Faulhaber MC 5004 Bedienungsanleitung
WE CREATE MOTION
Technical Manual
MC 5004
EN
Imprint
2
Version:
6th edition, 22.05.2023
Copyright
by Dr. Fritz Faulhaber GmbH & Co. KG
Faulhaberstraße 1 · 71101 Schönaich
All rights reserved, including those to the translation.
No part of this description may be duplicated, reproduced,
stored in an information system or processed or
transferred in any other form without prior express written
permission of Dr. Fritz Faulhaber GmbH & Co. KG.
This document has been prepared with care.
Dr. Fritz Faulhaber GmbH & Co. KG cannot accept any
liability for any errors in this document or for the
consequences of such errors. Equally, no liability can be
accepted for direct or consequential damages resulting
from improper use of the equipment.
The relevant regulations regarding safety engineering
and interference suppression as well as the requirements
specified in this document are to be noted and followed
when using the software.
Subject to change without notice.
The respective current version of this technical manual is
available on FAULHABER's internet site:
www.faulhaber.com
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Content
3
1 About this document ....................................................................................................... 5
1.1 Validity of this document ...................................................................................... 5
1.2 Associated documents ............................................................................................ 5
1.3 Using this document .............................................................................................. 5
1.4 List of abbreviations ............................................................................................... 6
1.5 Symbols and designations ...................................................................................... 7
2 Safety ................................................................................................................................ 8
2.1 Intended use ........................................................................................................... 8
2.2 Safety instructions .................................................................................................. 9
2.2.1 Dangers in the event of damages and changes.................................... 9
2.2.2 Correct installation and commissioning ................................................ 9
2.2.3 Heat development ................................................................................ 10
2.3 Environmental conditions .................................................................................... 10
2.4 EC directives on product safety ........................................................................... 11
3 Product description ........................................................................................................ 12
3.1 General product description ................................................................................ 12
3.2 Product information ............................................................................................. 13
3.3 Product variants .................................................................................................... 14
3.3.1 Controller PCBs...................................................................................... 14
3.3.1.1 Standard PCB.......................................................................... 14
3.3.1.2 PCB with vertical plug connector (option 5621) .................. 15
3.3.1.3 EtherCAT PCB ......................................................................... 16
3.3.2 Motherboard......................................................................................... 17
4 Installation ...................................................................................................................... 21
4.1 Mounting .............................................................................................................. 21
4.1.1 Mounting instructions .......................................................................... 21
4.1.2 Installation of Motion Controller PCBs................................................ 22
4.2 Electrical connection ............................................................................................ 23
4.2.1 Notes on the electrical connection ...................................................... 23
4.2.2 Drive connections.................................................................................. 24
4.2.3 Connection of the power supply ......................................................... 24
4.2.3.1 Power supply.......................................................................... 25
4.2.4 Connector pin assignment.................................................................... 25
4.2.4.1 Pin assignment of the Motion Controller connector strip .. 25
4.2.4.2 Pin assignment of the motherboard (motor side) ............... 27
4.2.4.3 Pin assignment of the motherboard (supply side)............... 32
4.2.5 Motherboard: connection at the motor side ...................................... 34
4.2.6 I/O circuit diagrams ............................................................................... 38
4.2.7 External circuit diagrams ...................................................................... 39
4.3 Electromagnetic compatibility (EMC) .................................................................. 43
4.3.1 Considered systems ............................................................................... 43
