Faulhaber MCDC 3002/03/06 RS/CF/CO Series User manual

WE CREATE MOTION
Technical Manual
Motion Controller
MCBL 3002/03/06 RS/CF/CO
MCDC 3002/03/06 RS/CF/CO
MCLM 3002/03/06 RS/CF/CO
MCBL 3002/03/06 AES RS/CF/CO
EN

Imprint
2
Version:
8th edition, 9-11-2018
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 .................................................................................................. 8
2.3 Environmental conditions ...................................................................................... 9
2.4 EC directives on product safety ............................................................................. 9
3 Product description ........................................................................................................ 10
3.1 General product description ................................................................................ 10
3.2 Product information ............................................................................................. 11
3.3 Product variants .................................................................................................... 12
3.3.1 Motion Controllers for motors in the lower power range ................. 12
3.3.1.1 MCxx 3002 S RS/CF/CO ........................................................... 12
3.3.1.2 MCxx 3002 F RS/CF/CO ........................................................... 12
3.3.1.3 MCxx 3002 P RS/CF/CO ........................................................... 12
3.3.1.4 MCxx 3003 P RS/CF/CO ........................................................... 13
3.3.2 Motion Controller for motors in the higher power range................. 13
3.3.2.1 MCxx 3006 S RS/CF/CO ........................................................... 13
4 Installation ...................................................................................................................... 14
4.1 Mounting .............................................................................................................. 14
4.1.1 Mounting instructions .......................................................................... 14
4.1.2 Install Motion Controller with housing ............................................... 15
4.2 Electrical connection ............................................................................................ 16
4.2.1 Notes on the electrical connection ...................................................... 16
4.2.2 Screening ............................................................................................... 16
4.2.3 Electrical connection of the Motion Controller .................................. 18
4.2.3.1 Connecting the supply........................................................... 18
4.2.3.2 EMC protective measures ...................................................... 20
4.2.4 Connections ........................................................................................... 21
4.2.4.1 Connections on the supply side (MCxx 3002/3003/3006)..... 21
4.2.4.2 MCDC 3002 connections on the motor side......................... 22
4.2.4.3 MCDC 3003 connections on the motor side......................... 24
4.2.4.4 MCDC 3006 connections on the motor side......................... 25
4.2.4.5 MCBL/MCLM 3002 connections on the motor side.............. 26
4.2.4.6 MCBL/MCLM 3003/3006 connections on the motor side..... 27
4.2.4.7 MCxx 3006 D-sub connector.................................................. 28
4.2.5 I/O circuit diagrams ............................................................................... 29
4.2.5.1 Analogue input...................................................................... 29
4.2.5.2 Digital output ........................................................................ 29
4.2.5.3 Error output ........................................................................... 30
4.2.6 External circuit diagrams (Examples) ................................................... 31
4.2.7 Communication port............................................................................. 33

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Content
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5 Maintenance ...................................................................................................................35
5.1 Maintenance instructions .................................................................................... 35
5.2 Maintenance tasks ................................................................................................ 35
5.3 Troubleshooting ................................................................................................... 35
6 Warranty ......................................................................................................................... 36

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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 following series:
MCBL 3002/03/06 RS/CF/CO
MCDC 3002/03/06 RS/CF/CO
MCLM 3002/03/06 RS/CF/CO
MCBL 3002/03/06 AES RS/CF/CO
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 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
Communications and Functional Manual Interface description – RS232
Communications and Functional Manual Interface description – CANopen with FAULHABER channel
Communications and Functional Manual Interface description – CANopen CiA 402
Software manual Operating instructions for FAULHABER Motion Manager PC soft-
ware

