Intelligent Motion Systems MDI42 AC User manual

www.imshome.com
TM
Excellence in Motion
42TM
MOTION CONTROL
Patent Pending
(with optional CANopen)
• Highly Integrated Microstepping Driver/
Intelligent Motion Controller with Optional
Encoder/NEMA 42 High Torque 1.8°
Brushless Step Motor
• Advanced 2nd Generation Current
Control for Exceptional Performance
and Smoothness
• Single Supply: 120 or 240 VAC
• Cost Effective
• Extremely Compact
• High Positioning Accuracy
• No Tuning Required
• Stable at Low Speeds
• No Dithering at Zero Speed
• High Starting Torque
• Allows for Greater Inertia Mismatch
• Built-in Regeneration Circuitry
• Available Options:
- Integral Optical Encoder for Closed
Loop Control
- External/Remote Encoder (not supplied)
for Closed Loop Control
- Control Knob for Manual Positioning
- Integrated Planetary Gearbox
- IP65 Sealed Configuration**
• Two Motor Lengths Available
• Auxiliary Logic Power Supply Input
• Up to 5 MHz Step Clock Rate
• 20 Microstep Resolutions up to
51,200 Steps Per Rev Including:
Degrees, Metric, Arc Minutes
• Open or Optional Closed Loop Control
• Programmable Motor Current
• Up to Eight +24 VDC Tolerant I/O Lines,
Sourcing or Sinking
• One 10 Bit Analog Input Selectable: 0 to +5
VDC, 0 to +10 VDC, 0-20 mA, 4-20 mA
• RS-422/485 or Optional CANopen
Communications
• 62 Software Addresses for Multi-Drop
Communications
• High Speed Position Capture Input or Trip
Output
• Electronic Gearing
**Consult Factory for Availability.
Optional communication protocols
include CANopen. The CAN bus is 2.0B
active (11 and/or 29 bit) and is capable
of all standard frequencies from 10 kHz
to 1 MHz. CANopen features include
node guarding, heartbeat producer,
SDOs and PDOs. Highlights include
variable PDO mapping and extended
node identifier.
The MDrive42AC Plus2Motion Control
is available with optional closed loop
control. This increases functionality by
adding stall detection, position mainte-
nance and find index mark.
The closed loop configuration is added
via a 512 line (2048 edge) optical
encoder with index mark, internal to the
MDrive42AC so there is no increase in
length. Or, for an expanded choice of
line counts and resolutions, closed loop
control is available with an interface
to a remotely mounted user-supplied
external encoder.
In addition to encoder options, the
MDrive42AC Plus2Motion Control has
the capability of electronic gearing by
following a rotary or linear axis at an
electronically controlled ratio, or an
output clock can be generated fixed to
the internal step clock.
A sealed version designed to meet
IP65 specifications is also available.
The sealed assembly allows the
MDrive42AC to be used in environ-
ments where exposure to chemical,
dust and liquids may occur.
Two rotary motor lengths are available
as are linear actuators with long life
Acme screw**.
Interface connections are accomplished
using standard industrial circular con-
nectors. And connectivity has never
been easier with options ranging from
all-inclusive QuickStart Kits to indi-
vidual interfacing cables. See pg 5.
FEATURES DESCRIPTION
The MDrive42AC Plus2 Motion Control
system offers designers a cost effec-
tive, full featured programmable motion
controller integrated with a NEMA 42 high
torque 1.8° brushless step motor and a
microstepping driver operating at 120 or
240 VAC.
Unsurpassed smoothness and perfor-
mance delivered by the MDrive42AC are
achieved through IMS's advanced 2nd
generation current control. By applying
innovative techniques to control current
flow through the motor, resonance is sig-
nificantly dampened over the entire speed
range and audible noise is reduced.
The MDrive42AC accepts a broad input
voltage range from 95 to 264 VAC, deliv-
ering enhanced performance and speed.
Oversized input capacitors are used to
minimize power line surges, reducing
problems that can occur with long cable
runs and multiple drive systems. An ex-
tended operating range of –40° to +75°C
provides long life, trouble free service in
demanding environments.
