Danaher Motion Standalone MMC User manual

Standalone MMCTM
Hardware Manual
Version 15.1
Keep all product manuals as a
product component during the life
span of the product.
Pass all product manuals to future
users/owners of the product.
Catalog No. M.1300.7620
Part No. M.3000.0451
Danaher Motion
IND. CONT. EQ.
89X2

Record of Revisions
Third party brands and trademarks are the property of their respective owners
Technical changes to improve the performance of the equipment may be made without notice!
Printed in USA
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other
method) or processed, copied or distributed by electronic means without the written permission of Danaher Motion.
Edition Valid for Description
03/2007 PiCPro V16.1 Added MMC-S16 Sercos Plus Module

NOTE
These products are being manufactured and sold by G & L Motion Control, Inc., a Danaher Motion company
(“Danaher Motion”).
Progress is an on-going commitment at Danaher Motion. We continually strive to offer the most advanced products
in the industry; therefore, information in this document is subject to change without notice. The text and illustrations
are not binding in detail. Danaher Motion shall not be liable for any technical or editorial omissions occurring in this
document, nor for any consequential or incidental damages resulting from the use of this document.
Danaher Motion makes every attempt to ensure accuracy and reliability of the specifications in this publication.
Specifications are subject to change without notice. Danaher Motion provides this information “AS IS” and
disclaims all warranties, express or implied, including, but not limited to, implied warranties of merchantability and
fitness for a particular purpose. It is the responsibility of the product user to determine the suitability of this product
for a specific application.
DO NOT ATTEMPT to use any Danaher Motion product until the use of such product is completely understood. It is
the responsibility of the user to make certain proper operation practices are understood. Danaher Motion products
should be used only by qualified personnel and for the express purpose for which said products were designed.
Should information not covered in this document be required, contact the Customer Service Department, Danaher
Motion, 672 South Military Road, P.O. Box 1960, Fond du Lac, WI 54936-1960. Danaher Motion can be reached by
telephone at [phone] or [phone] in the United States or by e-mail at
[e-mail].
Catalog No. (Order No.) M.1300.7620
Printed Version Part No. M.3000.0451
Electronic Version Part No. M.3000.0450
Release 042007
©2007, Danaher Motion

Standalone MMC Hardware Manual 5
Danaher Motion version 15.1 Table of Contents
Table of Contents
1 Introduction to the Standalone MMC .............................................................................................9
1.1 Overview...................................................................................................................................9
1.2 Contents of This Manual...........................................................................................................9
1.3 Software and Manuals..............................................................................................................9
1.3.1 Required Software and Manuals.....................................................................................9
1.3.2 Suggested Manuals ........................................................................................................9
1.4 Danaher Motion Support Contact...........................................................................................10
2 Safety Precautions.........................................................................................................................11
2.1 System Safety ........................................................................................................................11
2.1.1 User Responsibility .......................................................................................................11
2.1.2 Safety Instructions.........................................................................................................11
2.2 Safety Signs ...........................................................................................................................12
2.3 Warning Labels.......................................................................................................................12
2.4 Safety First .............................................................................................................................13
2.5 Safety Inspection ...................................................................................................................13
2.5.1 Before Starting System.................................................................................................13
2.6 After Shutdown.......................................................................................................................13
2.7 Operating Safely.....................................................................................................................14
2.8 Electrical Service & Maintenance Safety................................................................................14
2.9 Safe Cleaning Practices .........................................................................................................15
3 Installation, Operation, & Maintenance........................................................................................17
3.1 Mounting the MMC Control.....................................................................................................17
3.2 Adding an Option Module to the MMC Control.......................................................................18
3.3 Dimensions and Mounting of MMC with Option Modules Attached........................................20
3.4 System Power and Environment Requirements.....................................................................21
3.4.1 General Power and Environment Requirements...........................................................21
3.4.2 Control Cabinet Specifications......................................................................................22
3.4.3 Power Distribution Diagram ..........................................................................................22
3.4.4 Grounding the System ..................................................................................................23
3.4.5 Controlling Heat Within the System ..............................................................................24
3.4.6 Handling an MMC .........................................................................................................25
3.5 System Wiring Guidelines ......................................................................................................26
3.5.1 Recommended Signal Separation ................................................................................26
3.5.2 Differential Devices for Analog and Encoder Signals....................................................27
3.6 Starting an Application............................................................................................................28
3.7 Basic Setup and Maintenance Procedures ............................................................................28
3.8 System Status Lights..............................................................................................................29
3.8.1 Power Status.................................................................................................................29
3.8.2 Battery Status................................................................................................................29
3.8.3 Scan Status...................................................................................................................30
3.8.4 Power-up Diagnostics Status........................................................................................30
3.8.5 Run-time Diagnostic Status...........................................................................................30
3.8.6 Diagnostic Error Codes.................................................................................................31
4 Standalone MMC Control ..............................................................................................................33
4.1 Introduction.............................................................................................................................33
4.2 Features .................................................................................................................................33
4.3 Overview.................................................................................................................................33
4.3.1 Machine Control Board .................................................................................................36

