Faulhaber MCDC2805 series Bedienungsanleitung
Serie MCDC2805
Motion Controller with
Sine Wave Commutation for EC-Motors
Series MCBL2805
Instruction Manual
1
Table of Contents
2
General Information 4
Data Sheet 6
Cables and Connections 7
First Steps 8
Analog Velocity Control 9
Simple Possibilities to Set Command Velocity with a Potentiometer 10
RS-232 Port and the ASCII Commands 11
Default Configuration of the RS-232 Port 11
The ASCII Commands 11
Saving Configurations 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 with the HA, HL, and HN Commands 23
Programmable Homing Sequence 24
Hard Blocking Function 25
Hall Indexing Sequence 25
3
Additional Modes 26
Stepper Motor Mode 26
Gearing Mode 28
Position Control with a Voltage at the Analog Input 29
Using an External Encoder to Measure Actual Position 30
Voltage Regulator Mode 32
Handling Errors and the Error Output 33
Show Deviation from Command Speed as Error 33
Delayed Activation of the Error Display 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
The RS-232 Multiplexer Board 43
The ASCII Command Set 44
Example Configurations and Programs 52
Factory Configuration 57
General Information
4
The MCBL2805 was designed for Faulhaber
brushless motors with linear hall sensors. This
means that, even without an external encoder,
low speed and positioning with a resolution up
to 1/1000th of a revolution are possible. The
motion controller is based on a powerful 16-bit
microcontroller with excellent filtering quality.
This intelligent motion controller performs the
following tasks:
■Velocity Control: High performance speed
synchronization and the lowest possible
torque variance even in the most demanding
of applications. A PI-Controller makes sure
that the command velocity is accurately
achieved.
■
Velocity Profiles: Ramping, triangle, trapezoidal
and more complicated combined velocity
profiles are available to the user.
■Positioning Mode: Positioning with high
resolution including limit switches and zero
referencing.
■Additional Modes: For example, Stepper
Motor Mode to synchronize multiple motors.
■Torque Controlling: Achieved through current
regulation.
■Saving and Running Program Sequences: For
stand-alone positioning applications 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 reference mark input.
■Third digital input
■RS-232 Ports: For connecting a host PC and
controlling program sequences.
Setting the Parameters and
Configurations
All filter settings can be set over the RS-232 port
and saved to the onboard memory (EEPROM).
Configuration settings (operating modes,
in/outputs, etc.) can likewise be saved.
Therefore, depending on the operating mode,
the motion controllers can function fully in
stand-alone applications.
Programming
A complete ASCII command set is available for
programming and operating the motion con-
trollers. All that is necessary is a terminal pro-
gram such as the Windows Hyperterminal.
The “FAULHABER Motion Manager” program is
available for users of Windows 95/98/NT. This
program makes configuration and operation
easy and allows the user to perform an online
graphic analysis of the performance of the drive.
5
General Information
Area of Application
Ease of installation, integrated technology,
compatability, size, stand-alone capability and
the numerous connection possibilities allow this
motion controller to perform to the highest
standards in a wide range of applications, for
example in decentralized automated production
systems like handling or tooling machines.
Supply Side:
No. Function
V1 RS-232 TXD
V2 RS-232 RXD
V3 Analog GND
V4 Fault Output
V5 Analog Input
V6 +24V
V7 GND
V8 Input 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 customers specialized
needs we offer factory preconfiguring of
Modes and Parameters to fit the application.
■The “FAULHABER Motion Mananger” is
available for download from the internet at
www.faulhaber.de or upon request.
■The adapters allow for simple attatchment to
mounting railings.
Data Sheet
6
General Specifications
Supply Voltage UB12 ... 28 V DC
PWM Switching Frequency fPWM 31,25 kHz
Efficiency 95 %
Max. Continuous Current Icont 5A
Max. Peak Current Imax 10 A
Current Consumption in the Electronics Iel 0,06 A
Velocity Range 10 ... 15000 rpm
Out put Voltage for External Use VCC 5 V DC
– Max. Load Current ICC 60 mA
Input No. 11) Input Resistance 18 kΩ
Command Analog Velocity Voltage Signal ± 10 V
Slope of the Curve 10002)rpm/V
Command Digital Velocity PWM Signal low 0 ... 0,5 / high 4 ... 30 V
Frequency Range 100 ... 2000 Hz
Pulse Duty Ratio 50% 0 rpm
Pulse Duty Ratio <50% left turning
Pulse Duty Ration >50% right turning
External Encoder / Step Frequency fmax 150 kHz
Fault Output (Input No. 2) Open collector max. UB/ 30 mA
No Error Switched to GND
Programmed as an input low 0...0,5 / high 4...UBV
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-232 port.