The MDrive42AC Plus2Motion Control
system adds a versatile array of functions
by combining a full featured program-
mable motion controller with our compact
and cost effective MDrive42AC Micro-
stepping products, adding little cost and
no increase in size. Standard offerings
include up to 8 general purpose I/O lines
(sourcing or sinking) that operate to +24
VDC, one 10 bit analog input, electronic
gearing, high speed position capture
input/trip output, microstep resolutions up
to 51,200 steps per revolution, 0 to 5 MHz
step clock rate, and a full featured easy-
to-program instruction set.
The MDrive42AC Plus2Motion Control
system communicates over RS-422/485
which allows for point-to-point or multiple
unit configurations utilizing one commu-
nication port. Addressing and hardware
support multiple uniquely addressed units
communicating over a single line.
new

2 MDrive42AC Plus2 Motion Control REV060208
MDrive 42AC Plus2 MOTION CONTROL
Holding Torque Detent Torque Rotor Inertia Weight (Motor+Driver)
SINGLE LENGTH 1147 oz-in / 810 N-cm 35 oz-in / 25 N-cm 0.0917
oz-in-sec
2
/ 6.5 kg-cm
2
14.07 lb / 6.38 kg
DOUBLE LENGTH 2294 oz-in / 1620 N-cm 84 oz-in / 59 N-cm 0.1833
oz-in-sec
2
/ 13.0 kg-cm
2
21.25 lb / 9.64 kg
MOTOR SPECIFICATIONS
INPUT VOLTAGE Range 120 V MDrive – 95 to 132 VAC @ 50/60 Hz
240 V MDrive – 95 to 264 VAC @ 50/60 Hz
AUX. LOGIC INPUT VOLTAGE
Range +12 to +24 VDC
Maintains power to control and feedback circuits (only) when input voltage is removed.
ANALOG INPUT Resolution 10 Bit
Voltage Range 0 to +5 VDC, 0 to +10 VDC, 0-20 mA or 4–20 mA
GENERAL PURPOSE I/O
Number/Type 8 Sourcing or Sinking (or 4 when Remote Encoder Option is Selected)
Logic Range +5 to +24 VDC – Inputs and Sinking Outputs; Inputs TTL Level Compatible
+12 to +24 VDC – Sourcing Outputs
Output Sink/Source Current Up to 600 mA per Channel
Protection Over Temp, Short Circuit, Transient Over Voltage, Over Voltage, Inductive Clamp
COMMUNICATION
Type (Standard) RS-422/485
Baud Rate 4800 to 115.2kbps
Type (Optional) CANopen DSP-402 (V2.0), DS-301 (V3.0), 2.0B Active
ID 11 and/or 29 Bit
Isolation Galvanic
Features Node Guarding, Heartbeat, SDOs, PDOs (Variable Mapping)
MOTION
Open Loop
Configuration
Number of Settings 20
Steps Per Revolution
200, 400, 800, 1000, 1600, 2000, 3200, 5000,
6400, 10000, 12800, 20000, 25000, 25600,
40000, 50000, 51200, 36000 (0.01 deg/µstep),
21600 (1 arc minute/µstep), 25400 (0.001mm/µstep)
Closed Loop
Configuration
(Optional)
Internal
Encoder
Type Internal, Optical
Steps Per Revolution 51200
Resolution 512 Lines/2048 Edges Per Rev
Remote
Encoder
Type User-Supplied Differential Encoder
Steps Per Revolution
200, 400, 800, 1000, 1600, 2000, 3200, 5000,
6400, 10000, 12800, 20000, 25000, 25600,
40000, 50000, 51200, 36000 (0.01 deg/µstep),
21600 (1 arc minute/µstep), 25400 (0.001mm/µstep)
Resolution User-Defined
Note: µstep/rev 2X the encoder count/rev minimum
Counters Type Position, Encoder/32 Bit
Edge Rate (Max) 5 MHz
Velocity Range +/- 5,000,000 Steps Per Second
Resolution 0.5961 Steps Per Second
