JVL MAC050 User manual

LB0047-24GB Revised 17.9.2009
JVL Industri Elektronik A/S
MAC050 - MAC141
&
MAC400 - MAC800
Integrated Servo Motors
User Manual
Including expansion modules

Important
User Information
Please contact your nearest JVL representative in case of technical assist-
ance. Your nearest contact can be found on our web site www.jvl.dk
Copyright 1998-2009, JVL Industri Elektronik A/S. All rights reserved.
This user manual must not be reproduced in any form without prior written
permission of JVL Industri Elektronik A/S.
JVL Industri Elektronik A/S reserves the right to make changes to informa-
tion contained in this manual without prior notice.
Similarly JVL Industri Elektronik A/S assumes no liability for printing errors
or other omissions or discrepancies in this user manual.
MacTalk and MotoWare are registered trademarks
JVL Industri Elektronik A/S
Blokken 42
DK-3460 Birkerød
Denmark
Tlf. [phone]
Fax. [phone]
e-mail: [email protected]
Internet: http://www.jvl.dk
The MAC series of products are used to control electrical and
mechanical components of motion control systems.
You should test your motion system for safety under all potential
conditions. Failure to do so can result in damage to equipment
and/or serious injury to personnel.
!!
Warning

JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 1
Contents
1Introduction .................................................................................................................... 3
1.1 Features .............................................................................................................................................................. 4
1.2 Overall description ............................................................................................................................................. 5
1.3 Expansion modules overview ............................................................................................................................. 8
1.4 Setting up the MAC motor ............................................................................................................................... 12
2Function description ..................................................................................................... 17
2.1 Using Position mode ......................................................................................................................................... 18
2.2 Gear Mode ........................................................................................................................................................ 19
2.3 Coil Mode ......................................................................................................................................................... 22
2.4 Analogue bi position mode ............................................................................................................................... 25
2.5 Mechanical zero search ..................................................................................................................................... 26
2.6 Error Handling .................................................................................................................................................. 31
2.7 Under Voltage Handling .................................................................................................................................... 42
2.8 Servo filter adjustment ...................................................................................................................................... 43
2.9 Using external SSI encoder ............................................................................................................................... 49
2.10 Power Save ....................................................................................................................................................... 55
2.11 Scope Function ................................................................................................................................................. 56
3Hardware description ................................................................................................... 57
3.1 Connector overview......................................................................................................................................... 58
3.2 Power Supply.................................................................................................................................................... 59
3.3 Serial interface .................................................................................................................................................. 69
3.4 User I/O ............................................................................................................................................................ 70
4Expansion Modules ....................................................................................................... 77
4.1 Expansion Modules MAC00-CS ........................................................................................................................ 78
4.2 Expansion Modules MAC00-B1/B2/B4 ............................................................................................................. 79
4.3 Expansion module MAC00-B41 ........................................................................................................................ 95
4.4 Expansion Modules MAC00-FC2/FC4 ............................................................................................................ 109
4.5 Expansion Module MAC00-FD4 ..................................................................................................................... 166
4.6 Expansion Module MAC00-FP2/FP4 .............................................................................................................. 180
4.7 Expansion Module MAC00-FS1/FS4 ............................................................................................................... 199
4.8 Expansion module MAC00-P5 ........................................................................................................................ 204
4.9 Expansion Module MAC00-R1/R3/R4 ............................................................................................................. 213
5Appendix ..................................................................................................................... 251
5.1 Technical Data ................................................................................................................................................ 252
5.2 Torque Curves ................................................................................................................................................ 255
5.3 Efficiency curve ............................................................................................................................................... 257
5.4 Physical Dimensions ........................................................................................................................................ 258
5.5 Life time .......................................................................................................................................................... 261
5.6 Installation precautions ................................................................................................................................... 264
5.7 Emergency stop considerations ...................................................................................................................... 265
5.8 Trouble-shooting guide ................................................................................................................................... 271
5.9 Bus serial communication ............................................................................................................................... 273
5.10 Serial communication ...................................................................................................................................... 276
5.11 MacTalk communication ................................................................................................................................. 283
5.12 Connecting to other equipment ..................................................................................................................... 288
5.13 Accessories ..................................................................................................................................................... 291
5.14 CE Declaration of Conformity ........................................................................................................................ 293
5.15 UL Certificate of Compliance ......................................................................................................................... 295

