IMS Mforce micro drive Service manual

DRAFT COPY
Hardware
Reference
Excellence in Motion
www.imshome.com
TM
FORCE
MICRO DRIVE
MOTION CONTROL

The information in this book has been carefully checked and is believed to be accurate; however, no responsibility is
assumed for inaccuracies.
Intelligent Motion Systems, Inc., reserves the right to make changes without further notice to any products herein to
improve reliability, function or design. Intelligent Motion Systems, Inc., does not assume any liability arising out of the
application or use of any product or circuit described herein; neither does it convey any license under its patent rights of
others. Intelligent Motion Systems and are trademarks of Intelligent Motion Systems, Inc.
Intelligent Motion Systems, Inc.’s general policy does not recommend the use of its products in life support or aircraft
applications wherein a failure or malfunction of the product may directly threaten life or injury. Per Intelligent Motion
Systems, Inc.’s terms and conditions of sales, the user of Intelligent Motion Systems, Inc., products in life support or
aircraft applications assumes all risks of such use and indemnies Intelligent Motion Systems, Inc., against all damages.
TM
IMS PN MAN-MFIMicro
Revision R112706
Copyright © 2006 Intelligent Motion Systems, Inc., All Rights Reserved
Motion Control MForce MicroDrive Hardware Reference Change Log
Date Revision Changes
11/27/2006 R112706 Initial release.

i
Table of Contents
Getting Started ..................................................................................................................................1-1
Before You Begin....................................................................................................................... 1-1
Tools and Equipment Required................................................................................................. 1-1
Connecting the Power Supply ................................................................................................... 1-1
Connecting Communications ................................................................................................... 1-1
Connecting the Motor .............................................................................................................. 1-1
Minimum Required Connections.............................................................................................. 1-1
Install IMS Terminal Software................................................................................................... 1-2
Establishing Communications................................................................................................... 1-3
Apply Power to the MForce....................................................................................................... 1-4
Testing the MForce ................................................................................................................... 1-4
Make the MForce Move ............................................................................................................ 1-4
Motion Control Example Using Program Mode........................................................................ 1-5
Programming Notes .................................................................................................................. 1-5
Part 1: Hardware Specification
Section 1.1: Motion Control MForce MicroDrive Product Introduction ............................................1-9
Introduction.............................................................................................................................. 1-9
Feature Summary - Standard and Plus2Expanded ..................................................................... 1-9
Section 1.2: Motion Control MForce MicroDrive Detailed Specifications........................................1-11
Electrical Specifications ........................................................................................................... 1-11
Mechanical Specifications........................................................................................................ 1-13
Pin/Wire Assignments and Description................................................................................... 1-13
P1 Connector - I/O and Power Connections...................................................................... 1-13
P1 Connector Options ....................................................................................................... 1-14
P2 Connector - RS-422/485 Communications................................................................... 1-14
P2 Connector Options ....................................................................................................... 1-15
P3 Connector - Motor Phase Connector ............................................................................ 1-15
P3 Connector..................................................................................................................... 1-15
Options and Accessories.......................................................................................................... 1-16
Section 1.3: MForce MicroDrive Plus2Expanded Specifications ......................................................1-17
Electrical Specifications ........................................................................................................... 1-17
Mechanical Specifications........................................................................................................ 1-19
Pin Assignment and Description ............................................................................................. 1-20
P1 Connector - Power and Expanded I/O Configuration ................................................... 1-20
P1 Connector - Power and I/O with Remote Encoder Configuration................................. 1-20
P1 Connector Options ....................................................................................................... 1-21
P2 Connector - RS-422/485 Communications................................................................... 1-21
P2 Connector Options ....................................................................................................... 1-22
P3 Connector - Motor Phase Connector ............................................................................ 1-22
Options and Accessories.......................................................................................................... 1-22
Part 2: Connections and Interface
Section 2.1: Mounting and Connection Recommendations ...............................................................2-3
Mounting Recommendations.................................................................................................... 2-3
