Faulhaber MC 5010 User manual

WE CREATE MOTION
Technical Manual
MC 5010
MC 5005
EN

Imprint
2
Version:
3rd edition, 6-11-2017
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 markers ............................................................................................. 7
2 Safety ................................................................................................................................ 8
2.1 Use for the intended purpose ............................................................................... 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 Standard format.................................................................................... 13
3.3.1.1 Motor side of the standard format ...................................... 13
3.3.1.2 Supply side of the standard format...................................... 13
3.3.2 Extended format ................................................................................... 14
3.3.2.1 Motor side of the extended format ..................................... 14
3.3.2.2 Supply side of the extended format..................................... 15
4 Installation ...................................................................................................................... 16
4.1 Mounting .............................................................................................................. 16
4.1.1 Mounting instructions .......................................................................... 16
4.1.2 Attachment via the side plates ............................................................ 17
4.1.3 Installation on a top-hat rail ................................................................ 18
4.1.4 Installation with top-hat rail clips ........................................................ 19
4.2 Electrical connection ............................................................................................ 20
4.2.1 Instructions for the electrical connection............................................ 20
4.2.2 Connections at the motor side............................................................. 21
4.2.3 Screening ............................................................................................... 22
4.2.4 Connection at the supply side.............................................................. 23
4.2.4.1 Power supply.......................................................................... 23
4.2.5 Connector pin assignment.................................................................... 24
4.2.5.1 Pin assignment at the motor side ......................................... 24
4.2.5.2 Pin assignment at the supply side......................................... 28
4.2.6 Connection at the motor side .............................................................. 32
4.2.7 I/O circuit diagrams ............................................................................... 36
4.2.8 External circuit diagrams ...................................................................... 37
5 Maintenance and diagnostics ........................................................................................ 41
5.1 Maintenance instructions .................................................................................... 41
5.2 Maintenance activities ......................................................................................... 41
5.3 Diagnostics ............................................................................................................ 41
5.4 Troubleshooting ................................................................................................... 42
6 Accessories ...................................................................................................................... 43

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7 Warranty ......................................................................................................................... 44

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1 About this document
1.1 Validity of this document
This document describes the installation and use of the following series:
MC 5005
MC 5010
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 according 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.
Retain the document throughout the entire working life of the product.
Keep the document accessible to the operating personnel 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
AnIn Analogue Input
AnOut Analogue output
AGND Analogue Ground
CAN_L CAN-Low
CAN_H CAN-High
CLK Clock
CS Command Specifier
DC Direct Current
DigIn Digital input
DigOut Digital output
EMC Electromagnetic compatibility
ESD Electrostatic discharge
ET EtherCAT (Ethernet for Control Automation Technology)
GND Ground
PLC Programmable Logic Controller
PWM Pulse Width Modulation
RxD Receive data
TTL Transistor Transistor Logic
TxD Transmit data
NMT CANopen network management
RTR Remote Request
OD Object Dictionary

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1.5 Symbols and markers
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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2 Safety
2.1 Use for the intended purpose
The Motion Controllers described here are designed for use as slaves for control and posi-
tioning tasks for the following motors:
DC motors
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!
Penetration of foreign objects can damage the electronics.
Do not open the housing.
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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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)
Because of their small size, no serious threats to life or physical condition can normally be
expected from electric miniature drives. Therefore the Machinery Directive does not apply
to our products. The products described here are not "incomplete machines". Therefore
installation instructions are not normally issued by FAULHABER.
Low Voltage Directive (2014/35/EU)
The Low Voltage Directive applies for all electrical equipment with a nominal voltage of 75
to 1500 V DC and 50 to 1000 V AC. The products described in this technical manual do not
fall within the scope of this directive, since they are intended for lower voltages.
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.