Ordering Infomation:
The Motion Controllers were developed for and function only with the following motors:
1628T012B K1155 1628T024B K1155
2036U012B K1155 2036U024B K1155
2444S024B K1155 3056K012B K1155
3056K024B K1155 3564K024B K1155
The data sheets for the standard versions of these motors can be found in the catalog or the internet.
The code K1155 means that these motors have been fitted with linear Hall sensors to function with the MCBL2805
Note that the no load speed decreases to 80% of the standard version
Cables and Connections
7
Power Supply Requirements
The power supply should deliver at least 5 A.
It is important to be careful and connect the
controller with the correct polarity. Incorrect
polarity will damage the protection fuse and
it can only be replaced at the factory.
Analog Input (Analog Input,
Analog GND = AGND)
The analog input is a differential input.
The analog-GND should be connected to the
supply-GND. This avoids the effects of the
voltage drop in the supply leads on the given
speed value.
The analog input has, according to
configuration, various applications:
■Velocity control with a voltage over the
analog input (factory-installed setting)
■Velocity control with PWM through the
analog input
■Zero-Referencing (Limit Switch) when used
as a motion controller
■Input for the external encoder in Encoder
Mode (Analog input to ground: Channel A /
Analog-GND to ground: Channel 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 level): 10 kOhms
■In the case of a system error, the switch is
open (the LED is not lit.)
■Output current maximum 30 mA, voltage in
open condition may not exceed supply
voltage
The fault output is activated as a result of the
following situations:
■Dynamic current limiting active
■Low voltage (by voltage under 10 V)
■Overvoltage protection active
(by supply voltage over 32 V)
■Overtemperature protection active
The fault output port can also be configured to
perform other functions:
■Pulse output
■Digital output
■Limit switch input
■Direction of rotation input
Input No. 3
The third input is a digtal input and can be used
to evaluate homing points or as a control input
for program sequences.
First Steps
8
Upon delivery the MCBL2805 is configured for
the motor type 5 (2444S024B K1155).
Important: For successful operation of the
motion controller with the motor of choice
please read the following chapters carefully:
■Choosing the Motor Type (Page 13)
■Fine Tuning the Digital Filter
(Page 19)
■Current 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 is interfaced with the Fault-
Pin.
If these First Steps are ignored it can lead to
component damage.
Analog Velocity Control
9
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
It - Current
Limiting
RS
GND
V7
Microcontroller
RS- 3
Communication
and Configurations
Module
+ 4V DC
V6
UB
,7k
LED
V4
Fault
Output
PC TXD
PC RXD
GND
nact
V
V1
RXD
TXD
Iact
RS- 3
Interface
3 Phase
PWM
Sine Wave
Commutator
ϕ(t)
ncom
∆ϕ
Ua
Protection:
Current Limit
Overtemperature
Overvoltage
Undervoltage
5V-Regulator VCC
Signal GND
Evaluation
Input 3
Input 3V8
M8
M7
M1
M
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 operating mode the
RS-232 is not required but can
be used to alter configurations.
More on the topic of “Altering
Configurations” to come.
Diagram 1:
Velocity control with command velocity from the analog input.
Analog Velocity Control
10
Simple Possibilities to Set Command Velocity with a Potentiometer
M
GND
V7
+ 4V DC
V6
UB
,7k
LED
V4
V
V1
RXD
TXD
+
_
Analog
Input
AGND
V5
V3
ncom
10k
10k
M
GND
V7
+ 4V DC
V6
UB
,7k
LED
V4
V
V1
RXD
TXD
+
_
Analog
Input
AGND
V5
V3
ncom
1k
10k
0V
4,7k
4,7k
Diagram 2 shows the simplest possibility, but
note the following:
■The command velocity depends on the supply
voltage.
■The command velocity is not very accurate
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
means in this case that the motor would be
turning at a speed of about 2000 rpm. In order
to set 0 rpm the input must be connected over a
low ohm resistor to the analog ground (AGND)
or connected to the AGND-voltage level.
Diagram 2 Diagram 3
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