DC Power Recommendations ................................................................................................... 2-3
Layout and Interface Guidelines................................................................................................ 2-3
Recommended Wiring ......................................................................................................... 2-4
Recommended Mating Connectors and Pins........................................................................ 2-4
Securing Power Leads and Logic Leads ................................................................................. 2-4
Power Supply Connection......................................................................................................... 2-5
Aux-Logic Supply Connection .................................................................................................. 2-6
Section 2.2: Motor Sizing and Selection ............................................................................................2-7
Selecting a Motor ...................................................................................................................... 2-7
Types and Construction of Stepping Motors ........................................................................ 2-7
Sizing a Motor for Your System ............................................................................................ 2-7
Recommended IMS Motors ..................................................................................................... 2-8

ii
IMS Inside Out Stepper Motors ........................................................................................... 2-9
Motor Wiring.......................................................................................................................... 2-10
Connecting the Motor ............................................................................................................ 2-10
8 Lead Motors ................................................................................................................... 2-10
6 Lead Motors.................................................................................................................... 2-11
4 Lead Motors.................................................................................................................... 2-12
Section 2.3: Interfacing Communications .......................................................................................2-13
Available Communications Cables/Converters ........................................................................ 2-13
Interfacing Single Mode Communications .............................................................................. 2-13
Single Mode Communications Full Duplex (RS-422) ........................................................ 2-13
Single Mode Communications Half Duplex (RS-485) ....................................................... 2-14
Interfacing Party Mode Communications................................................................................ 2-14
Data Cable Termination Resistors....................................................................................... 2-14
MForce Communication Format........................................................................................ 2-15
MForce Response to Echo Mode........................................................................................ 2-15
Using Check Sum............................................................................................................... 2-17
MForce Party Mode Sample Codes..................................................................................... 2-18
MForce Immediate Party Mode Sample Codes................................................................... 2-18
Section 2.4: Interfacing and Using the MFI I/O...............................................................................2-20
The MForce Digital I/O.......................................................................................................... 2-20
Standard I/O Set ................................................................................................................ 2-20
Enhanced I/O Set - MForce Plus2Version .......................................................................... 2-20
Uses of the Digital I/O............................................................................................................ 2-20
MForce Digital Input Functions.............................................................................................. 2-21
Input Functions (I/O Points 1-4, 9-12).............................................................................. 2-21
Input Functions (Points 7 & 8 — Clock Inputs and Point 13 — Capture) ........................ 2-22
Active States Defined.......................................................................................................... 2-22
MForce Digital Output Functions........................................................................................... 2-22
Programmable Output Functions ....................................................................................... 2-22
Output Functions (Points 7 & 8 — Clock Outputs and Point 13 — Trip)......................... 2-23
MForce I/O Ratings ................................................................................................................ 2-24
MForce Standard I/O Connections ......................................................................................... 2-24
MForce Expanded Plus2I/O Connections............................................................................... 2-25
I/O Usage Examples — MForce Standard I/O Set .................................................................. 2-26
Input Interface Example - Switch Input Example (Sinking Input) ...................................... 2-26
Input Interface Example - Switch Input Example (Sourcing Input) .................................... 2-27
Output Interface Example (Sinking Output)...................................................................... 2-28
General Purpose I/O Usage Examples — Enhanced I/O Set ................................................... 2-29
Input Interface Example - Switch Input Example (Sinking Input) ...................................... 2-29
Input Interface Example - Switch Input Example (Sourcing Input) .................................... 2-30
Output Interface Example (Sinking Output)...................................................................... 2-31
Output Interface Example (Sourcing Output).................................................................... 2-32