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About this document
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1.4 List of abbreviations
Abbreviation Meaning
AnIn Analogue Input
AGND Analogue Ground
CAN Controller Area Network
CAN_L CAN-Low
CAN_H CAN-High
CF Controller with CANopen interface (Faulhaber channel)
CLK Clock
CO Controller with CANopen interface acc. to CiA 402
CS Chip Select Cable
Data Data cable
DigIn Digital input
DigOut Digital output
EMC Electromagnetic compatibility
ESD Electrostatic discharge
FAULT Fault output
GND Ground
PLC Programmable Logic Controller
PWM Pulse Width Modulation
RS Controller with serial RS232 interface
RxD Receive data
TTL Transistor Transistor Logic
TxD Transmit data

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1.5 Symbols and designations
CAUTION!
Hazards to persons. Disregard may lead to minor injuries.
Measures for avoidance
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 FAULHABER Motion Controllers described here are designed for the activation and con-
trol of DC-micromotors (MCDC), linear DC servomotors (MCLM) and brushless DC motors
(MCBL). They feature numerous functions and operating modes which facilitate flexible
adaptation to the respective drive task.
Thanks to their compact design, the units can be used in a wide variety of applications and
require only basic wiring. The flexible connection possibilities open a wide range of applica-
tions in all areas, such as in decentral systems in automation technology and in pick-and-
place machines and machine tools.
The following points must be observed to ensure that the motors are used as intended:
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 should be operated only within the limits specified in the data
sheet.
Please ask the manufacturer for information about use under individual special envi-
ronmental conditions.
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.

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Safety
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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.
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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Product description
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3 Product description
3.1 General product description
The FAULHABER Motion Controllers are based on a high-performance digital signal proces-
sor (DSP) that enables high control accuracy, exact positioning and very low speeds.
The Motion Controllers are designed for various drive applications, which can be config-
ured using the respective communication interface.
Depending on the version, the following tasks can be performed:
Position control with analogue or digital setpoint specification
Speed control with analogue or digital setpoint specification
Detection of reference marks and limit switches
Advanced operating modes such as stepper motor operation, electronic gearheads,
voltage controller mode or current control with analogue current setting
Execution of sequence programs stored in the controller (only with version RS)
Various inputs and outputs are available for implementing these tasks:
The set configuration can be stored permanently.
Input/output Possible applications
Analogue input Setpoint specification via analogue or PWM signal
Digital input for reference marks and limit switches
Pulse input
Incremental encoder connection
Fault output Digital output
Pulse output
Digital input for reference marks and limit switches
Rotation direction input
1 additional digital input Digital input for reference marks and limit switches
Communications interface Depending on the version, as serial RS232 or CAN interface for coupling to PC
or control
Motion Controllers with RS232 interface can also be operated independently of the
communication interface if a pre-programmed function or sequence program has been
programmed without digital command control.
As an option, the motor and control electronics can be supplied with power separately
(important for safety-relevant applications). In this case, the 3rd input is no longer
available.
Special preconfiguration of the modes and parameters is possible on request.

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Product description
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3.2 Product information
Fig. 1: Designation key
RS 232, serial interface
CAN interface FAULHABER
CAN interface CiA
Max. continuous output current 2 A
Max. continuous output current 3 A
Max. continuous output current 6 A
Max. supply voltage 30 V
DC micromotors
Brushless DC motors
Linear DC servomotors
Motion Controller
... ... ... …MC 30
RS:
CF:
CO:
S:
F:
P:
02:
03:
06:
30:
MC:
DC:
BL:
LM:
…
Housing with screw-type terminal strip
Housing with LIF connector (motor)
Board version with male connectors
Only for brushless DC motors with
absolute encoders
AES:

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3.3 Product variants
3.3.1 Motion Controllers for motors in the lower power range
3.3.1.1 MCxx 3002 S RS/CF/CO
Motion Controller with hot-melt housing and screw terminals on the supply and motor
side.
3.3.1.2 MCxx 3002 F RS/CF/CO
Motion Controller with hot-melt housing and screw terminals on the supply side and with
flexboard connection on the motor side.
3.3.1.3 MCxx 3002 P RS/CF/CO
Motion Controller without housing (board version) with plug connectors on the supply and
motor side.
1 Assembly sleeves
2 Screw terminal block on the motor side
3 Screw terminal block on the supply side
1 Assembly sleeves
2 LIF plug connector on the motor side for
FFC and FPC, 8-pole
3 Screw terminal block on the supply side
1 Plug connector on the supply side
2 Plug connector on the motor side

