Faulhaber MC 3001 B User manual

WE CREATE MOTION
Technical Manual
MC 3001 B/P
EN

Imprint
2
Version:
1st edition, 12.02.2021
Copyright
by Dr. Fritz Faulhaber GmbH & Co. KG
Daimlerstr. 23 / 25 · 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
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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
2.3 Environmental conditions ...................................................................................... 9
2.4 EC directives on product safety ........................................................................... 10
3 Product description ........................................................................................................ 11
3.1 General product description ................................................................................ 11
3.2 Product information ............................................................................................. 12
3.3 Product variants .................................................................................................... 13
3.3.1 Controller PCBs...................................................................................... 13
3.3.1.1 Standard PCB with micro board-to-board connectors
(MC3001 B) ............................................................................. 13
3.3.1.2 Standard PCB with plug connectors (MC 3001 P) ................ 17
3.3.2 Motherboards ....................................................................................... 20
3.3.2.1 Instructions for using other motherboards.......................... 20
3.3.2.2 Motherboard 6500.01802...................................................... 22
3.3.2.3 Motherboard 6500.01807...................................................... 29
3.3.2.4 Motherboard 6500.01808...................................................... 35
3.3.2.5 Motherboard 6500.01809...................................................... 40
3.3.2.6 Motherboard 6500.01810...................................................... 45
3.3.2.7 Motherboard 6500.01811...................................................... 50
4 Installation ...................................................................................................................... 55
4.1 Mounting .............................................................................................................. 55
4.1.1 Mounting instructions .......................................................................... 55
4.1.2 Installation of Motion Controller PCBs................................................ 56
4.2 Electrical connection ............................................................................................ 57
4.2.1 Notes on the electrical connection ...................................................... 57
4.2.2 Drive connections.................................................................................. 58
4.2.3 Connection of the power supply ......................................................... 59
4.2.3.1 Power supply.......................................................................... 59
4.2.4 I/O circuit diagrams ............................................................................... 60
4.2.5 External circuit diagrams ...................................................................... 62
4.3 Electromagnetic compatibility (EMC) .................................................................. 65
4.3.1 Considered systems ............................................................................... 65
4.3.2 Functional earthing .............................................................................. 67
4.3.3 Cable routing ........................................................................................ 67
4.3.4 Shielding................................................................................................ 69
4.3.4.1 Establishing the shield connection ....................................... 70
4.3.4.2 Establishing shield connection with cable lug ..................... 71

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4.3.5 Sensor and encoder interfaces ............................................................. 72
4.3.5.1 Analogue sensors and analogue Hall sensors ...................... 73
4.3.5.2 Incremental encoders / Digital Hall sensors /
Digital sensors ........................................................................ 73
4.3.5.3 Encoders with absolute interface ......................................... 73
4.3.6 Using filters ........................................................................................... 73
4.3.6.1 EMC-compliant mounting of the Motion Controller with
motherboard.......................................................................... 74
4.3.6.2 PWM filter (motor-side) ........................................................ 74
4.3.6.3 Emission-reducing, ferrite-based filters (motor side) .......... 74
4.3.6.4 Input-side filters..................................................................... 75
4.3.6.5 Insulation resistance .............................................................. 75
4.3.6.6 Coiling ferrite ring ................................................................. 75
4.3.7 Error avoidance and troubleshooting ................................................. 76
5 Maintenance and diagnostics ........................................................................................ 78
5.1 Maintenance tasks ................................................................................................ 78
5.2 Diagnosis ............................................................................................................... 78
5.3 Troubleshooting ................................................................................................... 78
6 Accessories ...................................................................................................................... 79
7 Warranty ......................................................................................................................... 80
8 Additional documents .................................................................................................... 81
8.1 Declaration of Conformity ................................................................................... 81
8.2 Declaration of Incorporation ............................................................................... 83

