Faulhaber MCLM 300 RS Series Parts list manual

WE CREATE MOTION
EN
Communication and
Function Manual
Motion Control
Series MCLM 300x RS

2
Imprint
Version:
3rd issue, 11.11.2013
Copyright
by Dr. Fritz Faulhaber GmbH & Co. KG
Daimlerstr. 23 / 25 · 71101 Schönaich
All rights reserved, including translation rights.
No part of this description may be duplicated, repro-
duced, stored in an information system or processed or
transferred in any other form without prior express writ-
ten permission of Dr. Fritz Faulhaber GmbH & Co. KG.
This communication and function manual has been pre-
pared with care.
Dr. Fritz Faulhaber GmbH & Co. KG cannot accept any
liability for any errors in this communication and function
manual 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 communication and function manual are
to be noted and followed when using the software.
Subject to change without notice.
The respective current version of this communication and
function manual is available on FAULHABER's internet
site:
www.faulhaber.com

3
Overview
Overview of the Faulhaber Motion Control Drives documents
Document Contents
Technical Manual Device installation, safety, specification
Communication and function manual
(RS232)
Initial start-up, function overview, protocol description,
parameter description and notes on autonomous sequen-
tial programs
Motion Manager instruction manual Operation of the "FAULHABER Motion Manager" PC soft-
ware for configuration and commissioning
Product data sheets Technical limit and operating data
Guide to the Document
Quick Start
Notes on the initial start-up of a Faulhaber Motion Control System
at the PC in the default configuration Page 8
Functional Description
Overview of the possible operating modes Page 10
Protocol Description
Specification of the communication protocol Page 50
Commissioning
Detailed description of the parameters for the implemented
function blocks within the drive Page 56
Sequence Programs
Notes on automation of the drive function via sequence programs Page 69
Parameter Description
Description of all the drive's parameters and commands
broken down into functional areas Page 76

4
Table of Contents
1 Important Information 6
1.1 Symbols used in this manual 6
1.2 Additional information 7
2 Quick Start 8
3 Functional Description 10
3.1 Position control 11
3.1.1 Set value presetting via the serial interface 11
3.1.2 Analog positioning mode (APCMOD) 14
3.1.3 External encoder as actual position value (ENCMOD) 16
3.2 Velocity control 19
3.2.1 Velocity presetting via the serial interface 19
3.2.2 Velocity presetting via an analog voltage or a PWM signal 22
3.2.3 External encoder as actual velocity value (ENCMOD) 24
3.3 Homing and limit switches 27
3.3.1 Limit switch connections and switching level 27
3.3.2 Motion control commands 28
3.3.3 Configuration of homing and limit switches 29
3.4 Enhanced operating modes 32
3.4.1 Stepper motor mode 32
3.4.2 Gearing mode (electronic gear) 34
3.4.3 Voltage regulator mode 36
3.4.4 Current control with analog current presetting 37
3.5 Special fault output functions 39
3.6 Technical information 41
3.6.1 Ramp generator 41
3.6.2 Sinus commutation 45
3.6.3 Current controller and I²t current limitation 45
3.6.4 Overtemperature protection 47
3.6.5 Under-voltage monitoring 47
3.6.6 Overvoltage regulation 47
3.6.7 Setting the controller parameters for velocity and position controller 47
4 Protocol Description 50
4.1 Baud rate and node number 52
4.2 Trace Function 54

5
Table of Contents
5 Commissioning 56
5.1 Basic settings 57
5.2 Configuration using Motion Manager 58
5.2.1 Connection setting 59
5.2.2 Motor selection 60
5.2.3 Drive configuration 60
5.2.4 Basic settings 60
5.2.5 Drive parameters 63
5.2.6 Controller settings 64
5.2.7 I / O connection and use 66
5.2.8 Data set management 67
5.2.9 Diagnosis 68
5.2.10 Trace Function 68
6 Sequence Programs 69
7 Parameter Description 76
7.1 Basic setting commands 76
7.1.1 Commands for special operating modes 76
7.1.2 Parameters for basic setting 77
7.1.3 General parameters 78
7.1.4 Configuration of fault pin and digital inputs 78
7.1.5 Configuration of homing and limit switches in 79
7.2 Query commands for basic setting 80
7.2.1 Operating modes and general parameters 80
7.2.2 Configuration of fault pin and digital inputs 81
7.2.3 Configuration of homing 82
7.3 Miscellaneous commands 82
7.4 Motion control commands 83
7.5 General query commands 84
7.6 Commands for sequence programs 85