2 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800

JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 3
1 Introduction

4 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1.1 Features
The MAC series of brushless servo motors with
integrated electronics represents a major step for-
ward in motion control systems. All of the neces-
sary electronics for a servo system are integrated
into the motor itself.
Traditional motor systems typically have the con-
troller and drive electronics placed some distance
away from the motor. This increases machine
costs and has the negative effect that installation
time and costs are a major part of the total ex-
pense of building machinery.
The basic idea of the MAC motor is to minimise
these costs, but also to make a component that is
much better protected against electrical noise
which can be a typical problem when using long
cables between a controller and motor.
All user inputs and outputs are filtered, which
means that the MAC motors will work properly
even in an environment with a high level of electri-
cal noise.
The major advantages are:
• Lower installation costs
• Faster installation
• Quiet and maintenance-free operation
• Replacement for pneumatic solutions
• Replacement for step motors, offering much
faster response
• Great flexibility due to many I/O possibilities and
many functions.
• Less machine space required.
• Fewer possibilities for wiring errors.
Main Features:
• Low cost and high performance make the
MAC series ideal for high-volume applica-
tions
• Pulse and direction inputs make it possible
to replace step motors.
• Quadrature input for gearing applications.
• ±10V input for controlling speed and
torque
• 2 ch. Quadrature output to master control-
ler when used as driver.
• Accepts position and velocity commands
sent via RS232/422 interface.
• Wide supply voltage range 12 to 48VDC
and 90 to 240VAC.
• Excellent efficiency compared to
step motors.
• High resolution (4096/8000 cpr) compared
to cost.
• Wide variety of expansion modules which
can be mounted internally:
- Profibus DP module
- CAN-Open® or DeviceNet module
- Ethernet module
- nano-PLC w/graphic programming
- Several module connector options
- Custom-designed modules on request
• Outputs for In position and Error
indication.
• High order digital filter which only needs a
single inertia adjustment.
• Standard NEMA23 flange.
• Built-in sensors make the motor stay sta-
tionary when powering up.
• Easy and simple Windows program - Mac-
Talk available for installation/setup.
• High-efficiency power stage keeps temper-
ature at a low level.
• CE approved. UL recognized (MAC800)

JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 5
1.2 Overall description
All the internal building blocks of the MAC motor are shown in the illustration above.
The central microprocessor takes care of all the processes in the motor via the various
I/O blocks such as the serial interface, differential transceiver (Multifunction I/O) and the
motor driver sections.
Please notice that the MAC400 and MAC800 have 2 supply voltages.
3-phase
brushless
motor
Optical
incremental
encoder
Hall
elements
+12-48VDC
(+24V and
90-240VAC)
Ground
AIN
Analogue
input ±10V
A+
A
B+
B
Output 1
Output 2
Tr a n s m i t
Ground
( ) = Valid for MAC400 and MAC800
Receive
+5VDC Out
Switchmode
Power
Supply
Power Dump
for absorbing
regenerative
energy
3-phase
driver
Current
Sensing
High speed
A/D converter
High speed
digital logic
array
Analogue input
Level shifter
and filter
2 channel
differential
Tr a n s c e i v e r
Asynchronous
serial interface Memory
and system
control
2 Digital NPN
outputs showing
motor status
16 (32) Bit
Microprocessor
A
HU
HV
B
W
V
U
HW
P
ower
supp
l
y
connector(s)
User I/O connector
S
er
i
a
l i
n
t
er
f
ace
connector
Basic MAC motor block diagram including motor and feedback devices
TT0934GB

6 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1.2 Overall description
The MAC motor is available in 6 different sizes: MAC050, MAC95, MAC140, MAC141,
MAC400 and MAC800, with continuous power ratings from 46W to 750W. The basic
functions and I/O features are the same for all models.
1.2.1 Basic modes/functions in the MAC motor
The MAC motor offers the following functions.
- Passive mode.
The motor will be in a completely passive state but communication is active and in-
ternal registers can be set up.
-Velocitymode.
The motor velocity can be controlled using MacTalk software or by sending com-
mands via the serial interface.
- Position mode
The motor position can be controlled using MacTalk or by sending position com-
mands via the serial interface.
- Gear mode
The position of the motor is controlled by the multifunction I/O, which is configured
as input. Either a pulse and direction signal can be applied or a quadrature A and B
signal from, for example, an incremental encoder.
This mode is very powerful if the MAC motor is used to upgrade a step motor system
or if the motor is used in electronic gear applications such as a flying saw where an
external encoder tracks the position of a moving object.
- Gear Follow Mode
Same mode as gear mode, except that the input pulses are not buffered so that con-
trol strictly follows the input pulses.
-Analogue Velocity Mode
The motor velocity is controlled by a voltage applied at the ±10V analogue input.
This mode can be used in several applications but typical applications include main-
taining variable but constant speed in feeding mechanisms or as a slave driver in multi-
axis systems with a master position controller for several axes.
(continued next page)
Basic
Motor Type
Continuous
Torque
Peak
Torque
Power
(cont.)
Nom.
Speed
Flange Total
length
MAC050 0.11 Nm
(15.58 oz-in)
0.32Nm
(45,3 oz-in) 46 Watt 4000 RPM
NEMA23
57x57mm
(2.3”x2.3”)
111.2 mm,
(4,38”)
MAC95 0.22 Nm
(31.15 oz-in)
0.62 Nm
(87.8 oz-in) 92 Watt 4000 RPM
NEMA23
57x57mm
(2.3”x2.3”)
130.5 mm
(5.13”)
MAC140 0.32 Nm
(45,32 oz-in)
0.9 Nm
(127.45 oz-in) 134 Watt 4000 RPM
NEMA23
57x57mm
(2.3”x2.3”)
152.5 mm
(6”)
MAC141 0.48 Nm
(168 oz-in)
1.59 Nm
(225,16 oz-in) 134 Watt 2700 RPM
NEMA23
57x57mm
(2.3”x2.3”)
172.0 mm
(6.77”)
MAC400 1.27 Nm
(180 oz-in)
3.8 Nm
(538,1 oz-in) 400 Watt 3000 RPM 60x60mm (2.86”x2.86”)
192.0 mm
(7.56”)
MAC800 2.38 Nm
(337 oz-in)
7.2 Nm
(1019.6 oz-in) 750 Watt 3000 RPM 80x80mm (3,14”x3,14”)
175 mm
(6,89”)