6 Standalone MMC Hardware Manual
Table of Contents version 15.1 Danaher Motion
4.3.2 Motion Control Board.................................................................................................... 36
4.3.2.1 Analog Servo board ............................................................................................ 36
4.3.2.2 SERCOS board................................................................................................... 37
4.4 Power Supply Requirements..................................................................................................37
4.5 Machine Control Connection & Operation.............................................................................. 41
4.5.1 PiCPro Port................................................................................................................... 41
4.5.2 Block I/O Port ............................................................................................................... 43
4.5.3 User Port ...................................................................................................................... 47
4.5.4 General I/O Port ........................................................................................................... 53
4.5.4.1 DC Output Operation .......................................................................................... 57
4.5.4.2 DC Input Operation............................................................................................. 60
4.5.5 Power Connection ........................................................................................................ 62
4.6 Analog Motion Control Connections & Operation .................................................................. 62
4.6.1 Axis I/O Ports................................................................................................................ 62
4.6.1.1 Axis I/O Port DC Outputs.................................................................................... 67
4.6.1.2 Axis I/O Port DC Input......................................................................................... 69
4.6.1.3 Axis I/O Port Analog Output................................................................................ 70
4.6.1.4 Axis I/O Port Encoder Input................................................................................. 71
4.6.2 Aux I/O Port.................................................................................................................. 72
4.6.2.1 Isolated Breakout Box Details............................................................................. 77
4.6.2.2 Aux I/O Port Fast Inputs...................................................................................... 79
4.6.2.3 Aux I/O Port DC Inputs........................................................................................ 81
4.6.2.4 Aux I/O Port Encoder Input................................................................................. 82
4.6.2.5 Aux I/O Port Analog Input ................................................................................... 83
4.7 SERCOS Motion Control Connections & Operation .............................................................. 83
4.7.1 SERCOS Receive and Transmit Ports......................................................................... 83
4.7.2 Loader Port................................................................................................................... 85
4.8 Replacing the MMC Battery................................................................................................... 87
4.9 Specifications ........................................................................................................................ 89
5 Standalone Digital MMC Control.................................................................................................. 95
5.1 Introduction ............................................................................................................................ 95
5.2 Features................................................................................................................................. 95
5.3 Overview................................................................................................................................ 95
5.4 Power Supply Requirements..................................................................................................96
5.5 Connectors & Operation......................................................................................................... 97
5.5.1 Block I/O Port ............................................................................................................... 98
5.5.2 User Port .................................................................................................................... 102
5.5.3 PiCPro Port................................................................................................................. 108
5.5.4 Ethernet Port .............................................................................................................. 110
5.5.5 Digital Link Ports......................................................................................................... 112
5.5.6 User USB Port............................................................................................................114
5.5.7 PiCPro USB Port........................................................................................................ 114
5.5.8 Power Connection ...................................................................................................... 114
5.6 Replacing the MMC Battery................................................................................................. 115
5.7 Specifications ...................................................................................................................... 117
6 MMC Ethernet TCP/IP Option Module........................................................................................ 119
6.1 Introduction .......................................................................................................................... 119
6.2 Connections......................................................................................................................... 119
6.2.1 The Ethernet Port ....................................................................................................... 121
6.2.2 The RS232 COMM Ports............................................................................................ 123
6.3 LEDs .................................................................................................................................... 125
6.4 Firmware Update.................................................................................................................. 126