6
1 Important Information
1.1 Symbols used in this manual
WARNING! Warning!
This pictogram with the wording "Warning!" indicates an imminent danger which can result in
physical injuries.
fThis arrow points out the appropriate action to take to prevent the imminent danger.
CAUTION! Caution!
This pictogram with the wording "Caution!" indicates an imminent danger which can result in slight
physical injuries or material damage.
fThis arrow points out the appropriate precautions.
REGULATION! Regulations, guidelines and directives
This pictogram with the wording "Regulation" indicates a statutory regulation, guideline or directive
which must be observed in the respective context of the text.
NOTE Note
This "Note" pictogram provides tips and recommendations for use and handling of the component.

7
1 Important Information
1.2 Additional information
WARNING! Risk of injuries
Failure to comply with the safety instructions during installation and operation can result in irrepara-
ble damage to the device and a risk of injuries to the operating personnel.
fPlease read through the whole of your drive's technical manual before installing the drive.
fKeep this communication and function manual in a safe place for subsequent use.
NOTE Always use the current version of the Faulhaber MotionManager.
The respective current version is available to download from www.faulhaber.com/MotionManager.
NOTE The information given in this instruction manual refers to the standard version of the drives.
Please refer to any additional information sheet provided in the event of differences in information
due to a customer-specific motor modification.
NOTE RS232 interface
The drive can also be operated independently of the RS232 interface if the desired function, such as
velocity or position controller, has been previously programmed via analog input, stepper motor or
electronic gear.

8
2 Quick Start
To facilitate introduction, this chapter highlights the initial steps for commissioning and operation
of FAULHABER Motion Controllers with serial interface. However, the detailed documentation must
always be read and adhered to, particularly Chapter 5.1 „Basic settings“!
The units are delivered as standard without a valid node address (NODEADR0) and with a transfer
rate of 9 600 baud. The settings can be changed via the interface, e.g. with the FAULHABER Motion
Manager (see Chapter 5.2.1 „Connection Parameters“).
The following steps are necessary for commissioning using the default configuration:
1. Connect the drive unit to a 12V – 24V voltage source.
For details of the connection cable assignment, see Chapter 3 “Installation” in the technical
manual.
2. Connect drive unit to a serial interface of the PC (e.g. COM1) and switch on.
For details of the interface, see Chapter 3 “Installation” in the technical manual.
3. Configuration and motion commands can now be executed via suitable software,
e.g. FAULHABER Motion Manager.
NOTE Use of a USB serial adapter is recommended if the PC used does not have a serial port.
Operation via FAULHABER Motion Manager
The FAULHABER Motion Manager offers easy access to the Motion Controller’s command set. The
desired node must have been activated beforehand by double clicking in Node Explorer in the case
of network operation.
The FAULHABER commands described below can be entered directly in the command input line or
selected from the Commands menu.
In order to drive a motor via the Motion Manager, follow the procedure below (assuming a matching
baud rate):
1. Start FAULHABER Motion Manager.
2. Configure drive functions:
Motion controllers for linear motors must be equipped with current limiting values suitable for the mo-
tor and suitable controller parameters before being started up.
The Motor Wizard is available in Motion Manager for selection of the motor and basic parameters
suitable for the motor.
Other settings, e.g. for the function of the fault output, can be made under the “Configuration –
Drive functions” menu item, where a convenient dialog is provided (see Chapter 5.2 „Configuration
using Motion Manager“). The configuration dialog is also available for direct access in the Wizard
bar of the Motion Manager (Configuration Wizard).
CAUTION! Check basic settings
Incorrect values in the Motion Controller's settings can result in damage to the controller and / or
drive (see Chapter 5.1 „Basic settings“).
To operate the drive via the PC, set value presetting must be set to digital (SOR0).
If the settings are to be permanently stored, press the “EEPSAV” button.