4.3.2 Functional earthing .............................................................................. 45
4.3.3 Cable routing ........................................................................................ 46
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Content
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4.3.4 Shielding................................................................................................ 47
4.3.4.1 Establishing the shield connection ....................................... 48
4.3.4.2 Establishing shield connection with cable lug ..................... 49
4.3.5 Sensor and encoder interfaces ............................................................. 50
4.3.5.1 Analog sensors and analog Hall sensors .............................. 51
4.3.5.2 Incremental encoders / Digital Hall sensors / Digital sensors 51
4.3.5.3 Encoders with absolute interface ......................................... 51
4.3.6 Using filters ........................................................................................... 52
4.3.6.1 Installing the Motion Controller PCB in the top-hat-rail
housing................................................................................... 53
4.3.6.2 PWM filter (motor-side) ........................................................ 54
4.3.6.3 Emission-reducing, ferrite-based filters (motor side) .......... 54
4.3.6.4 Input-side filters..................................................................... 54
4.3.6.5 Insulation resistance .............................................................. 54
4.3.6.6 Coiling ferrite ring ................................................................. 55
4.3.7 Error avoidance and troubleshooting ................................................. 56
5 Maintenance and diagnostics ........................................................................................ 58
5.1 Maintenance tasks ................................................................................................ 58
5.2 Diagnosis ............................................................................................................... 58
5.3 Troubleshooting ................................................................................................... 60
6 Accessories ...................................................................................................................... 61
7 Warranty ......................................................................................................................... 62
8 Additional documents .................................................................................................... 63
8.1 Declaration of Conformity ................................................................................... 63
8.2 Declaration of Incorporation ............................................................................... 65
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About this document
5
1 About this document
1.1 Validity of this document
This document describes the installation and use of the MC 5004 series.
This document is intended for use by trained experts authorized to perform installation and
electrical connection of the product.
All data in this document relate to the standard versions of the series listed above. Changes
relating to customer-specific versions can be found in the corresponding data sheet.
1.2 Associated documents
For certain actions during commissioning and operation of FAULHABER products additional
information from the following manuals is useful:
These manuals can be downloaded in pdf format from the web page www.faulhaber.com/
manuals.
1.3 Using this document
Read the document carefully before undertaking configuration, in particular chapter
“Safety”.
Retain the document throughout the entire working life of the product.
Keep the document accessible to the operating and, if necessary, maintenance person-
nel at all times.
Pass the document on to any subsequent owner or user of the product.
Manual Description
Motion Manager 6 Operating instructions for FAULHABER Motion Manager PC software
Quick start guide Description of the first steps for commissioning and operation of FAULHABER Motion
Controllers
Drive functions Description of the operating modes and functions of the drive
Accessories manual Description of the accessories
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About this document
6
1.4 List of abbreviations
Abbreviation Meaning
AC Alternating Current
AES Absolute encoder
AGND Analog Ground
AnIn Analog input
CAN Controller Area Network
CAN_L CAN-Low
CAN_H CAN-High
CLK Clock
CLK Clock with logically inverted signal
CS Chip Select
CS Chip Select
Data Data cable
Data Data cable with logically inverted signal
DigIn Digital input
DigOut Digital output
DIP Dual In-Line Package
EFC Electronics Filter Conformity
EFM Electronics Filter Motor
EFS Electronics Filter Supply
EMC Electromagnetic compatibility
ESD Electrostatic discharge
ET EtherCAT (Ethernet for Control Automation Technology)
GND Ground
I/O Input/Output
LA Status LED EtherCAT
MC Motion Controller
Mot Motor
n.c. not connected
PWM Pulse Width Modulation
RxD Receive Data
SGND Signal ground
TxD Transmit data
UDD Power supply
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About this document
7
1.5 Symbols and designations
DANGER!
!
Danger with high level of risk: if not avoided, death or serious injury will result.
Measures for avoidance
WARNING!
!
Danger with medium level of risk: if not avoided, death or serious injury may result.
Measures for avoidance
CAUTION!
!
Danger with low level of risk: if not avoided, minor or moderate injury may result.
Measures for avoidance
NOTICE!
Risk of damage.