Accel/Decel Range 1.5 x 109Steps Per Second2
Resolution 90.9 Steps Per Second2
Electronic Gearing
Range‡/Resolution/Threshold
(External Clock In) 0.001 to 2.000/32 Bit/TTL
Input Filter Range 50 nS to 12.9 µS (10 MHz to 38.8 kHz)
Range‡ (Secondary Clock Out) 1 to 1
High Speed I/O
Position Capture Input Filter Range 50 nS to 12.9 µS (10 MHz to 38.8 kHz)
Resolution 32 Bit
Trip Output – Speed/Resolution/
Threshold 150 nS/32 Bit/TTL
SOFTWARE
Program Storage Type/Size Flash/6384 Bytes
User Registers (4) 32 Bit
User Program Labels and
Variables 192
Math Functions +, –, ×, ÷, >, <, =, <=, >=, AND, OR, XOR, NOT
Branch Functions Branch & Call
General Purpose I/O
Functions
Inputs Home, Limit Plus, Limit Minus, Go, Stop, Pause, Jog
Plus, Jog Minus, Analog In, General Purpose
Outputs Moving, Fault, Stall, Velocity Change, General Purpose
Trip Functions Trip on Input, Trip on Position, Trip on Time, Trip Capture
Party Mode Addresses 62
Encoder Functions Stall Detection, Position Maintenance, Find Index
THERMAL Operating Temperature Heat Sink –40° to +75°C (non-condensing)
Motor –40° to +90°C (non-condensing)
PROTECTION Type Thermal, Internal Fuse†
GENERAL SPECIFICATIONS
†Designed for line-neutral systems.
‡Adjusting the microstep resolution can increase the range.

MDrive42AC Plus2 Motion Control REV060208 3
P3: POWER CONNECTOR
Euro AC
(Male) Function
Pin 1 Chassis Ground
Pin 2 AC Power Line
Pin 3 AC Power Neutral
P1: I/O CONNECTOR
M23 Circular
(Male)
Function
Expanded I/O Remote Encoder Closed Loop Control
Pin 1 I/O 9 Channel A +
Pin 2 I/O 11 Channel B +
Pin 3 Step/Clock I/O Index +
Pin 4 I/O 1 I/O 1
Pin 5 Direction/Clock I/O Index –
Pin 6 No Connect No Connect
Pin 7 Aux-Logic (+12 to +24 VDC) Aux-Logic (+12 to +24 VDC)
Pin 8 Aux-Ground Aux-Ground
Pin 9 I/O 3 I/O 3
Pin 10 I/O Ground I/O Ground
Pin 11 I/O Power I/O Power
Pin 12 Shell Connect Shell Connect
Pin 13 I/O 12 Channel B –
Pin 14 Capture/Trip I/O Capture/Trip I/O
Pin 15 Analog In Analog In
Pin 16 I/O 2 I/O 2
Pin 17 I/O 4 I/O 4
Pin 18 I/O 10 Channel A –
Pin 19 No Connect No Connect
P2: COMM CONNECTOR
RS-422/485 CANopen
M12
Circular
(Female)
Function
M12
Circular
(Male)
Function
Pin 1 TX – Pin 1 Shield
Pin 2 TX + Pin 2 CAN +V
Pin 3 RX + Pin 3 CAN –V
Pin 4 RX – Pin 4 CAN High
Pin 5 Comm Ground Pin 5 CAN Low
LMAX2 Option
Ø 1.90
(Ø 48.3)
Ø 0.53
(Ø 13.5)
Ø 0.87
(Ø 22.1)
Connectors
P2: 5-Pin M12 (Female)
(or CANopen – Male)
P1: 19-Pin M23
(Male)
P3: 3-Pin Euro AC
(Male)
Ø 0.87
(Ø 22.1)
Control Knob
Connectivity details:
www.imshome.com/cables_cordsets.html
600
800
1000
1200
400
200
Torque in Oz-In
Torque in N-cm
424
565
706
847
282
141
Speed – Full Steps/Second (RPM)
0 2000
(600)
4000
(1200)
6000
(1800)
10000
(3000)
8000
(2400)
0
1400
1600
1800
989
1130
1271
Double Motor Length
Single Motor Length
0.75
(19.05)
0.059
(1.5)
0.49
(12.5)
2.17
(55.0)
1.375
(34.9)
LMAX
LMAX2
P3
0.65
(16.51)
Ø 0.75
(Ø 19.05)
Ø 2.185
(Ø 55.5)
P1
P2
0.83
(21.08) 4.50
(114.3)
0.1875
(4.76)
6.75
(171.45)
7.4
(187.96)
0.335
(8.51)
3.0
(76.2)
4.331 SQ.
(110.0 SQ.)