9
2 Quick Start
3. Activate drive:
“EN” command.
Enter in command input field and press “Send” button or select in “Commands – Motion control
– Enable drive” menu and press “Send” button.
4. Operate drive (examples):
Move the motor by 10000 increments with a relative positive positioning speed of 100 mm/s:
Command “SP100” to set the positioning speed, command “LR10000” to load the relative
target position, command “M”, to move to the loaded target position.
5. Deactivate drive again
“DI” command.
The controller tuning wizard
Motion Manager also provides a Controller Tuning Wizard, with which the controller parameters of
the velocity and positioning controller can be adjusted to the application.
WARNING! Warning!
During operation with the tuning wizard, the motor is alternately run within the set range limits.
fThe motor must be installed so that it can freely move for the parameter search.

10
3 Functional Description
The Motion Controllers can be configured for different operating modes. As standard the drive unit
is delivered as a servomotor with set value presetting via the serial interface. The drive can be recon-
figured by means of the corresponding FAULHABER commands.
Command Argument Function Description
SOR 0 – 4 Source for Velocity Source for velocity presetting
0: Serial interface (default)
1: Voltage at analog input
2: PWM signal at analog input
3: Current target value via analog input
4: Current target value via analog input with preset-
ting of the direction via input polarity
CONTMOD - Continuous Mode Switch back to normal mode from an enhanced mode
.
STEPMOD - Stepper Motor Mode Change to stepper motor mode
APCMOD - Analog Position Con-
trol Mode
Change to position control via analog voltage
ENCMOD - Encoder Mode Change to encoder mode An external encoder serves as
position detector (the current position value is set to 0)
HALLSPEED - Hall sensor as speed
sensor
Speed via Hall sensors in encoder mode
ENCSPEED - Encoder as speed
sensor
Speed via encoder signals in encoder mode
GEARMOD - Gearing Mode Change to gearing mode
VOLTMOD - Set Voltage Mode Activate Voltage Regulator Mode
If the settings are to be permanently stored, the command SAVE must be executed after the configu-
ration; this saves the current settings in the Flash data memory, from where they are reloaded when
the unit is next switched on. Alternatively, the EEPSAV command can also be executed. Both com-
mands are identical, therefore SAVE only is used in the following.
The power stage must be activated (EN) for the drive to operate.
All commands listed further below are summarised and explained again in Chapter 7 „Parameter
Description“.
Guide
Position control Page 11
Velocity control Page 19
Homing and limit switches Page 27
Enhanced operating modes Page 32
Special fault output functions Page 39
Technical information Page 41

11
3 Functional Description
3.1 Position control
3.1.1 Set value presetting via the serial interface
Controller structure for set value presetting via the serial interface or via a sequence program
Speed controller
I²t current limitation
LM
Motor
Hall
Gate Driver
Ramp generator
Pos. controller
Target Pos.
RS232
APCMOD
SOR0
Posact.
PI
vact.
Iact.
3
Position and
velocity calculation
In this operating mode, target positions can be preset via the serial interface or a sequence program:
Basic settings
CONTMOD and SOR0 operating mode.
The positioning range limits can be set via the command LL and activated via APL.
The proportional amplification PP and a differential term PD can be set for the position controller.
Command Argument Function Description
PP Value Load Position Propor-
tional Term
Load position controller amplification.
Value: 1 … 255
PD Value Load Position Differen-
tial Term
Load position controller D-term.
Value: 1 … 255
LL Value Load Position Range
Limits
Load limit positions (the drive cannot be moved out of
these limits). Positive values specify the upper limit and
negative values the lower.
The range limits are only active if APL1 is.
Value: –1.8 · 109… 1.8 · 109
APL 0 - 1 Activate / Deactivate
Position Limits
Activate range limits (LL) (valid for all operating modes
except VOLTMOD).
1: Position limits activated
0: Position limits deactivated
Guide
Positioning mode with set value presetting via the serial interface:
Set value presetting via the serial interface Page 11
Positioning mode with set value presetting via the analog input:
Analog positioning mode (APCMOD) Page 14
Positioning mode with external encoder as actual value:
External encoder as actual position value (ENCMOD) Page 16
Positioning on predefined limit switches:
Configuration of homing and limit switches Page 29