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3 Product description
3.1 General product description
The MC 5005 and MC 5010 products are housed versions of the FAULHABER Motion Con-
troller and can control DC, LM or BL motors as required. Configuration of the Motion Con-
troller is performed using the FAULHABER Motion Manager V6.
The drives can be incorporated into the network by means of the CANopen or EtherCAT
field bus interfaces. In smaller installations networking can be performed using the RS232
interface. The Motion Controller operates within the network principally as a slave. Master
functionality for controlling other axes is not provided. Alternatively, after initial commis-
sioning by the Motion Manager, the controller can also be operated without any communi-
cations interface.
The controller is mounted on a flat baseplate, using the installation holes. Optional accesso-
ries also permit the controller to be mounted on a top-hat rail.
The output stages are exchangeable and are matched to the various sizes and types of
motors, i.e. DC, BL and LM motors from 12 – 44 mm, as listed in the FAULHABER product
portfolio.
The following connections are available on the supply side:
Communications interfaces
Common or separate power supplies between motor and controller
Various inputs and outputs
The following connections are available on the motor side, depending on the product com-
bination:
Motor phases
Feedback components such as:
Digital/analogue Hall sensors
Incremental encoders with or without line drivers.
Motion Controllers with RS232, CANopen or EtherCAT interfaces can also be operated
independently of the communications interface if a pre-programmed function or
sequence program has been programmed without digital command controls.

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3.2 Product information
Fig. 1: Designation key
RS: Serial Interface RS 232
CO: Interface CANopen
ET: Interface EtherCAT
S: Housing with Connectors/Terminals
05: Continuous Output Current 5 A
10: Continuous Output Current 10 A
50: Max. Supply Voltage 50 V
MC: Motion Controller
50 … S …MC

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3.3 Product variants
The housed variant of the Motion Controller is available in 2 formats.
3.3.1 Standard format
The standard format of the housed Motion Controller has a CANopen or RS232 interface.
The USB interface is available in all devices.
3.3.1.1 Motor side of the standard format
Fig. 2: Motor side of the standard format
Tab. 1: Connector overview on the motor side
3.3.1.2 Supply side of the standard format
Fig. 3: Supply side of the standard format
Tab. 2: Connector overview on the supply side
Designation Function
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.
Motor • M1 Sensor • M2 Encoder • M3
Designation Function
X1 (USB) Connection of the USB communication
X2 (COM) Interface connection RS232/CAN
X3 (I/O) Inputs or outputs for external circuits
X4 (Up)Power supply of the controller
X5 (Umot) Power supply of the motor
USB • X1 COM • X2 I/O • X3 Up • X4
PowerStatus
Umot • X5

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Tab. 3: LED overview
3.3.2 Extended format
The extended format of the housed Motion Controller has a further EtherCAT port in addi-
tion to the standard format.
3.3.2.1 Motor side of the extended format
Fig. 4: Motor side of the extended format
Tab. 4: Connector overview on the motor side
Designation Function
Status LED Green (continuous): 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.
Power LED Green: Power supply within the permissible range.
Off: Power supply not within the permissible range.
Designation Function
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.
Motor • M1 Sensor • M2 Encoder • M3

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3.3.2.2 Supply side of the extended format
Fig. 5: Supply side of the extended format
Tab. 5: Connector overview on the supply side
Tab. 6: LED overview
Designation Function
X1 (USB) Connection of the USB communication
X2 (COM) Interface connection RS232/CAN
X3 (I/O) Discrete I/Os and sensor supply +5 V
X4 (Up)Power supply of the controller
X5 (Umot) Power supply of the motor
IN/OUT Connection of the EtherCAT communication
Designation Interface Function
Status LED all Green (continuous): 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.
Power LED all Green: Power supply within the permissible range.
Off: Power supply not within the permissible range.
RUN LED EtherCAT Green (continuous): Connection available. Device is ready for operation.
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): Defective configuration.
Red (single flash): Local error.
Red (double flash): Watchdog timeout.
Off: No connection error
LA LED EtherCAT Green (continuous): No data transfer. Connection to another participant has
been established.
Green (flashing): Data transfer active.
Off: No data transfer. No connection to another participant.
USB • X1 COM • X2 I/O • X3 Up • X4
LALA
Power
INOUT
RUN
Status
ERR
Umot • X5