3.50 SQ.
(88.88 SQ.)
*CANopen option increases
overall height by 0.09"/2.0mm
MECHANICAL SPECIFICATIONS
Dimensions in Inches (mm)
MDrive42AC Plus2
SPEED-TORQUE
MDrive42AC – 120VAC
MDrive42AC – 240VAC
LMAX LMAX2
Motor
Length
SINGLE SHAFT or
ENCODER VERSION
CONTROL KNOB
VERSION
Single 7.4 (187.96) 9.4 (238.76)
Double 9.4 (238.76) 11.4 (289.56)
MDrive Lengths Inches (mm)
600
800
1000
1200
400
200
Torque in Oz-In
T
orque
i
n
N
-cm
424
565
706
847
282
141
Speed in full steps per second (RPM)
0 2000
(600)
4000
(1200)
6000
(1800)
10000
(3000)
8000
(2400)
0
1400
1600
1800
989
1130
1271
Double Motor Length
Single Motor Length
PIN ASSIGNMENTS
I/O Comm Power

4 MDrive42AC Plus2 Motion Control REV060208
Planetary Gearbox for MDrive42Plus
Dimensions in Inches (mm)
Permitted
Output Torque
(oz-in/Nm)
Gearbox
Efficiency
Maximum
Backlash
Output Side with Ball Bearing
Maximum Load
(lb-force/N)
Weight
(lb/kg)
Radial Axial Gearbox w/Flange
PM105
1-STAGE 4956/35.0 0.80 1.0° 135/600 27/120 9.7/4.4 10.0/4.5
2-STAGE 14869/105.0 0.75 1.5° 202/900 40/180 13.2/6.0 13.6/6.2
3-STAGE 27614/195.0 0.70 2.0°
337/1500 67/300 16.8/7.6 17.3/7.8
PM120
1-STAGE 7080/50.0 0.80 0.55° 135/600 27/120 12.3/5.6 12.7/5.8
2-STAGE 21242/150.0 0.75 0.60° 202/900 40/180 17.6/8.0 18.1/8.2
3-STAGE 42484/300.0 0.70 0.65°
337/1500 67/300 22.9/10.4 23.5/10.7
Ratios and Part Numbers
Planetary
Gearbox
Ratio
(Rounded)
Part Number‡
PM105
Model
PM120
Model
1-Stage 3.71:1 ** G1A1 G2A1
1-Stage 5.18:1 G1A2 —
1-Stage 6.75:1** G1A3 G2A3
2-Stage 13.73:1** G1A4 G2A4
2-Stage 15.88:1 G1A5 —
2-Stage 18.37:1 G1A6 —
2-Stage 19.20:1 G1A7 —
2-Stage 22.21:1 G1A8 —
2-Stage 25.01:1** G1A9 G2A9
2-Stage 26.85:1 G1B1 —
2-Stage 28.93:1 G1B2 —
2-Stage 34.98:1 G1B3 —
2-Stage 45.56:1** G1B4 G2B4
3-Stage 50.89:1** G1B5 G2B5
3-Stage 58.86:1 G1B6 —
3-Stage 68.07:1 G1B7 —
3-Stage 71.16:1 G1B8 —
3-Stage 78.72:1 G1B9 —
3-Stage 92.70:1** G1C1 G2C1
3-Stage 95.18:1 G1C2 —
3-Stage 99.51:1 G1C3 —
3-Stage 107.21:1 G1C4 —
3-Stage 115.08:1 G1C5 —
3-Stage 123.98:1 G1C6 —
3-Stage 129.62:1 G1C7 —
3-Stage 139.14:1 G1C8 —
3-Stage 149.90:1 G1C9 —
3-Stage 168.85:1** G1D1 G2D1
3-Stage 181.25:1 G1D2 —
3-Stage 195.27:1 G1D3 —
3-Stage 236.10:1 G1D4 —
3-Stage 307.55:1** G1D5 G2D5
PM105 Model
PM120 Model
**Indicates limited ratios available for PM120 gearbox.
‡ Include optional planetary gearbox by adding –G plus
3 characters to the end of an MDrive part number.