Standalone MMC Hardware Manual 7
Danaher Motion version 15.1 Table of Contents
6.5 Theory of operation ..............................................................................................................126
6.6 Specifications Table .............................................................................................................128
6.7 Useful Internet Links.............................................................................................................129
7 MMC DeviceNetTM Option Module................................................................................................131
7.1 Introduction...........................................................................................................................131
7.2 Connections..........................................................................................................................132
7.2.1 The DeviceNet Port.....................................................................................................133
7.2.2 The Configuration (RS232) Port..................................................................................133
7.3 LEDs.....................................................................................................................................134
7.4 Theory of Operation..............................................................................................................134
7.5 Specifications .......................................................................................................................136
8 MMC ProfibusOption Module .....................................................................................................137
8.1 Introduction...........................................................................................................................137
8.2 Connections..........................................................................................................................138
8.2.1 The Profibus Port........................................................................................................139
8.2.2 The Configuration (RS232) Port..................................................................................139
8.3 LEDs.....................................................................................................................................140
8.4 Theory of Operation..............................................................................................................140
8.5 Specifications for Profibus Module.......................................................................................142
9 MMC Axis I/O Option Module......................................................................................................143
9.1 Specifications .......................................................................................................................145
10 MMC 32In/32Out Option Module...............................................................................................149
10.1 Introduction.........................................................................................................................149
10.2 Connections & Operation ...................................................................................................150
10.2.1 DC Output Operation ................................................................................................154
10.2.2 DC Input Operation...................................................................................................157
10.3 Specifications .....................................................................................................................159
11 CE and EMC Guidelines ............................................................................................................161
11.1 Background on EMC (Electromagnetic Compatibility) Compliance....................................161
11.2 Background on Low Voltage Compliance...........................................................................161
11.3 RFI Emission and Immunity................................................................................................161
11.4 Classes of EMC Operating Environments..........................................................................162
11.5 Conformance with the EMC Directive.................................................................................163
11.6 Conformance With the Low Voltage Directive....................................................................163
11.7 Changes to the PiC Products .............................................................................................163
11.7.1 Changes Affecting the User......................................................................................163
11.8 Using CE/EMC and Non-CE/EMC Modules ......................................................................166
11.9 Declarations of Conformity .................................................................................................168
Appendix A - Operation Details .....................................................................................................173
A.1 Introduction ..........................................................................................................................173
A.2 DC Inputs .............................................................................................................................173
A.3 DC Outputs ..........................................................................................................................174
A.3.1 Inductive Loads...........................................................................................................174
A.4 Encoder Inputs.....................................................................................................................175
Index.................................................................................................................................................177
Sales and Service............................................................................................................................182

8 Standalone MMC Hardware Manual
Table of Contents version 15.1 Danaher Motion

Standalone MMC Hardware Manual 9
Danaher Motion version 15.1 Introduction to the Standalone MMC
1 Introduction to the Standalone MMC
1.1 Overview
The Standalone Machine and Motion Control (MMC) product line consists of three
distinct products:
•The Standalone MMC Control, which is available in two configurations to control:
•Analog Interfaced drives (such as the Analog Interfaced MMC-SD) via a +10V
analog output.
•SERCOS Interfaced drives.
•The Standalone Digital MMC Control, which controls Digital Interfaced drives
(such as the Digital MMC-SD) via a digital connection (Digital Link).
•MMC Option Modules, which provide various added functionality to the Standal-
one MMC Control and the Standalone Digital MMC Control.
Unless otherwise noted, all of the information in this manual applies to both the
Standalone MMC Control and the Standalone Digital MMC Control.
1.2 Contents of This Manual
This manual includes the following major topics:
•Information to safely operate and maintain the equipment in a safe manner.
•User responsibilities for product acceptance and storage.
•Power and environmental information for general power, control cabinet, ground-
ing, heat control and handling.
•Procedures for mounting, wiring, and connecting the MMC Control.
•The function, location, and signal descriptions of connectors on the MMC Control.
•Physical, electrical, environmental and functional specifications/dimensions.
•Description of the minimal maintenance necessary.
•A troubleshooting chart of potential problems and possible solutions.
•Part numbers and descriptions for the MMC Control, MMC Option Modules, and
related equipment.
1.3 Software and Manuals
1.3.1 Required Software and Manuals
•PiCPro (one of the following):
•Professional Edition
•MMC Limited Edition
•Monitor Edition
1.3.2 Suggested Manuals
•Function/Function Block Reference Guide
•Motion Application Specific Function Block Manual
•Ethernet Application Specific Function Block Manual