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Product description
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3.3.1.4 MCxx 3003 P RS/CF/CO
Motion Controller without housing (board version) with plug connectors on the supply and
motor side.
3.3.2 Motion Controller for motors in the higher power range
3.3.2.1 MCxx 3006 S RS/CF/CO
Motion Controller with metal housing and screw terminals on the supply and motor side.
1 Plug connector on the supply side
2 Plug connector on the motor side
1 Mounting holes
2 Screw terminal block on the supply side
3 D-sub connector for serial connection (RS)
or CAN connection (CF/CO)
4 Screw terminal block on the motor side
4

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4 Installation
This description must be carefully read and observed before commissioning.
Observe the environmental conditions (see chap. 2.3, p. 9).
Only trained experts and instructed persons with knowledge of the following fields may
install and commission the motors with integrated Speed Controller:
Automation technology
Standards and regulations (such as the EMC Directive)
Low Voltage Directive
Machinery Directive
VDE regulations (DIN VDE 0100)
Accident prevention regulations
4.1 Mounting
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.

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4.1.2 Install Motion Controller with housing
NOTICE!
Pressing out of the assembly sleeves.
On a soft or uneven surface, the assembly sleeves can be pushed out while screwing on the
Motion Controller.
Select a smooth and hard surface that supports the assembly sleeves against the screw-
ing forces.
Fig. 2: Mounting (example)
1. Secure the Motion Controller at the assembly sleeves or mounting holes with fastening
screws on a flat and hard surface (for screw size and torque, see Tab. 1).
2. Protect the fastening screws to prevent displacement due to the effect of heat.
Tab. 1: Attachment specifications
Motion Controller Min. tightening torque (Ncm) Max. tightening torque (Ncm)
MCxx 3002 S RS/CF/CO 12 15
MCxx 3002 F RS/CF/CO 12 15
MCxx 3006 S RS/CF/CO 50 60

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4.2 Electrical connection
4.2.1 Notes on the electrical connection
NOTICE!
Electrostatic discharges to the Motion 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!
Excessive force can damage the flexboard.
Do not press in the plug connectors by force.
Use a suitable tool (tweezers, flat-nose pliers) if necessary.
Do not pinch the flexboard.
4.2.2 Screening
Fig. 3: MCBL motor wiring
The encoder and signal cables are susceptible to interference. Therefore, a maximum
cable length cannot be specified.
Shielded wires must always be used with cable lengths > 300 mm.
Cable Shield
Motor A Phase A
Sensor C Hall Sensor C
Sensor A Hall Sensor A
Motor B Phase B
U
DD
Sensor B Hall Sensor B
Motor C Phase C
Brushless
DC-Servomotor
SGND
Cable Shield

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Fig. 4: MCDC motor wiring
Connect screen connections for the sensor systems and the motor cables to the Motion
Controller to the earthed mounting plate or the screen connection screw on the Motion
Controller by the shortest available route.
The best screening effect is achieved if the braiding is laid flat for instance on a screen
terminal.
If the installation ensures potential equalisation, the braid can also be attached to an
earthed surface on the motor.
Alternatively equalisation currents can also be suppressed by connected the cable
screen at the motor end via a capacitor (approx. 1μF … 2μF / 50 V).
Mot +
Channel A
Mot –
Channel B
DC-Motor
with Encoder
SGND
UDD
Cable Shield
Cable Shield