12
3 Functional Description
3.1 Position control
Additional settings
Ramp generator
The slopes of the acceleration and deceleration ramps, and the maximum speed can be defined using
the AC, DEC and SP commands (see Chapter 3.6.1 „Ramp generator“).
Velocity controller / current limitation
The controller parameters POR and I of the velocity controller can be adjusted. In addition, the cur-
rent limitation values LPC and LCC can be used to protect the drive against overload (see Chapter 3.2
„Velocity control“).
Motion control commands
The positioning is executed via the FAULHABER motion control commands. An overview of all mo-
tion control commands is given in Chapter 7.4 „Motion control commands“.
Command Argument Function Description
EN - Enable Drive Activate drive
DI - Disable Drive Deactivate drive
LA Value Load Absolute Position Load new absolute target position
Value: –1.8 · 109… 1.8 · 109
LR Value Load Relative Position Load new relative target position, in relation to last
started target position.
The resulting absolute target position must lie between
the values given below.
Value: –2.14 · 109… 2.14 · 109
M - Initiate Motion Activate position control and start positioning
HO - / value Define Home Position Without argument:
Set actual position to 0.
With argument:
Set actual position to specified value.
Value: –1.8 · 109… 1.8 · 109
NP - / value Notify Position Without argument:
A “p” is returned when the
target position is attained.
With argument:
When the specified position is passed
a "p" is returned.
Value: –1.8 · 109… 1.8 · 109
NPOFF - Notify Position Off A notify position command not yet triggered
is deactivated again.
Example:
Load target position: LA40000
Start positioning: M
Attainment of the target position or any intermediate position is indicated by a “p” on the serial
interface if “Notify Position” is set before the start of positioning, provided that ANSW1 or ANSW2 is
set:
Position resolution
The TM parameter represents the magnetic pitch (τm) of the linear motor. If the linear Hall sensors of
the motors are used as position transducers, 3000 pulses per magnetic pitch (τm) are supplied.

13
3 Functional Description
3.1 Position control
Complex motion profiles
More complex motion profiles can be generated through appropriate presetting of new values (max-
imum speed, acceleration, end position) during positioning. After a value change, simply execute a
new motion start command (M). The commands NP and NV can be used to control the sequence.
Further information on compiling motion profiles is given in Chapter 3.6.1 „Ramp generator“.
Digital signal target position
The entry into the target corridor can be displayed via the fault output as a digital output signal in
the POSOUT function. The signal is not reset until a further Motion start command (M).
For notes on configuration, see Chapter 3.5 „Special fault output functions“.

14
3 Functional Description
3.1 Position control
3.1.2 Analog positioning mode (APCMOD)
Controller structure for set-point presetting via an analog voltage
Speed controller
I²t current limitation
LM
Motor
Hall
Gate Driver
Ramp generator
Pos. controller
Target Pos.
RS232
APCMOD + SOR1
SOR0
Posact.
PI
vact.
Iact.
Position and
velocity calculation
APCMOD + SOR2
AnIn
PWM
3
In this operating mode the target position can be preset using an analog voltage at the AnIn input.
Basic settings
APCMOD mode and SOR1 or SOR2.
The positioning range limits can be set via the command LL and activated via APL.
The proportional amplification PP and a differential term PD can be set for the position controller.
The maximum position to be approached with a voltage of 10 V can be preselected with the LL com-
mand. At -10 V the drive moves in the opposite direction up to the set negative range limit.
Irrespective of the preset LL value, the maximum position is limited to 3 000 000 in APCMOD.
Comment: The resolution of the analog input is limited to 12 bit (4096 steps).
The direction can be predefined with the commands ADL and ADR.
Additional settings
Ramp generator
The slopes of the acceleration and deceleration ramps, and the maximum speed can be defined using
the AC, DEC and SP commands (see Chapter 3.6.1 „Ramp generator“).
Velocity controller / current limitation
The controller parameters POR and I of the velocity controller can be adjusted. In addition, the cur-
rent limitation values LPC and LCC can be used to protect the drive against overload (see Chapter 3.2
„Velocity control“).