10 Standalone MMC Hardware Manual
Introduction to the Standalone MMC version15.1 Danaher Motion
•General Purpose Application Specific Function Block Manual
1.4 Danaher Motion Support Contact
Contact your local Danaher Motion representative for:
•Sales and order support
•Product technical training
•Warranty support
•Support service agreements
Danaher Motion Technical Support can be reached:
•In the United States, telephone [phone]
•Outside the United States, telephone [phone]
•E-mail address: glmotion.supp[email protected]
•Web site: www.glcontrols.com

Standalone MMC Hardware Manual 11
Danaher Motion version 15.1 Safety Precautions
2 Safety Precautions
READ AND UNDERSTAND THIS SECTION IN ITS ENTIRETY
BEFORE UNDERTAKING INSTALLATION OR ADJUSTMENT OF
THE MMC SMART DRIVE AND ANY ASSOCIATED SYSTEMS OR
EQUIPMENT
The instructions contained in this section will help users to operate and maintain the
equipment in a safe manner.
PLEASE REMEMBER THAT SAFETY IS EVERYONE'S
RESPONSIBILITY
2.1 System Safety
The basic rules of safety set forth in this section are intended as a guide for the safe
operation of equipment. This general safety information, along with explicit service,
maintenance and operational materials, make up the complete instruction set. All
personnel who operate, service or are involved with this equipment in any way should
become totally familiar with this information prior to operating.
2.1.1 User Responsibility
It is the responsibility of the user to ensure that the procedures set forth here are
followed and, should any major deviation or change in use from the original
specifications be required, appropriate procedures should be established for the
continued safe operation of the system. It is strongly recommended that you contact
your OEM to ensure that the system can be safely converted for its new use and
continue to operate in a safe manner.
2.1.2 Safety Instructions
•Do not operate your equipment with safety devices bypassed or covers removed.
•Only qualified personnel should operate the equipment.
•Never perform service or maintenance while automatic control sequences are in
operation.
•To avoid shock or serious injury, only qualified personnel should perform mainte-
nance on the system.

12 Standalone MMC Hardware Manual
Safety Precautions version15.1 Danaher Motion
•GROUNDING (Protective Earth)
The equipment must be grounded (connected to the protective earth connection)
according to OEM recommendations and to the latest local regulations for electrical
safety. The grounding (protective earth) conductor must not be interrupted inside or
outside the equipment enclosures. The wire used for equipment grounding
(connection to protective earth) should be green with a yellow stripe.
2.2 Safety Signs
The purpose of a system of safety signs is to draw attention to objects and situations
which could affect personal or plant safety. It should be noted that the use of safety
signs does not replace the need for appropriate accident prevention measures.
Always read and follow the instructions based upon the level of hazard or potential
danger.
2.3 Warning Labels
Hazard warning
When you see this safety sign on a system, it gives a warning of a hazard or
possibility of a hazard existing. The type of warning is given by the pictorial
representation on the sign plus text if used.
To ignore such a caution could lead to severe injury or death arising from an unsafe
practice.
ATTENTION
Do not touch the main power supply fuses or any com-
ponents internal to the power modules while the main
power supply switch is ON. Note that when the main
power switch is OFF, the incoming supply cable may
be live.
Danger Electric
Shock Risk