Dedicated Digital I/O - Enhanced I/O Set.............................................................................. 2-33
Step/Direction/Clock I/O .................................................................................................. 2-33
Capture/Trip ...................................................................................................................... 2-34
Interfacing the Analog Input ................................................................................................... 2-35
Sample Usage ..................................................................................................................... 2-35
Appendices
Appendix A: Recommended Power and Cable Configurations .......................................................... A-3
Example A – Cabling Under 50 Feet, DC Power.......................................................................A-3
Example B – Cabling 50 Feet or Greater, AC Power to Full Wave Bridge ..................................A-3
Example C – Cabling 50 Feet or Greater, AC Power to Power Supply .......................................A-3
Recommended IMS Power Supplies ..........................................................................................A-4
Recommended Power Supply Cabling.......................................................................................A-4
Appendix B: I/O Application Guide.................................................................................................. A-5
Standard I/O Set Interfacing and Application............................................................................A-5
NPN Sinking Input..............................................................................................................A-5
PNP Sourcing Input.............................................................................................................A-6
Sinking Output ....................................................................................................................A-7

iii
Mixed Input/Output Example..............................................................................................A-7
Enhanced I/O Set Interfacing and Application..........................................................................A-8
NPN Sinking Input..............................................................................................................A-8
PNP Sourcing Input.............................................................................................................A-8
Sourcing Output ..................................................................................................................A-8
Mixed Input/Output Example............................................................................................A-10
Interfacing Inputs as a Group Example....................................................................................A-10
Interfacing Outputs as a Group Example.................................................................................A-11
Appendix C: Encoder Options......................................................................................................... A-12
MForce Motion Control Closed Loop Options.......................................................................A-12
Remote Differential Encoder - MForce MicroDrive Plus2..................................................A-12
Encoders Available from IMS..................................................................................................A-12
General Specifications ........................................................................................................A-12
Encoder Signals.......................................................................................................................A-13
Differential Encoder...........................................................................................................A-13
Characteristics ....................................................................................................................A-13
Encoder Cables ......................................................................................................................A-14
Recommended Encoder Mating Connectors ...........................................................................A-14
Appendix D: Optional Cables and Cordsets .................................................................................... A-15
Communications Converter Cables.........................................................................................A-15
USB to 10-Pin IDC (MD-CC400-000).............................................................................A-15
Electrical Specifications ......................................................................................................A-15
Mechanical Specifications...................................................................................................A-15
Installation Procedure for the MX-CC40x-000 .......................................................................A-16
Installing the Cable/VCP Drivers .......................................................................................A-16
Determining the Virtual COM Port (VCP)........................................................................A-18
Prototype Development Cables ...............................................................................................A-18
PD16-1417-FL3 — Power and I/O....................................................................................A-19
Prototype Development Cable PD10-1434-FL3 (All MForce Plus Motion Control)...............A-20
Setup Instructions — Cable #1 ..........................................................................................A-20
Setup Instructions — Cable #2 and Subsequent MDrives ..................................................A-20
Appendix E: IMS Enhanced Torque Stepping Motors...................................................................... A-22
Size 14 Enhanced Torque Stepping Motor...............................................................................A-22
General Specifications ........................................................................................................A-22
Wiring And Connection.....................................................................................................A-22
Mechanical Specifications...................................................................................................A-22
Size 17 Enhanced Torque Stepping Motor...............................................................................A-23
General Specifications ........................................................................................................A-23