15
3 Functional Description
3.1 Position control
Positioning via pulse width signal (PWM) at the analog input (SOR2)
If SOR2 is set in APCMOD, the pulse duty factor of a PWM signal can be used as position set-point.
On delivery:
Pulse duty factor > 50% positive target position
Pulse duty factor = 50% target position = 0
Pulse duty factor < 50% negative target position
Absolute positioning within a magnetic pole pitch:
In motion control systems, after switching on, the initial position is absolutely initialised within a
pole pitch (-1 500 … 1 500 corresponds to the spacing of the magnetic poles). This means that even
if the power supply is disconnected, the position determination supplies the correct position value
after restarting (if the cage bar has only been moved within one magnetic pole pitch).
The following commands enable the drive to be accurately positioned in the voltage range 0 V …
10 V within one magnetic pole pitch and to return to the correct position even after the supply has
been switched off, without homing (not MCDC):
Switch over to analog positioning: APCMOD
Hide negative range: LL-1
Limit 0 V … 10 V at AnIn to one magnetic pole pitch: LL3000

16
3 Functional Description
3.1 Position control
3.1.3 External encoder as actual position value (ENCMOD)
Controller structure for using and external encoder as the actual value encoder
Gate Driver
Gate Driver
-
-
Speed controller
I²t current limitation
HALLSPEED
ENCSPEED
LM
Motor
Hall
IE
Gate Driver
Ramp engeneratorPos. controller
Target Pos.
RS232
SOR0
Posact.
PI
vact.
Iact.
Position and
velocity calculation
Position and
velocity calculation
AnIn
3
For high-precision applications, the actual values of LM motors can be derived from an external
encoder.
Depending on the application, the velocity can be derived from the encoder or from the Hall
sensors.
The external encoder can be connected directly to the motor shaft, but an encoder that is
mounted to the application output (e.g. glass scale) is particularly advantageous. This allows the
high precision to be set directly at the output.
Commutation still occurs via the analog Hall sensors.
Basic settings
ENCMOD and SOR0 operating mode.
The positioning range limits can be set via the command LL and activated via APL. The proportional
amplification PP and a differential term PD can be set for the position controller.
Command Argument Function Description
PP Value Load Position Propor-
tional Term
Load position controller amplification.
Value: 1 … 255
PD Value Load Position Differen-
tial Term
Load position controller D-term.
Value: 1 … 255
LL Value Load Position Range
Limits
Load limit positions (the drive cannot be moved out of
these limits). Positive values specify the upper limit and
negative values the lower.
The range limits are only active if APL1 is.
Value: –1.8 · 109… 1.8 · 109
APL 0 - 1 Activate / Deactivate
Position Limits
Activate range limits (LL) (valid for all operating modes
except VOLTMOD).
1: Position limits activated
0: Position limits deactivated

17
3 Functional Description
3.1 Position control
Settings for external encoder
Command Argument Function Description
ENCMOD - Encoder Mode Change to encoder mode An external encoder serves
as position transducer (the current position value is set
to 0).
ENCSPEED - Encoder as speed
sensor
Speed via encoder signals in encoder mode
HALLSPEED - Hall sensor as speed
sensor
Speed via hall sensors in encoder mode
ENCRES Value Load Encoder Resolu-
tion
Load resolution of external encoder (4 times lines/mm).
Value: 8 … 65 535
Additional settings
Ramp generator
The slopes of the acceleration and deceleration ramps, and the maximum speed can be defined using
the AC, DEC and SP commands (see Chapter 3.6.1 „Ramp generator“).
Velocity controller / current limitation
The controller parameters POR and I of the velocity controller can be adjusted. In addition, the cur-
rent limitation values LPC and LCC can be used to protect the drive against overload (see Chapter 3.2
„Velocity control“ and Chapter 3.6.3 „Current controller and I²t current limitation“).