Standalone MMC Hardware Manual 13
Danaher Motion version 15.1 Safety Precautions
Danger, Warning, or Caution warning
Hot Surface warning
2.4 Safety First
Danaher Motion equipment is designed and manufactured with consideration and
care to generally accepted safety standards. However, the proper and safe
performance of the equipment depends upon the use of sound and prudent operating,
maintenance and servicing procedures by trained personnel under adequate
supervision.
For your protection, and the protection of others, learn and always follow these safety
rules. Observe warnings on machines and act accordingly. Form safe working habits
by reading the rules and abiding by them. Keep these safety rules handy and review
them from time to time to refresh your understanding of them.
2.5 Safety Inspection
2.5.1 Before Starting System
•Ensure that all guards and safety devices are installed and operative and all doors
which carry warning labels are closed and locked.
•Ensure that all personnel are clear of those areas indicated as potentially hazard-
ous.
•Remove (from the operating zone) any materials, tools or other objects that could
cause injury to personnel or damage the system.
•Make sure that the control system is in an operational condition.
•Make certain that all indicating lights, horns, pressure gauges or other safety
devices or indicators are in working order.
2.6 After Shutdown
Make certain all controlled equipment in the plant is safe and the associated electrical,
pneumatic or hydraulic power is turned off. It is permissible for the control equipment
contained in enclosures to remain energized provided this does not conflict with the
safety instructions found in this section.
Symbol plus DANGER, WARNING or CAUTION:
These notices provide information intended to prevent potential
sonal injury and equipment damage.
Symbol plus HOT SURFACE:
These notices provide information intended to prevent potential p
e
sonal injury.

14 Standalone MMC Hardware Manual
Safety Precautions version15.1 Danaher Motion
2.7 Operating Safely
•Do not operate the control system until you read and understand the operating
instructions and become thoroughly familiar with the system and the controls.
•Never operate the control system while a safety device or guard is removed or
disconnected
•Where access to the control system is permitted for manual operation, only those
doors which provide that access should be unlocked. They should be locked
immediately after the particular operation is completed.
•Never remove warnings that are displayed on the equipment. Torn or worn labels
should be replaced.
•Do not start the control system until all personnel in the area have been warned.
•Never sit or stand on anything that might cause you to fall onto the control equip-
ment or its peripheral equipment.
•Horseplay around the control system and its associated equipment is dangerous
and should be prohibited.
•Never operate the equipment outside specification limits.
•Keep alert and observe indicator lights, system messages and warnings that are
displayed on the system.
•Do not operate faulty or damaged equipment. Make certain proper service and
maintenance procedures have been performed.
2.8 Electrical Service & Maintenance Safety
•ALL ELECTRICAL OR ELECTRONIC MAINTENANCE AND SERVICE
SHOULD BE PERFORMED BY TRAINED AND AUTHORIZED PERSONNEL
ONLY.
•It should be assumed at all times that the POWER is ON and all conditions treated
as live. This practice assures a cautious approach which may prevent accident or
injury.
•To remove power:
LOCK THE SUPPLY CIRCUIT DISCONNECTING MEANS IN THE OPEN POSI-
TION.
APPLY LOCKOUT/TAGOUT DEVICES IN ACCORDANCE WITH A DOCU-
MENTED AND ESTABLISHED POLICY.
ATTENTION
Know the emergency stop
procedures for the system.

Standalone MMC Hardware Manual 15
Danaher Motion version 15.1 Safety Precautions
•Make sure the circuit is safe by using the proper test equipment. Check test equip-
ment regularly.
•There may be circumstances where troubleshooting on live equipment is required.
Under such conditions, special precautions must be taken:
•Make sure your tools and body are clear of the areas of equipment which
may be live.
•Extra safety measures should be taken in damp areas.
•Be alert and avoid any outside distractions.
•Make certain another qualified person is in attendance.
•Before applying power to any equipment, make certain that all personnel are clear
of associated equipment.
•Control panel doors should be unlocked only when checking out electrical equip-
ment or wiring. On completion, close and lock panel doors.
•All covers on junction panels should be fastened closed before leaving any job.
•Never operate any controls while others are performing maintenance on the sys-
tem.
•Do not bypass a safety device.
•Always use the proper tool for the job.
•Replace the main supply fuses only when electrical power is OFF (locked out).
2.9 Safe Cleaning Practices
•Do not use toxic or flammable solvents to clean control system hardware.
•Turn off electrical power (lock out) before cleaning control system assemblies.
•Keep electrical panel covers closed and power off when cleaning an enclosure.
ATTENTION
Care should be taken if you are manually discharging
the bus capacitors.
WARNING
Even after power to the drive is removed, it may take up
to 10 minutes for bus capacitors to discharge to a level
below 50 VDC. To be sure the capacitors are dis-
charged, measure the voltage across the + and - termi-
nals for the DC bus.