Wiring And Connection.....................................................................................................A-23
Mechanical Specifications...................................................................................................A-23
Size 23 Enhanced Torque Stepping Motor...............................................................................A-24
General Specifications ........................................................................................................A-24
Wiring And Connection.....................................................................................................A-24
List of Figures
Figure GS.1: MForce MicroDrive Minumum Required Connections........................................ 1-2
Figure GS.2: Product CD Entry and Installation Screens .......................................................... 1-2
Figure GS.3: IMS Terminal Main Screen................................................................................... 1-3
Figure GS.4: IMS Terminal Preferences Dialog.......................................................................... 1-3
Figure GS.5 MForce MicroDrive Sign-On Message................................................................... 1-4
Figure GS.6: Download the Program ........................................................................................ 1-5
Part 1: Hardware Specification
Figure 1.1.1: MForce MicroDrive with 7-Pin Terminal Strip..................................................... 1-9
Figure 1.1.2: MForce MicroDrive Plus2with Locking Wire Crimp ........................................... 1-9
Figure 1.2.1: Mechanical Specifications................................................................................... 1-13
Figure 1.2.2: P1 Wire Color and Pin Assignment.................................................................... 1-14
Figure 1.2.3: P2 Pin Assignment ............................................................................................. 1-15
Figure 1.2.4: P3 — 4-Pin Locking Wire Crimp Motor Connector.......................................... 1-15

iv
Figure 1.3.1: Mechanical Specifications................................................................................... 1-19
Figure 1.3.2: 16-Pin Wire Crimp Connector P1 Pin Numbers................................................ 1-21
Figure 1.3.3: P2 Pin Assignment ............................................................................................. 1-22
Figure 1.3.4: P3: 4-Pin Locking Wire Crimp Motor Connector.............................................. 1-22
Part 2: Connections and Interface
Figure 2.1.1: MForce MicroDrive Mounting Recommendations............................................... 2-3
Figure 2.1.2: Grounding and Shielding for Logic Connections.................................................. 2-4
Figure 2.1.3: MForce MicroDrive Power Connections .............................................................. 2-5
Figure 2.1.4: Aux-Logic Connection ......................................................................................... 2-6
Figure 2.2.1 A & B: Per Phase Winding Inductance.................................................................. 2-8
Figure 2.2.2: 8 Lead Motor Series Connections....................................................................... 2-10
Figure 2.2.3: 8 Lead Motor Parallel Connections.................................................................... 2-11
Figure 2.2.4: 6 Lead Half Coil (Higher Speed) Motor Connections ....................................... 2-11
Figure 2.2.5: 6 Lead Full Coil (Higher Torque) Motor Connections ...................................... 2-12
Figure 2.2.6: 4 Lead Motor Connections................................................................................. 2-12
Figure 2.3.1: Full Duplex Communications (RS-422)............................................................. 2-13
Figure 2.3.2: Half Duplex 2 Wire Communications (RS-485) ................................................ 2-14
Figure 2.3.3: RS-485 Interface, Multiple MForce System........................................................ 2-15
Figure 2.4.1: Uses for the Digital I/O...................................................................................... 2-20
Figure 2.4.2: Flying Lead I/O Connections ............................................................................. 2-24
Figure 2.4.3: 7-Pin Pluggable Terminal I/O Connections........................................................ 2-24
Figure 2.4.4: Plus 2 I/O Connections - Expanded I/O Configuration..................................... 2-25
Figure 2.4.5: Plus 2 I/O Connections - Closed Loop Configuration........................................ 2-25
Figure 2.4.6: Sinking Input Example using a Push Button Switch ........................................... 2-26
Figure 2.4.7: Sourcing Input Example using a Push Button Switch ......................................... 2-27
Figure 2.4.8: Sinking Output Example.................................................................................... 2-28
Figure 2.4.9: Switch Interface to Input, Sinking ...................................................................... 2-29
Figure 2.4.10 Sourcing Input Example using a Push Button Switch ........................................ 2-30
Figure 2.4.11: Sinking Output Example.................................................................................. 2-31
Figure 2.4.12: Sourcing Output Example................................................................................ 2-32
Figure 2.4.13: MFI Clock Functions....................................................................................... 2-33
Figure 2.4.14: Step Direction I/O Equivalent Circuit.............................................................. 2-33
Figure 2.4.15: Capture/Trip I/O Equivalent Circuit................................................................ 2-34
Figure 2.4.16: Analog Input - Voltage Mode ........................................................................... 2-35
Figure 2.4.17: Analog Input - Current Mode .......................................................................... 2-36
Appendices
Figure A.1: DC Cabling - Under 50 Feet...................................................................................A-3
Figure A.2: DC Cabling - 50 Feet or Greater - AC To Full Wave Bridge Rectifier......................A-3
Figure A.3: AC Cabling - 50 Feet or Greater - AC To Power Supply..........................................A-3
Figure B.1: NPN Interface to an MDI Sinking Input................................................................A-5
Figure B.2: PNP Interface to a Sourcing Input ..........................................................................A-6