4.20 SQ.
(106.7 SQ.)
3.35 ±0.004 SQ.*
(85.0 ±0.1 SQ.)
k1 ±0.02 (±0.5)
M8 x 0.630 (16.0) Deep*
4x 0.33 (Ø 8.5) Hole
*Gearbox without Flange
†Gearbox with Flange
Ctrg. DIN 332-D M10
Key DIN 6885-A-8x7x40mm
0.20*
(5.0) 0.079 (2.0)
2.33 ±0.02*
(59.1 ±0.5)
2.04 ±0.02
(51.7 ±0.5)
Ø 2.76* (Ø 70.0)
Ø 0.98 (Ø 25.0)
Ø 4.13
(Ø 105.0)
MDrive42AC Plus
0.35*
(9.0)
†
†
†
Ø 2.187 (Ø 55.54)
†
†
3.50
(
88.9
)
or
or
0.50
(12.7)
†
or
MDrive42AC Plus
*Gearbox without Flange
†Gearbox with Flange
Ø 3.15* (Ø 80.0) Ø 2.187 (Ø 55.54)
or
M10 x 0.866 (22.0) Deep*
4x 0.35 (Ø 9.0) Hole†
†
†
†or
or
k1 ±0.02 (±0.5)
Ctrg. DIN 332-D M12
Key DIN 6885-A-10x8x50mm
0.20*
(5.0) †
0.079
(2.0)
†
0.24
(6.2)
0.59*
(15.0)
2.86 ±0.02*
(72.7 ±0.5)
2.53 ±0.02
(64.2 ±0.5)
Ø 1.26
(Ø 32.0)
Ø 4.72
(Ø 120.0)
4.33 SQ.
(110.0 SQ.)
3.94 SQ.*
(
100.0 SQ.
)
3.50 SQ.
(88.9 SQ.)
or
0.59
(15.0)
†
MDRIVE42AC PLUS WITH PLANETARY GEARBOX
The MDrive42AC Plus is available with a Planetary Gearbox option developed to increase torque at lower speeds, enable better
inertia matching and produce finer positional resolutions. These efficient, low maintenance Planetary Gearbox come fully assembled
with the MDrive and are offered in a large number of reduction ratios in 1-, 2- and 3-stage configurations. An optional NEMA Output
Flange allows mounting the Planetary Gearbox to the load using a standard NEMA bolt circle. Planetary Gearbox may be combined
with other MDrive42AC Plus options, however are unavailable with Linear Actuators.
Planetary Gearbox Parameters
Gearbox Lengths Inches (mm)
k1
GEARBOX* with FLANGE†
1-Stage 5.73 (145.5) 5.9 (149.9)
2-Stage 7.07 (179.6) 7.13 (181.0)
3-Stage 8.41 (213.7) 8.35 (212.0)
Gearbox Lengths Inches (mm)
k1
GEARBOX* with FLANGE†
1-Stage 6.23 (158.2) 6.58 (167.2)
2-Stage 7.57 (192.4) 7.93 (201.4)
3-Stage 8.92 (226.6) 9.28 (235.6)

© Intelligent Motion Systems, Inc. All Rights Reserved. REV060208
IMS Product Disclaimer and most recent product information at www.imshome.com.
Intelligent Motion Systems, Inc.
370 North Main Street, P.O. Box 457
Marlborough, CT 06447 - U.S.A.
Tel. [phone] - Fax [phone]
e-mail: [email protected]
http: //www.imshome.com
U.S.A. SALES OFFICES
Eastern Region
Tel. [phone] - Fax [phone]
e-mail: [email protected]
Central Region
Tel. [phone] - Fax [phone]
e-mail: [email protected]
Western Region
Tel. [phone]
e-mail:
[email protected]
IMS ASIA PACIFIC OFFICE
30 Raffles Pl., 23-00 Caltex House , Singapore 048622
Tel. [phone] - Fax [phone]
e-mail: [email protected]
IMS EUROPEAN SALES MANAGEMENT
4 Quai Des Etroits
69005 Lyon, France
Tel. [phone] - Fax [phone]
e-mail: [email protected]
IMS UK Ltd.