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About this document
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1 About this document
1.1 Validity of this document
This document describes the installation and use of the FAULHABER MC 3001 series.
This document is intended for use by trained experts authorised 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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1.4 List of abbreviations
Abbreviation Meaning
AC Alternating Current
AES Absolute encoder
AGND Analogue Ground
AnIn Analogue input
CAN Controller Area Network
CAN_L CAN-Low
CAN_H CAN-High
CLK Clock
CS Chip Select
DigIn Digital input
DigOut Digital output
EFM Electronics Filter Motor
EFS Electronics Filter Supply
EMC Electromagnetic compatibility
ESD Electrostatic discharge
GND Ground
I/O Input/Output
MC Motion Controller
Mot Motor
n.c. not connected
PWM Pulse Width Modulation
RxD Receive Data
SGND Signal ground
TxD Transmit data

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1.5 Symbols and designations
CAUTION!
Hazards due to hot surfaces. Disregard may lead to burns.
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 optimising 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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2.2 Safety instructions
NOTICE!
Electrostatic discharges can damage the electronics.
Wear conductive work clothes.
Wear an earthed wristband.
NOTICE!
Foreign bodies can damage the electronics.
Keep foreign objects away from the electronics.
NOTICE!
Inserting and withdrawing connectors whilst supply voltage is applied at the device can
damage the electronics.
Do not insert or withdraw connectors whilst supply voltage is applied at the device.
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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Safety
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2.4 EC directives on product safety
The following EC directives on product safety must be observed.
If the Motion Controller is being used outside the EU, international, national and
regional directives must be also observed.
Machinery Directive (2006/42/EC)
The controllers with attached motor described in these installation instructions may be
drive systems according to the Machinery Directive. They are therefore to be considered
incomplete machines according to the Machinery Directive. Compliance is documented by
the Declaration of Incorporation for the product and by the EC Declaration of the Conform-
ity.
EMC Directive (2014/30/EU)
The directive concerning electromagnetic compatibility (EMC) applies to all electrical and
electronic devices, installations and systems sold to an end user. In addition, CE marking can
be undertaken for built-in components according to the EMC Directive. Conformity with
the directive is documented in the Declaration of Conformity.
Applied standards
Various harmonised standards were applied to the products described in this technical
manual; these standards are documented in the EC Declaration of Conformity. You can find
the Declaration of Incorporation for the product and the EC Declaration of Conformity in
chap. 8, p. 81.

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Product description
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3 Product description
3.1 General product description
The MC 3001 products are unhoused versions of the FAULHABER Motion Controllers and
control either DC, LM or BL motors. The Motion Controllers are configured here via the
FAULHABER Motion Manager software V6 (version 6.7 and higher).
The drives can be operated in the network via the CANopen fieldbus interface. The Motion
Controller operates in the network in principle as a slave; master functionality for actuating
other axes is not provided. After basic commissioning via Motion Manager, the controllers
can alternatively also be operated without communication interface.
The controllers can be plugged into a motherboard via 3 micro board-to-board connectors
(MC 3001 B) or a 28-pin plug connector (MC 3001 P).
With the integrated output stage with optimised current measurement, DC, BL and LM
motors from the FAULHABER product line from 06 to 30 mm can be controlled.
The following connections are available on the connector strip:
Communications interfaces
Common or separate power supplies between motor and controller
Various inputs and outputs
Motor phases
Feedback components such as:
Digital/analogue Hall sensors
Incremental encoders with or without line drivers.
Motion Controllers with RS232 or CANopen interface can also be operated inde-
pendently of the communication interface if a function or a suitable sequence pro-
gram was previously stored locally.