18
3 Functional Description
3.1 Position control
Motion control commands
Positioning in the ENCMOD is executed in precisely the same way as in CONTMOD, using the
FAULHABER motion control commands. An overview of all motion control commands is given in
Chapter 7.4 „Motion control commands“.
Command Argument Function Description
EN - Enable Drive Activate drive
DI - Disable Drive Deactivate drive
LA Value Load Absolute Position Load new absolute target position
Value: –1.8 · 109… 1.8 · 109
LR Value Load Relative Position Load new relative target position, in relation to last
started target position.
The resulting absolute target position must lie between
the values given below.
Value: –2.14 · 109… 2.14 · 109
M - Initiate Motion Activate position control and start positioning
HO - / value Define Home Position Without argument:
Set actual position to 0.
With argument:
Set actual position to specified value.
Value: –1.8 · 109… 1.8 · 109
NP - / value Notify Position Without argument:
A “p” is returned when the target position is attained.
With argument:
A “p” is returned if the specified position is over-
travelled.
Value: –1.8 · 109… +1.8 · 109
NPOFF - Notify Position Off Notify Position command that has not yet been trig-
gered is deactivated again.
Example:
Load target position: LA1000
Start positioning: M
Attainment of the target position or any intermediate position is indicated by a “p” on the serial
interface if “Notify Position” is set before the start of positioning, provided that ANSW1 or ANSW2 is
set.
Actual value resolution
In ENCMOD the resolution of the position values depends on the resolution of the encoder.
Complex motion profiles
More complex motion profiles can be generated through appropriate presetting of new values (max-
imum speed, acceleration, end position) during positioning. After a value change, simply execute a
new motion start command (M). The commands NP and NV can be used to control the sequence.
Further information on compiling motion profiles is given in Chapter 3.6.1 „Ramp generator“.
Digital signal target position
The entry into the target corridor can be displayed via the fault output as a digital output signal in
the POSOUT function. The signal is not reset until a further Motion start command (M).
For notes on configuration, see Chapter 3.5 „Special fault output functions“.

19
3 Functional Description
3.2 Velocity control
In velocity control mode the velocity of the drive is controlled by a PI controller. Provided the drive is
not overloaded, the drive follows the presetting without deviation.
The current velocity of LM motors can be detected both from the Hall signals and via an additional
encoder; an incremental encoder.
The velocity can be preset via the serial interface or from sequence programs, via an analog voltage
preset or a PWM signal.
3.2.1 Velocity presetting via the serial interface
Controller structure for velocity control
Gate Driver
Gate Driver
-
Speed controller
I²t current limitation
LM
Motor
Hall
Gate Driver
Rampengenerator
RS232
SOR0
SOR1
SOR2
PI
vact.
vtarget
Iact.
Position and
velocity calculation
AnIn
PWMIn
In this operating mode the drive can be operated by velocity controlled with set-point presetting via
RS232 or from a sequence program.
Basic settings
CONTMOD and SOR0 operating mode.
The controller parameters POR and I and the sampling rate can be adjusted for the velocity controller.
Command Argument Function Description
POR Value Load Velocity Proportional
Term
Load velocity controller amplification.
Value: 1 … 255
I Value Load Velocity Integral Term Load velocity controller integral term.
Value: 1 … 255
SR Value Load Sampling Rate Load sampling rate of the velocity controller as a multi-
ple of the basic sampling time.
Value: 1 … 20

20
3 Functional Description
3.2 Velocity control
Velocity input
In LM motors the current velocity is determined in CONTMOD by evaluating the Hall sensor signals,
which supply 3 000 pulses per magnetic pitch.
Additional settings
Movement limits
The LL command can also be used to define a movement range limit for velocity mode. The APL1
command activates monitoring of these limits.
Ramp generator
The slopes of the acceleration and deceleration ramps, and the maximum speed can be defined using
the AC, DEC and SP commands (see Chapter 3.6.1 „Ramp generator“).
Current limitation
The current limitation values LPC and LCC can be used to protect the drive against overload (see
Chapter 3.6.3 „Current controller and I²t current limitation“).
Motion control commands
An overview of all motion control commands is given in Chapter 7.4 „Motion control commands“.
Command Argument Function Description
EN - Enable Drive Activate drive
DI - Disable Drive Deactivate drive
V Value Select Velocity Mode Activate velocity mode and set specified value as target
velocity (velocity control).
Unit: mm/s
Value: –10 000 … 10 000
Example:
Drive motor at 100 mm/s: V100
In order to change the direction, simply assign a negative velocity value (e.g. V-100).
Stop motor: V0
NOTE Check that the maximum speed SP is not set below the desired target velocity.
Due to the short stroke, the speed controller must be used with extreme caution, as the mechanical
system can be damaged if the target velocities (speeds) are too high. The positioning limits must be
defined using the APL1 command (default setting).