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4.2.3 Electrical connection of the Motion Controller
4.2.3.1 Connecting the supply
NOTICE!
Risk of damage caused by inadequately dimensioned power supply unit.
Using an inadequately dimensioned power supply unit can result in malfunctions.
Make sure that the power supply unit is adequately dimensioned.
Tab. 2: Recommended values for the lengths of the motor connection cable
To ensure the allowable emissions or necessary immunity in industrial use, it may be neces-
sary to use an EMC filter and / or shielding or an EMC suppressor circuit.
The connection cables are <3 m
1. Take the appropriate EMC protective measures (see chap. 4.2.3.2, p. 20).
2. Take the appropriate ESD protective measures.
3. Connect wires or flexboard according to pin assignment (see chap. 4.2.4, p. 21).
4. Connect the power supply as described in the explanation below.
There are 2 options for supplying power to the motor and the FAULHABER Motion Control-
ler:
With the exception of the power supply, all connection cables on the supply side must
not exceed a length of 3 m. The maximum permissible length of the motor connection
cable is dependent on the used encoder type (see Tab. 2). Whether or not a longer
motor connection cable may be used must be checked on a case-by-case basis.
Encoder
type
Length of the motor connection cable, unshielded Length of the motor connection cable,
shielded
Analogue
Hall
0.3 m 2.0 m
IE2/IE3 0.5 m On request
IE3L Several meters, dependent on speed and resolution On request
AES 0.3 m On request

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Power supply with common electronics supply
In the case of power supply with common electronics supply, the controller and motor are
switched off simultaneously if a fault occurs. After interruption of the power supply, the
reference run must be performed again.
Fig. 5: Circuit diagram – common electronics supply
Power supply with separate electronics supply (option 3085)
In the case of power supply with separate electronics supply, the motor supply can be
switched off (e.g. by means of a safety relay) in the event of a fault while the controller
continues to be supplied. As a result, the reference run does not need to be performed
again after a fault because the sensor supply of the motor was maintained during the fault.
In the case of a separate electronics supply, power is supplied using the connection 3.In /
UEL in addition to the connection UB. Motion Controllers with a separate electronics
supply do not therefore have a third digital input.
Fig. 6: Circuit diagram – separate electronics supply
GND
Motor
Int. Supply
UB
GND
3. In
+24 V
Motor
Int. Supply

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4.2.3.2 EMC protective measures
To reduce the effects on the DC power supply network, L1 ferrite sleeves (such as WE 742
700 790) can be used on the supply cables.
To protect against overvoltage on the supply side (surge), it is recommended to additionally
connect an external diode D1 (e. g. NTE 4934, 1500 W).
Fig. 7: EMC suppressor circuit
NOTICE!
Risk of damage caused by EMC interaction in the case of separate electronics supply
In the case of a separate electronics supply, the suppressor circuit (see Fig. 7) must be
such that it protects both supply connections.
Mcxx 3003/3006 protective measures
The devices are intended only for use in industrial applications. If the devices are used in
the home, in business, in commerce or in a small business, appropriate measures must be
taken to ensure that the emitted interference is below the permissible limit value.
Tab. 3 shows which additional EMC measures can be implemented to optimise the behav-
iour of the equipment in the intended environment with regard to transient emission and
interference resistance.
Tab. 3: EMC measures
EMC filter (MCDC 3006 S and MCBL 3006 S only):
The supply and motor supply cables must be installed directly at the device with two
windings through a suitable ferrite sleeve (e.g. Würth Elektronik No.: 74270090).
EMC suppressor circuit (MCBL 3006 S and MCLM 3006 S only):
The signal cables of the MCBL 3006 S and MCLM 3006 S must be installed directly at the
device with two windings through a star ring (e.g., Würth Elektronik No.: 7427153).
To provide the required interference resistance in industrial applications, it may be
necessary to use an EMC filter or a screen and an EMC suppressor circuit.
L1
D1
GND
Motor
Int. Supply
UB
Motion Controller Operational environment Interference type Action
MCDC 3006 S Industrial area Transient emission EMC filter
MCBL 3006 S Industrial area Transient emission EMC filter
MCBL 3006 S Industrial area Interference resistance EMC suppressor circuit