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4 Installation
4.1 Mounting
Only trained experts and instructed persons with knowledge of the following fields may
install and commission the Motion Controller:
Automation technology
Standards and regulations (such as the EMC Directive)
Low Voltage Directive
Machinery Directive
VDE regulations (DIN VDE 0100)
Accident prevention regulations
This description must be carefully read and observed before commissioning.
Also comply with the supplementary instructions for installation (see chap. 2.3, p. 9).
4.1.1 Mounting instructions
CAUTION!
The Motion Controller can become very hot during operation.
Place a guard against contact and warning notice in the immediate proximity of the
controller.
NOTICE!
Improper installation or installation using unsuitable attachment materials can damage the
Motion Controller.
Comply with the installation instructions.
NOTICE!
Installation and connection of the Motion Controller when the power supply is applied can
damage the device.
During all aspects of installation and connection work on the Motion Controller, switch
off the power supply.
CAUTION!
The Speed Controller can become very hot during operation.
Place a guard against contact and warning notice in the immediate proximity of the
controller.
NOTICE!
Improper installation or installation using unsuitable attachment materials can damage the
Speed Controller.
Comply with the installation instructions.

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NOTICE!
Installation and connection of the Speed Controller when the power supply is applied can
damage the device.
Prior to all aspects of installation and connection work on the Speed Controller, switch
off the power supply.
4.1.2 Attachment via the side plates
NOTICE!
Installation of the Motion Controller on a surface that is not flat can lead to the Motion
Controller becoming damaged.
Install the Motion Controller on a flat surface.
Fig. 6: Attachment via the side plates
Attach the Motion Controller (2) to the mounting plate with screws (1) as described in
Fig. 6.
1Screw 2MotionController

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4.1.3 Installation on a top-hat rail
The top-hat rail adapter is available as an accessory, see the Accessories Manual.
Fig. 7: Installation on a top-hat rail
1. Using countersunk screws (3), screw the top-hat rail adapter (2) onto the Motion Con-
troller (1).
The tightening torque of the countersunk screws is max. 60 Nm.
2. Click the Motion Controller with the top-hat rail adapter onto the top-hat rail.
3 Motion Controller
4 Top-hat rail adapter
5 Countersunk screw

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4.1.4 Installation with top-hat rail clips
Fig. 8: Installation with top-hat rail clips
1. Push the clamping pins (2) for the two top-hat rail clips (3) into the side plates as far as
they will go.
2. Click the top-hat rail clips onto the top-hat rail.
Top-hat rail clips are not part of the FAULHABER product portfolio, they must be pro-
vided by the user (recommendation: Mounting foot, WAGO item number 209-188).
3 Motion Controller
4 Clamping pin
5 Top-hat rail clip

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4.2 Electrical connection
4.2.1 Instructions for the electrical connection
NOTICE!
Electrostatic discharges to the Motion Controller connections can damage the electronic
components
Observe the ESD protective measures.
NOTICE!
Electrostatic discharges to the Speed Controller connections can damage the electronic
components
Observe the ESD protective measures.
NOTICE!
Incorrect connection of the wires can damage the electronic components.
Connect the wires as shown in the connection assignment.
NOTICE!
A short-term voltage peak during braking can damage the power supply or other con-
nected devices.
For applications with high load inertia, the FAULHABER Braking Chopper of the BC
5004 series can be used to limit overvoltages and thereby protect the power supply. For
more detailed information see the data sheet for the Braking Chopper.
The Motion Controller contains a PWM output stage for controlling the motors. Power
losses arising during operation and alternating electrical fields arising due to the pulsed
control of the motors, must be dissipated and damped by appropriate installation.
Connect the Motion Controller to a grounding system. This should be done preferably
by mounting it on an earthed baseplate, or alternatively by connecting it to an earthed
mounting rail.
Make sure that potential equalisation is present between all coupled parts of the sys-
tem. This applies even if the Motion Controller and motor are mounted separately.
If several electrical devices or controllers are networked by means of RS232 or CAN,
make sure that the potential difference between the earth potentials of the various
parts of the system is less than 2 V.
The cross-section of the required potential equalisation conductors between the various
parts of the system is specified in VDE 100 and must satisfy the following conditions:
At least 6 mm2
Larger than half the cross-section of the supply conductor