Figure B.3: Sinking Output to Relay .........................................................................................A-7
Figure B.4: Mixed Output Example- Standard I/O Set..............................................................A-7
Figure B.5: NPN Sinking Input on an MForce Plus2Motion Control .....................................A-8
Figure B.6: PNP Sourcing Input on an MForce Plus2Motion Control.....................................A-8
Figure B.7: Sourcing Output to Sourcing Input ........................................................................A-9
Figure B.8: Mixed Input/Output Example - Enhanced I/O.....................................................A-10
Figure B.9: TTL Interface to an Input Group..........................................................................A-10
Figure B.10: Outputs Interfaced to LED’s as a Group .............................................................A-11
Figure C.1: Connecting a Remote Encoder .............................................................................A-12
Figure C.2: Differential Encoder Signals..................................................................................A-13
Figure D.1: MD-CC400-000..................................................................................................A-15
Figure D.2: MD-CC400-000 Mechanical Specifications.........................................................A-15
Figure D.3: Hardware Update Wizard.....................................................................................A-16
Figure D.4: Hardware Update Wizard Screen 2.......................................................................A-16
Figure D.5: Hardware Update Wizard Screen 3.......................................................................A-17
Figure D.6: Windows Logo Compatibility Testing ..................................................................A-17
Figure D.7: Hardware Update Wizard Finish Installation........................................................A-17
Figure D.8: Hardware Properties .............................................................................................A-18
Figure D.9: Windows Device Manager....................................................................................A-18
Figure D.10: PD16-1417-FL3 Prototype Development Cable ................................................A-19
Figure D.11: PD10-1434-FL3 ................................................................................................A-21
Figure E.1: Size 14 Wiring and Connection ............................................................................A-22
Figure E.2: Size 14 Mechanical Specifications..........................................................................A-22

v
List of Tables
Table GS.1: Minimum Required Connections .......................................................................... 1-1
Part 1: Hardware Specification
Table 1.2.1: P1 — Pin Assignment, Power and I/O................................................................. 1-13
Table 1.2.2: P2 — Pin Assignment, RS-422/485 Communications......................................... 1-14
Table 1.2.3: P3 — Pin Assignment, Motor Phase Connections ............................................... 1-15
Table 1.3.1: P1 — Pin Assignment, Expanded I/O Configuration .......................................... 1-20
Table 1.3.2: P1 — Pin Assignment, Remote Encoder Configuration....................................... 1-20
Table 1.3.3: P2 — Pin Assignment, RS-422/485 Communications......................................... 1-21
Table 1.3.4: P3 — Pin Assignment, Motor Phase Connections ............................................... 1-22
Part 2: Connections and Interface
Table 2.3.1: MForce Response to Echo Mode - Party and Check Sum are Zero (0)................. 2-16
Table 2.3.2: MForce Response to Echo Mode - Party is One (1) and Check Sum is Zero (0) .. 2-16
Table 2.3.3: MForce Response to Echo Mode - Party is Zero (0) and Check Sum is One (1) .. 2-16
Table 2.3.4: MForce Response to Echo Mode - Party and Check Sum are One (1) ................. 2-17
Table 2.4.1: Programmable Input Functions............................................................................ 2-21
Table 2.4.2: Dedicated Input Functions .................................................................................. 2-22
Table 2.4.3: Programmable Output Functions ........................................................................ 2-23
Table 2.4.4: Dedicated Output Functions ............................................................................... 2-23
Table 2.3.5: MForce I/O and Protection Ratings..................................................................... 2-24
Appendices
Table A.1: Recommended Supply Cables ..................................................................................A-4
Table B.1: Output Bit Weight Examples - Outputs set as a group ...........................................A-11
Table C.1: Available Encoder Line Counts, Part Numbers and Pin Configurations .................A-12
Table D.1: MD-CC400-000 Electrical Specifications..............................................................A-15
Table D.2: PD16-1417-FL3 Wire Color Codes.......................................................................A-19
Table D.3: PD10-1434-FL3 Wire Color Codes.......................................................................A-20
Table E.1: Size 14 General Specifications.................................................................................A-22
Table E.2: Size 17 General Specifications.................................................................................A-23
Table E.3: Size 23 General Specifications.................................................................................A-24

vi
Page Intentionally Left Blank

1-1
Part 1: Hardware Specifications
Ge tt in g St ar te d
Getting Started
Before You Begin
A printed Quick Reference guide designed to help get you connected and communicating with the MForce is
shipped with your product. The following examples will help you get the motor turning for the first time and intro-
duce you to Immediate and Program modes of operation.
Immediate Mode: In Immediate Mode, commands are issued and executed directly to the MForce
MicroDrive by user input into the terminal window of the IMS Terminal Program, shown later in this
section.
Program Mode: Program mode is used to input user programs into the Motion Control MForce
MicroDrive .
Tools and Equipment Required
• Motion Control MForce MicroDrive.
• NEMA Size 14, 17 or 23 frame stepping motor.
• Communications Converter Cable IMS P/N MD-CC400-000 or equivalent (USB to RS-422).
• Product CD or internet access to www.imshome.com.
• A +12 to +48 VDC unregulated power supply.
