SP5000 AC50 NV1000 M AC100 NV2000 M AC50 NP M The ...

Page 40: ...he peak to the continuous current value Time I TModel Tcritical Several Loads Imax Icont Time IMotor ILimit Diagram 12 The I2t current limiting Operating Mode of the Current Controller When the power is turned on to the motor the current controller sends the value for peak current as the command current value With increasing load the current will increase until the peak current has been reached Th...

Page 41: ...The command velocity must be set to 0 The actual motor speed must be lower than 50 rpm About Measuring the Temperature of the MOSFET The temperature of the Motion Controller is measured on the casing and compared to the measured current value to calculate the power loss With the help of a thermal model the controller calculates the MOSFET temperature In most cases this method performs as over temp...

Page 42: ...kV through air according to VDE 0847 part 4 2 EN61000 4 2 HF fields according to VDE 0847 part 4 3 EN61000 4 3 Fast transients according to VDE 0847 part 4 4 EN61000 4 4 Cable bourne HF currents according to VDE 0847 part 4 6 EN61000 4 6 The forementioned requirements are met when the following conditions are fulfilled Operation according to the instruction manual and given system data The supply ...

Page 43: ... up to 255 motors It is also possible to chain the 3564K024B C with other Faulhaber motion controllers for example the MCDC2805 and the MCBL2805 It is important to remember that when controlling multiple motors from one host a strict master slave structure must be applied That means that the host PC sends the commands to the motors and motors only answer when called Therefore asynchronus answers m...

Page 44: ...wer limit APL Activate Deactivate APL1 Activate position limits even while in APL1 Position Limits speed control and stepper motor mode APL0 Deactivate Limits default GPL Get Positve Limit Calls up the upper positioning limit at the RS 232 GPL 60000000 GNL Get Negative Limit Calls up the lower positioning limit at the RS 232 GNL 30000000 RN Reset Node Resets the parameter at the node address to th...

Page 45: ...t NVOFF Notify Velocity Off Deactivates a given Notify Velocity Command NVOFF that has not yet been carried out Commands for Velocity Control Command Function Description Example MV Minimum Velocity Sets the minimum speed in rpm MV100 GMV Get Minimum Velocity Calls up the minimum velocity on the host terminal GMV 0 MAV Minimum Analog Sets the minimum analog voltage MAV500 Voltage GMAV Get Minimum ...

Page 46: ...nce to the intermediate CAHOSEQ Sequence memory Actions that are defined with the HL HN and HA commands will be saved POHOSEQ Power On Homing Activate the homing sequence upon turning POHOSEQ1 Sequence the motor on 1 activate 0 deactivate GOHOSEQ Go Homing Executes the programmed homing sequence GOHOSEQ Sequence without regard to the current mode HOSP Load Homing Speed Loads the homing speed HOSP1...

Page 47: ...Maximum Loads a new maximum velocity SP4000 Speed Arguement in rpm Range 0 to 30000 For use in all modes GSP Get Maximum Speed Calls up actual maximum velocity GSP 10000 AC Load Command Load new acceleration AC100 Acceleration Arguement in Rev s2 Range 0 to 30000 GAC Get Acceleration Calls up acceleration GAC 500 POR Load Proportional Load controller amplification Range 0 to 255 POR8 Term GPOR Get...

Page 48: ...trol ENCMOD Encoder Mode Switches to encoder mode Uses external ENCMOD encoder for actual position Upon switching the position is automatically set to 0 HALLSPEED Hall Sensor as Actual speed is given by the Hall Sensors HALLSPEED Speed Sensor ENCSPEED Encoder as Actual speed is given by the external encoder ENCSPEED Speed Sensor ENCRES Load Encoder Sends the encoder resolution to the motor ENCRES5...

Page 49: ...in 1 100th seconds GDCE Get Delayed Calls up the delayed current error value GDCE Current Error 200 DEV Load Deviation Loads the allowable degree of deviation of the actual DEV500 to the command speed value GDEV Get Deviation Calls up the programmed degree of deviation GDEV 200 Commands for Programming Sequences Command Function Description Example PROGSEQ Program Sequence Defines the beginning of...