Sanderson Centre, 15 Lees Lane
Gosport, Hampshire PO12 3UL
Tel. [phone] - Fax [phone]
e-mail: [email protected]
TECHNICAL SUPPORT
Tel. [phone] - Fax [phone]
e-mail: [email protected]
–N
–EE
Remote
Encoder
Control
Knob
Example: MDI3MRQ42B2–EE adds differential encoder inputs for
use with remote encoder (not supplied).
May not be combined with internal encoder option.
Example: MDI3MRQ42B2–N adds a rear control knob to
example #1. Not available with sealed –65 versions.
–EQ
Internal
Encoder
OPTIONS
Example: MDI3MRQ42B2–EQ adds a 512-line internal
optical encoder with index mark to example #1.
MDI M Q42 –
A = Single Length
B = Double Length
Example #1: Part Number MDI3MRQ42B2 is an
MDrive42AC Plus2
Motion Control with 19-pin M23
circular I/O interface, RS-422/485 communications
with 5-pin M12 circular connector, NEMA 42 double
length motor and 240 input voltage.
OPTION
Input Voltage
1 = 120 Volt
2 = 240 Volt
Communications
R = RS-422/485
C = CANopen
MDrive Version
3 = Plus2
4 = Plus2-65 (sealed)**
–G
Planetary
Gearbox
Example: MDI3MRQ42B2–G1A2 adds a PM105 1-stage
planetary gearbox with 5.18:1 ratio to example #1.
Add –F for optional NEMA flange.
Refer to gearbox page for complete
table of ratios and part numbers.
– FOptional NEMA Flange
P1: I/O, 19-Pin M23 Circular Connector
P3: Power, 3-Pin Euro AC Connector
P2: Communications, 5-Pin M12
Circular Connector
**Consult Factory for Availability.
Motor
Plus2
expanded features
Plus2-65**
IP65 sealed
QuickStart Kit
details above
K
ORDER INFORMATION — MDrive42AC Plus2Motion Control
CONNECTING
QuickStart Kit
For rapid design verification, all-inclusive QuickStart Kits have com-
munication converter, prototype development cable(s), instructions
and CD for MDrivePlus initial functional setup and system testing.
Communication Converter
Electrically isolated, in-line converter pre-wired with mating connec-
tor to conveniently set/program communication parameters for a
single MDrivePlus via a PC's USB port. Length 12.0' (3.6m).
Mates to connector:
5-Pin M12 ............................................MD-CC401-001
5-Pin M12 CANopen ..............................MD-CC500-000*
*Requires mating connector adapter and power supply, not supplied.
Prototype Development Cables
Speed test/development with pre-wired mating connectors that
have flying leads other end. Single-ended cordsets are PVC jack-
eted with foil shield and unconnected drain wire. Length 13.0'
(4.0m).
Mates to connector:
19-Pin M23
Straight Termination ..........................MD-CC100-000
Right Angle Termination .....................MD-CC101-000
3-Pin Euro AC
Straight Termination ..........................MD-CC200-000
Right Angle Termination .....................MD-CC201-000
OPTIONS
Internal Encoder
An internal 512-line (2048 count) differential optical
encoder with index mark is available factory-mounted.
Remote Encoder
This MDrivePlus Motion Control is offered with differential en-
coder inputs for use with a remote encoder (not supplied).
Control Knob ‡
For manual shaft positioning, a factory-mounted rear control
knob is available.
Planetary Gearbox
Efficient, low maintenance planetary gearboxes are
offered factory-mounted. Refer to details and part num-
bers on the back cover.
**Consult Factory for Availability.
‡ Not Available with Sealed –65 Versions.
Connectivity details: www.imshome.com/cables_cordsets.html
PART NUMBERING
CONNECTIVITY OPTIONS
new
new