• Basic tools: wire cutters / strippers / screwdriver.
• 20 AWG wire for power supply.
• 20 AWG wire for motor or optional prototype development cable IMS P/N PD04-MF17-FL3.
• A PC with Windows XP Service Pack 2.
• A free serial communications or USB port.
Connecting the Power Supply
Using 20 AWG wire, connect the DC output of the power supply to the +V input of the MForce MicroDrive.
Connect the power supply ground to the Power Ground pin appropriate for your MForce MicroDrive. See Figure
GS.1.
Connecting Communications
Connect the Host PC to the Motion Control MForce MicroDrive using the IMS Communications Converter
Cable MD-CC400-000 or equivalent. See Figure GS-1.
Connecting the Motor
In accordance with the motor manufacturer documentation, connect the Motor Phases to the MForce MicroDrive
Connector P4 (Prototype Development Cable IMS P/N PD04-MF17-FL3 recommended). See Figure GS.1.
Minumum Required Connections
The following Table and Diagram illustrate the minimum required connections to operate the MForce MicroDrive.
Minumum Required Connections
Connector P1 Flying Leads 7-Pin Termnal 16-Pin Wire Crimp
+12 to +48 VDC Red Pin 7 Pin 15
Power Ground Black Pin 6 Pin 16
Connector P2 10 Pin IDC 10 Pin Wire Crimp
TX+ Pin 1 Pin 9
TX – Pin 2 Pin 10
RX + Pin 3 Pin 7
RX - Pin 4 Pin 8
COMM GND Pin 10 Pin 2
Connector P4 4-Pin Locking Wire Crimp
Motor Phase A Pin 1
Motor Phase A Pin 2
Motor Phase B Pin 3
Motor Phase B Pin 4
Table GS.1: Minimum Required Connections
WARNING! Please
ensure that you
read the sections
of the product
manual pertaining to the
MForce MicroDrive model you
purchased in their entirety
prior to placing the unit into full
operation.

1-2 Motion Control MForce MicroDrive Hardware Manual Revision R112706
WARNI N G :
Do not connect
or disconnect
DC input to
the MForce MicroDrive
with power applied!
Disconnect the AC power
side to power down the DC
Supply.
For battery operated
systems, conditioning
measures should be taken
to prevent device damage
caused by in-rush current
draws, transient arcs and
high voltage spikes.
Install IMS Terminal Software
IMS Terminal is an integrated ASCII text editor and terminal emulator designed to easily communicate with and
program IMS Motion Control products. Using this freely provided program will eliminate the added complication
of configuring and using a separate text editor and terminal software.
1. Insert the CD included with the product into the CD Drive of your PC.
If not available, go to http://www.imshome.com/software_interfaces.html.
2. The CD will autostart.
3. Click the Software Button in the top-right navigation Area.
4. Click the IMS Terminal link appropriate to your operating system.
5. Click SETUP in the Setup dialog box and follow the on-screen instructions.
6. Once IMS Terminal is installed, the Communications Settings can be checked and/or set.
Figure GS.2: Product CD Entry and Installation Screens
P3
P1
1 2 3 4
+V (+12 to +48 VDC)
+V Return (Ground)
7-Pin Terminal Connector shown
at P1 - Power and I/O interface.
Other Connector Pin Assignments
detailed with product specifications.
ØA ØBØA ØB
MForce MicroDrive (Front View)
Stepping Motor
Motor Interface Cable
IMS P/N PD04-MF17-FL3
MForce MicroDrive (Side View)
P2
RS-422
Converter
COMM GND
COMM GND
TX+RX+
TX-
RX-
RX+
RX-
TX+
TX-
Host PC
USB/Serial Port
10-Pin IDC Connector shown at P2 -
Communications Interface. Other
connector pin assignments are
detailed with product specifications.
COMM GND is ONLY
to be used for grounding
communications. Grounding
Aux-Logic or any other
device to COMM GND may
damage the MForce!
Communications Cable
IMS P/N MD-CC400-000
or equivalent
Figure GS.1: MForce MicroDrive Minimum Required Connections
Note: Interactive
Tutorials covering
the installation and
use of the IMS Terminal are
located on the IMS Web Site
at http://www.imshome.com/
tutorials.html.