Page 50: ...elocity given at the RS 232 Bit 2 1 Velocity is PWM Bit1 1 0 Velocity is analog Bit1 1 Bit 3 1 Drive enabled 0 Drive disabled Bit 4 1 Command position has been reached 0 Command position has not yet been reached Bit 5 1 Positive edge at limit switch is active 0 Negative edge at limit switch is active Bit 6 1 Limit switch set to high level 0 Limit switch set to low level GFS Get Fault Status Calls ...

Page 51: ...lt pin is limiter switch input 2 Bit1 0 Fault pin is not a digital output Bit 4 1 Rising edge at limit switch 2 is active 0 Falling edge at limit switch 2 is active Bit 5 1 Rising edge at limit switch 3 is active 0 Falling edge at limit switch 3 is active Bit 6 1 Program sequence is active 0 Program sequence is inactive Bit 7 1 Automatic answering is active 0 Automatic answering is inactive GES Ge...

Page 52: ...0 SP5000 POR30 I15 EEPSAV Saves configuration in EEPROM Velocity Control Command value received at the RS 232 port Goals Velocity control at the RS 232 port Two active limiter switches high level active cannot be passed Set peak current to 3 A ASCII Command form SOR0 REFIN Defines the fault pin as a limiter switch input HP3 Both limiter switches are set to high level HB3 Both limiter switches are ...

Page 53: ...volution 557 Active Power On Homing Sequence with the fault pin as reference input Reference point at falling edge Homing sequence runs with direction of rotation left and 300 rpm ASCII Commands STEPMOD STW3 STN557 REFIN Programs fault pin as the reference input HA2 When edge triggers at limiter switch 2 set the position to 0 HL2 When edge triggers at limiter switch 2 the motor stops CAHOSEQ Progr...

Page 54: ...equence 1000 times 10 revolutions forward 1 second pause 5 revolutions backward than 0 5 second pause Configuration SOR0 Switches to receive command speed at the RS 232 LR0 Motion stop M Switches to position control no motion HA1 HL1 Analog input is limiter switch HN1 CAHOSEQ Saves homing sequence in the intermediate memory HOSP200 Loads homing speed HP1 Rising edge is trigger edge ENPROG Run prog...

Page 55: ... is still high after 5 revolutions then the motor should run to position 0 Configuration SOR0 Switches to speed control over the RS 232 LR0 No motion M Switches to position control REFIN Reprograms fault output as an input HA1 HL1 Analog input is limiter switch HN1 CAHOSEQ Saves homing sequence to the intermediate memory POHOSEQ1 Activates power on homing sequence A4 Jump in address for sequence 2...

Page 56: ...P1 Logic level low is registered at input 2 Fault Pin Input A3 JPF3 Continuous loop until logic level is high at input 2 evaluation of the positive edge LR5000 NP M 5 revolutions forward DELAY50 0 5 second delay then evaluate input 2 JPF1 When low logic is registered at input 2 jump to the beginning of the program LA0 NP0 M Run to position 0 if high logic level at input 2 JMP1 Jump to the beginnin...

Page 57: ...ocked at all limit switches HA0 HL0 HN0 CAHOSEQ Deavctivate homing sequence POHOSEQ0 Power on homing sequence is deactivated HOSP100 Homing speed is 100 with direction of rotation right ANSW1 Asynchronus answering is active DIPROG Program will not start when power is turned on BAUD9600 Baud rate is 9600 NODEADR0 Sets node address to 0 MOTTYP5 Sets to the 2444S024B K1155 motor RN Represents the fol...

Page 58: ...58 Notes ...

Page 59: ...59 Notes ...

Page 60: ...ebssysteme Daimlerstraße 23 71101 Schönaich Germany Tel 49 0 70 31 638 0 Fax 49 0 70 31 638 100 info faulhaber de www faulhaber de From Software Version 305010A and upwards DR FRITZ FAULHABER GMBH CO KG MA05002 english 1 Edition 13 06 01 ...

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