Measures for avoidance
Pre-requirement for a requested action
1. First step for a requested action
Result of a step
2. Second step of a requested action
Result of an action
Request for a single-step action
Instructions for understanding or optimizing the operational procedures
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Safety
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2 Safety
2.1 Intended use
The Motion Controllers described here are designed for use as slaves for control and posi-
tioning tasks for the following motors:
DC-Micromotors
Linear DC-Servomotors
Brushless DC-motors
The Motion Controller is suitable in particular for tasks in the following fields of applica-
tion:
Robotics
Toolbuilding
Automation technology
Industrial equipment and special machine building
Medical technology
Laboratory technology
When using the Motion Controllers the following aspects should be observed:
The Motion Controller contains electronic components and should be handled in
accordance with the ESD regulations.
Do not use the Motion Controller in environments where it will come into contact with
water, chemicals and/or dust, nor in explosion hazard areas.
The Motion Controller is not suitable for use in combination with stepper motors.
The Motion Controller should be operated only within the limits specified in the data
sheet.
Please ask the manufacturer for information about use under individual special
environmental conditions.
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Safety
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2.2 Safety instructions
In addition to the safety risks described in this technical manual, machine-specific dangers
could arise that cannot be foreseen by the manufacturer of the Motion Controller (e.g., risk
of injury from driven components). The manufacturer of the machine in which the Motion
Controller is installed must perform a risk analysis in accordance with the regulations appli-
cable to the machine and inform the end user of the residual risks.
2.2.1 Dangers in the event of damages and changes
Damage to the Motion Controller can impair its functions. A damaged Motion Controller
can unexpectedly start, stop or jam. This can result in damage to other components and
materials.
Do not start up a drive system with a defective or damaged Motion Controller.
Appropriately mark a defective or damaged Motion Controller.
Do not replace defective or damaged components of the Motion Controller.
Make no changes (modifications, repairs) to the Motion Controller.
Have loose or defective connections immediately replaced by an electrician.
After replacing a defective or damaged Motion Controller, test and document the cor-
rect function.
2.2.2 Correct installation and commissioning
Errors during the installation and commissioning of the Motion Controller could impair its
function. An incorrectly installed Motion Controller can unexpectedly start, stop or jam.
This can result in damage to other components and materials.
Follow the instructions for installation and commissioning given in these installation
instructions exactly.
Only have work on electrical operating equipment performed by an electrician.
During all work on the electrical equipment, observe the 5 safety rules:
a) Disconnect from power
b) Secure against being switched on again
c) Check that no voltage is present
d) Ground and short-circuit
e) Cover or block-off adjacent parts that are under voltage
Electrostatic discharges can damage the electronics.
Store and transport the Motion Controller in suitable ESD packaging.
Handle the Motion Controller in compliance with the ESD handling regulations (e.g.
wear an ESD wristband, ground surrounding components).
During installation, ensure that components in the surroundings cannot be electrostati-
cally discharged.
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Safety
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Soiling, foreign bodies, humidity and mechanical influences can damage the electronics.
Keep foreign objects away from the electronics.
Install the Motion Controller in a housing that protects it from mechanical influences
and is adapted to the ambient conditions (protection class determination).
Installation and connection work whilst supply voltage is applied at the device can dam-
age the electronics.
Do not insert or withdraw connectors whilst supply voltage is applied at the Motion
Controller.
During all aspects of installation and connection work on the Motion Controller, switch
off the power supply.
Incorrect connection of the pins can damage the electronic components.
Connect the wires as shown in the connection assignment.
2.2.3 Heat development
Active components may cause the Motion Controller to heat up. If touched, there is a risk
of burning.
Protect the Motion Controller against being touched and cool sufficiently.
If necessary, affix a suitable warning sign in the immediate vicinity of the controller.
Fig. 1: Suitable warning sign acc. to DIN EN ISO 7010
2.3 Environmental conditions
Select the installation location so that clean dry air is available for cooling the Motion
Controller.
Select the installation location so that the air has unobstructed access to flow around
the drive.
When installed within housings and cabinets take particular care to ensure adequate
cooling of the Motion Controller.
Select a power supply that is within the defined tolerance range.
Protect the Motion Controller against heavy deposits of dust, in particular metal dust
and chemical pollutants.
Protect the Motion Controller against humidity and wet.
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