Faulhaber MC 5004 User manual

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
6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
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

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Content
4
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

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
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

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
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

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
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

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Safety
8
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.

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Safety
9
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.

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Safety
10
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.

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Safety
11
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 this technical manual may be drive sys-
tems according to the Machinery Directive. They are therefore to be considered incomplete
machines according to the Machinery Directive. Compliance is documented by the Declara-
tion of Incorporation for the product and by the EC Declaration of the Conformity.
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 harmonized 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. 63.
WEEE Directive (2012/19/EU)
The directive on the disposal of electrical and electronic devices prescribes the separate col-
lection of old electrical and electronic devices. The products described in this technical man-
ual fall within the scope of this directive.

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
12
3 Product description
3.1 General product description
The MC 5004 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 softwareV6.
The drives can be operated in the network via the CANopen or EtherCAT fieldbus interface.
In smaller setups, networking can also be performed via the RS232 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 the 50-pin connector strip. For this
purpose, FAULHABER offers a motherboard for connecting up to four MC 5004 controllers.
With the integrated output stage with optimized current measurement, DC, BL and LM
motors from the FAULHABER product line from 08 to 32 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/analog Hall sensors
Incremental encoders with or without line drivers.
Not all options of the BiSS-C interface are supported by FAULHABER Motion Control-
lers of the V3.0 series. Before using encoders from other manufacturers, clarify the
compatibility with FAULHABER Support.
Motion Controllers with RS232, CANopen or EtherCAT interface can also be operated
independently of the communications interface if a pre-programmed function or
sequence program has been programmed without digital command controls.

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
13
3.2 Product information
Fig. 2: Designation key

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
14
3.3 Product variants
The following product variants are possible:
MC 5004 P RS/CO
MC 5004 P ET
The Motion Controller PCBs can be mounted on a motherboard. The FAULHABER mother-
board can accommodate up to four Motion Controller PCBs.
3.3.1 Controller PCBs
3.3.1.1 Standard PCB
Fig. 3: Isometric (left) and front view (right) of the standard PCB
Tab. 1: Connector overview
Tab. 2: LED overview
Status LED USB (X1)
Power LED
Designation Function
USB (X1) Connection of the USB communication
Designation Function
State LED 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): Booting has failed. Please contact FAULHABER Support.
Power LED Green: Power supply within the permissible range.
Off: Power supply out of the permissible range.

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
15
3.3.1.2 PCB with vertical plug connector (option 5621)
Fig. 4: Isometric view (left) and top view (right) of PCB with vertical plug connector
Tab. 3: Connector overview
Tab. 4: LED overview
USB (X1)
Status LED
Power LED
Designation Function
USB (X1) Connection of the USB communication
Designation Function
State LED 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): Booting has failed. Please contact FAULHABER Support.
Power LED Green: Power supply within the permissible range.
Off: Power supply out of the permissible range.

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
16
3.3.1.3 EtherCAT PCB
Fig. 5: Isometric (left) and front view (right) of the plugged-in EtherCAT PCB
Tab. 5: Connector overview
Tab. 6: LED overview
Status LED
USB (X1)
LA
Power LED
Run LED Error LED
OUT IN
Designation Function
IN/OUT Connection of the EtherCAT communication
USB (X1) Connection of the USB communication
Designation Interface Function
State LED all 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): Booting has failed. Please contact FAULHABER Support.
Power LED all Green: Power supply within the permissible range.
Off: Power supply out of the permissible range.
RUN LED EtherCAT Green (continuous light): Connection present. Device is ready for use.
Green (flashing): Device is in the Pre-Operational. state
Green (single flash): Device is in the Safe-Operational. state
Off: Device is in the Initialisation state.
ERR LED EtherCAT Red (flashing): Faulty configuration.
Red (single flash): Local error.
Red (double flash): Watchdog timeout.
Off: No connection error
LA LED EtherCAT Green (continuous light): No data transfer. Connection to another participant
established.
Green (flashing): Data transfer active.
Off: No data transfer. No connection to another participant.

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
17
3.3.2 Motherboard
Fig. 6: Side view (top), top view (middle) and isometric view (bottom) of the mother-
board with vertical connectors
max. 52
max. 18.5
5.08
1.6
130
106
250
260
92.3 18.85
65 120 65
5
12
Ø3

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
18
Fig. 7: Side view (top), top view (middle) and isometric view (bottom) of the mother-
board with horizontal connectors
max. 52
max. 16
5.08
1.6
130
106
250
260
92.3 18.85
65 120 65
5
12
Ø3

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
19
Fig. 8: Connector overview of the motherboard (board area)
Fig. 9: Connector overview of the motherboard (general area)
Tab. 7: Connector overview of the motherboard
On delivery, there are rubber pads in the outer and center holes of the motherboard.
These holes are marked in blue in Fig. 6 and Fig. 7.
DIP switch:
RS232 - BUS Active/Inactive
RS232 connector (X2)
I/O connector (X3)
Motor connector (M1)
Sensor connector (M2)
Encoder connector (M3)
Motion Controller
connector
Board Area X
General Area
DIP switch:
CAN termination On/Off
CAN 1/CAN 2
connector
EtherCAT communication
(IN/OUT)
Power supply
controller (X4)
Power supply motor (X5)
EtherCAT ribbon cable
connector
Designation Function
Motion Controller connector Connection of the Motion Controller PCB
M1 (motor) Connection of the motor phases
M2 (sensor) Connection of the Hall sensors
M3 (encoder) Connection of an incremental encoder with or without line driver.
Alternatively an absolute encoder can be connected with or without line
driver.
X2 (COM) RS232 interface connection
CAN 1/CAN 2 CANopen interface connection
X3 (I/O) Inputs or outputs for external circuits
X4 (Up) Voltage supply of the controller
X5 (Umot) Voltage supply of the motor
IN/OUT Connection of the EtherCAT communication

6th edition, 22.05.2023 7000.05060, 6th edition, 22.05.20237000.05060
Product description
20
EtherCAT ribbon cable connector Optional ribbon cable connection
DIP switch CAN termination CAN termination resistor (On/Off):
On: Termination resistor active
Off: Termination resistor inactive
DIP switch RS232 active/inactive RS232 net mode (on/off):
On: RS232 net mode active
Off: RS232 net mode inactive
Designation Function