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3.2 Product information
Fig. 1: Designation key
…… MC
RS:
CO:
P:
0:1
MC:
30:
……
B:
Serial interface RS232
Interface CANopen
PCB version with pin terminals
Max. continuous output current 1 A
Max. power supply 30 V
Motion Controller
PCB version with micro board-to-board connectors

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3.3 Product variants
The following product variants are possible:
MC 3001 B RS/CO
MC 3001 P RS/CO
The Motion Controller PCBs can be mounted on a motherboard. The FAULHABER mother-
board offers space for a Motion Controller PCB.
3.3.1 Controller PCBs
3.3.1.1 Standard PCB with micro board-to-board connectors (MC3001 B)
Fig. 2: Isometric view (left) and rear view (right) of the standard PCB with micro board-to-
board connectors
State LED
Tab. 1: LED function
Status LED
A
B
C
LED indicator Function
Green (continuous
light)
Device active.
Green (flashing) Device active. However the state machine has not yet reached the Operation Enabled
state.
Red (continuously
flashing)
The drive has switched to a fault state. The output stage will be switched off or has
already been switched off.
Red (error code) Boot procedure failed. Please contact FAULHABER Support.

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Pin assignment of the connector
The MC 3001 B Motion Controller has 3 connectors by means of which the connection
between Motion Controller and motherboard or customer-specific peripherals is estab-
lished.
Fig. 3: Pin overview of the micro board-to-board connectors of the MC 3001 B
Tab. 2: Pin assignment of connector A
For technical data, see motherboard pin assignment.
Pin Designation Meaning
1 GND Ground connection
2, 3 UpPower supply of the electronics
4 CAN-L CAN-Low interface
5CAN-H CAN-High interface
6 GND Ground connection
7Reserved Do not connect
8 GND Ground connection
9 UDD 5V supply connection for sensors
10 DigIn 1 Digital input
11 DigIn 2 Digital input
12 DigIn 3 Digital input
13 DigOut 1 Digital output
14 DigOut 2 Digital output
15 TxD RS232 interface transmit direction
16 RxD RS232 interface receive direction
17, 18 EGND Earth connection
19 USB ID USB port ID
20 USB D+ USB port D+
21 USB D– USB port D–
A
BC
117
1834
117
1834
117
1834
35363536
3536

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Tab. 3: Pin assignment of connector B
22 USB VCC USB port VCC
23…31 Reserved Do not connect
32, 33 UpPower supply of the electronics
34, 35 GND Ground connection
36 Umot Power supply of the motor
Pin Designation Meaning
1U
DD 5V supply connection for sensors
2…4 GND Ground connection
5…7 Reserved Do not connect
8n.c. –
9 AnIn 1 Analogue input
10 AGND Analogue ground connection
11 AnIn 2 Analogue input
12, 13 n.c. –
14…16 GND Ground connection
17 Reserved Do not connect
18 GND Ground connection
19 Channel A Encoder channel A (logically inverted signal)
20 Channel B Encoder channel B (logically inverted signal)
21 Index Index channel (logically inverted signal)
22 Index Index channel
23 Channel B Encoder channel B
24 Channel A Encoder channel A
25, 26 Reserved Do not connect
27 Sens A Hall sensor A
28 Sens B Hall sensor B
29 Sens C Hall sensor C
30…33 GND Ground connection
34 UDD 5V supply connection for sensors
35 GND Ground connection
36 UDD 5V supply connection for sensors
Pin Designation Meaning

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Tab. 4: Pin assignment of connector C
Pin Designation Meaning
1n.c. –
2…5 Reserved Do not connect
6…9 GND Ground connection
10…13 Phase B Motor phase B
14…17 GND Ground connection
18…28 Phase B Motor phase B
29…34 Reserved Do not connect
35 Phase C Motor phase C
36 Phase A Motor phase A
The motor phase B signal is assigned multiple times to achieve sufficient current-carry-
ing capacity. For the motor phase A and motor phase C connections, multiple assign-
ment is not necessary since sufficient current-carrying capacity is achieved at pin 35 and
pin 36 due to the design of the connector.