16 Standalone MMC Hardware Manual
Safety Precautions version15.1 Danaher Motion
•Always clean up spills around the equipment immediately after they occur.
•Never attempt to clean a control system while it is operating.
•Never use water to clean control equipment unless you are certain that the equip-
ment has been certified as sealed against water ingress. Water is a very good
conductor of electricity and the single largest cause of death by electrocution.

Standalone MMC Hardware Manual 17
Danaher Motion version 15.1 Installation, Operation, & Maintenance
3 Installation, Operation, & Maintenance
3.1 Mounting the MMC Control
Mount the unit to your cabinet using the mounting slots on the MMC as shown. (Note:
the Standalone MMC Digital Control requires a minimum of 1/2 in clearance on the left
side, for proper fan air movement). The MMC unit must be mounted vertically. The
recommended size of mounting hardware is #10 bolts with #10 star washers (to
ensure proper ground connection) as shown in Figure 3-1 below.

18 Standalone MMC Hardware Manual
Installation, Operation, & Maintenance version15.1 Danaher Motion
Figure 3-1: MMC Mounting Dimensions
3.2 Adding an Option Module to the MMC Control
Several Option Modules are available to add functionality to the MMC system. These
modules are described in the later sections of this manual. The standard Standalone
MMC Control (MMC-A2, MMC-A4, and MMC-S8) accepts up to two MMC Option
Modules. The Standalone MMC Control Plus (MMC-A2 Plus and MMC-A4 Plus), as
MMC
.55" (13.97 mm)
1.00"
(25.4 mm)
2.10" (53.34 mm)
9.59" (243.59 mm)
8.75" (222.25 mm)
.218" (5.54 mm)
1.05" (26.67 mm)
.55"
Side Cover
Screw Head
.040" Thickness
.080" Thickness
NOTE: Add the side
cover and screw
head thicknesses to
theunit’sdimensions
for total width.
.500" (12.70 mm) clearance required
for Standalone Digital MMC Control
(13.97 mm)
Note: Unit is 5.3”
(134.62 mm) deep.

Standalone MMC Hardware Manual 19
Danaher Motion version 15.1 Installation, Operation, & Maintenance
well as the Standalone Digital MMC Control (MMC-D32 and MMC-D64), accepts up to
four MMC Option Modules.
Option modules are shipped with a 50-pin square post connector and screws needed
to attach the module to the MMC (or to another option module). Follow the procedure
below to add an option module to the MMC (or to another option module).
1. Place the MMC and the option module on a static free surface. Ground yourself
using a properly grounded wrist strap before you begin. These are standard pre-
cautions before handling any electronic components.
2. Remove the five screws securing the MMC cover using a #1 Phillips screwdriver
and set them aside. There are two screws on the top, two screws on the bottom,
and one screw on the side of the module.Lift the side cover off and set aside.
3. Locate the 50-pin square post socket at the top of the MMC board. Press one side
of the 50-pin square post male connector into this socket ensuring that the pins
are aligned and it is firmly seated.
4. Pick up the option module. Line up the socket on the option module with the male
end of the connector extending from the MMC ensuring that the pins are aligned.
Press firmly into place. Be sure to align the screw tabs on the top and bottom of
the option module with the screw slots on the top and bottom of the MMC module
so that the modules slide together easily.
5. Screw four screws (of the five included in your package) into the screw tabs to
attach the option module to the MMC.
6. Lay the unit on the bench. Place the cover you set aside in Step 3 on the option
module. Be sure to align the screw tabs on the top and bottom of the cover with
the screw slots on the top and bottom of the option module.
7. Screw the five screws removed in Step 2 back into place to secure the cover.

20 Standalone MMC Hardware Manual
Installation, Operation, & Maintenance version15.1 Danaher Motion
Figure 3-2: Location of Screws on the MMC Control
(MMC A-4 Servo Unit Shown)
3.3 Dimensions and Mounting of MMC with Option Modules Attached
After attaching option modules to the MMC module, mount the unit to your cabinet
using the mounting slots on the MMC and the option module. The recommended size
of mounting hardware is #10 bolts with #10 star washers (to ensure proper ground
connection).
Cover Side of Module
Side Screw
Top Screws
Bottom Screws
+24
COM