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3.3.1.2 Standard PCB with plug connectors (MC 3001 P)
Fig. 4: Isometric view (left) and top view (right) of the standard PCB with plug connectors
State LED
Tab. 5: LED function
USB (X1)
Connection of the USB communication (USB micro B).
Status LED
USB (X1)
Status LED
USB (X1)
LED indicator Function
Green (continuous
light)
Device active.
Green (flashing) Device active. However the state machine has not yet reached the Operation Enabled
state.
Red (continuously
flashing)
The drive has switched to a fault state. The output stage will be switched off or has
already been switched off.
Red (error code) Boot procedure failed. Please contact FAULHABER Support.

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Pin assignment of the plug connector
The MC 3001 P Motion Controller has a connector strip by means of which the connection
between Motion Controller and motherboard or customer-specific peripherals is estab-
lished.
Fig. 5: Pin overview of the plug connector of the MC 3001 P
Tab. 6: Pin assignment of the plug connector
For technical data, see motherboard pin assignment.
Pin Designation Meaning
1 GND Ground connection
2 Umot Power supply of the motor
3U
pPower supply of the electronics
4CAN-H
TxD
CAN-High interface
RS232 interface transmit direction
5 CAN-L
RxD
CAN-Low interface
RS232 interface receive direction
6DigIn 1 Digital input
7 DigIn 2 Digital input
8DigIn 3 Digital input
9 DigOut 1 Digital output
10 DigOut 2 Digital output
11 EGND Earth connection
12 GND Ground connection
13 AnIn 1 Analogue input
14 AGND Analogue ground connection
15 AnIn 2 Analogue input
16 Channel A Encoder channel A (logically inverted signal)
17 Channel B Encoder channel B (logically inverted signal)
110
19
11
28

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18 Index Index channel (logically inverted signal)
19 Index Index channel
20 Channel B Encoder channel B
21 Channel A Encoder channel A
22 Sens C Hall sensor C
23 Sens B Hall sensor B
24 Sens A Hall sensor A
25 UDD 5V supply connection for sensors
26 Phase C Motor phase C
27 Phase B Motor phase B
28 Phase A Motor phase A
Pin Designation Meaning

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3.3.2 Motherboards
The following motherboards are available and each support both products MC 3001 B and
MC 3001 P:
Tab. 7: Available motherboards from FAULHABER
When using other motherboards, observe the instructions in chap. 3.3.2.1, p. 20.
3.3.2.1 Instructions for using other motherboards
The following sockets are recommended as counterparts to the controller connectors:
MC 3001 P
For each MC 3001 P, 2x 10-pin sockets and 1x 8-pin socket are needed.
Option Description Reference
6500.01802 MB1 MC 3001 for general combination with BL/DC-motors including Hall
sensors and/or encoders
chap. 3.3.2.2, p. 22
6500.01807 MB1 MC 3001 for combination with DC-motors and encoders IE2, IEH2,
IEH3(L)
chap. 3.3.2.3, p. 29
6500.01808 MB1 MC 3001 for combination with DC-motors and encoders IE3(L),
IER3(L), IERS3(L)
chap. 3.3.2.4, p. 35
6500.01809 MB1 MC 3001 for combination with DC-motors and encoders PA2-100,
HEM3
chap. 3.3.2.5, p. 40
6500.01810 MB1 MC 3001 for combination with BL-motors and encoders AESM, IEM3 chap. 3.3.2.6, p. 45
6500.01811 MB1 MC 3001 for combination with BL/DC-motors and encoders PA2-50,
HXM
chap. 3.3.2.7, p. 50
If motherboards other than those offered by FAULHABER are used (see Tab. 7), they
must be manufactured in accordance with the following guidelines:
PCB: IPC-A-600H Class 2
Mounting/soldering: IPC-A-600E Class 2
Manufacturer:W+P
Series: Socket Strip 10 (2 pieces)
Details: 10-pin, contact spacing 2.54, gold-plated
Manufacturer
number:
153-010-1-50-00
Manufacturer:W+P
Series: Socket Strip 10 (1 piece)
Details: 8-pin, contact spacing 2.54, gold-plated
Manufacturer
number:
153-008-1-50-00