MUSCLE Corporation COOL MUSCLE 2 User manual

Integrated AC Servo System
MDUG-CM2/08215E-01

PR-001
Before use, read through this User's Guide to ensure proper use.
In particular, be sure to read "Instructions for Safety" without fail for safety purpose.
Keep this User's Guide at an easily accessible place so as to be referred anytime as necessary.
The contents of this User's Guide are subject to change without notice for the improvement in product,
specication, or usability of this User's Guide.
This User's Guide is only intended to provide information about the product, and dose not guarantee any
results from usage of the product. Muscle Corporation is not responsible for any damages and/or injuries
resulting from the implementation in accordance with the contents of this User's Guide.
Please notify our sales representative if you have some questions or comments with the contents of this
User's Guide.
The contents of this User's Guide do not guarantee or grant rights to patents, copyright, or any other rights to
the intellectual property of Muscle Corporation or any third party. Muscle Corporation is not responsible for
any problems that may occur concerning the intellectual property rights of third parties resulting from the
application of information provided in this User's Guide.
Cool Muscle is a registered trademark of Muscle Corporation.
Microsoft and Windows are registered trademarks of Microsoft Corporation in the United States and other
countries.
Other company names and product names described in this User's Guide are trademarks or registered
trademarks of their respective holders. The trademark notices (TM, ®) are not necessarily appended to
company, system, and product names described in this User's Guide.
© 2007 Muscle Corporation. All rights reserved.
It is prohibited to reprint or copy all or any part of this User's Guide without prior written permission.

PR-002
Instructions for Safety
【Besuretoreadbeforeuseforsafety】
Toensuresafeuse
To ensure the safe and proper use of our products, it is important that you read this User's Guide thoroughly
prior to its use. Failure to read, fully understand and implement following instructions and precautions may
result in damage to the product, the machine to which it is installed, or operator injury.
About product application
These products are manufactured as a general-purpose part for the application in general industries.
They are not designed or manufactured for equipments or systems which have an affect on human life,
or applications in which faulty operation or failure may result in personal injury or significant damage to
property.
These products shall not be used in applications which require an extremely high degree of reliability and
safety, such as those listed below.
Medical equipment or system that have a direct affect on human life.
Applications that directly affect on the safety of people.
(For example, the operation and control of aircraft, cars, elevators railroads, etc.)
Applications in which failure may signicantly damage or impact the society and public.
(For example, nuclear power, electric power, aerospace, public transportation system, etc.)
Equipments or systems used under special environmental condition.
Applications with the same level of importance as those described above.
* When considering the product for use in such special applications, please contact our sales representative.
We ask that you employ fail-safe systems when applying these products to the equipment in which any
failure on its part can be expected to cause a serious accident or loss.
SafetyPrecautions
Please read following precautions in order to ensure safe and proper use of the product, and avoid dameges
on machinery and injuries to the operators and other people.
This User's Guide should carefully be kept in a convenient place for the operator's easy reference.

PR-003
In this User's Guide, safety precautions are classied as either “Warning” or “Caution”, indicating the level of
hazard seriousness possibly occurred when handling the product incorrectly.
The symbols are explaind below.
Note that some items described as Cautions may result in more serious damage under certain
conditions. Please observe the precautions of both levels because they are important to personnel safety.
“What must not be done” and “What must be done” are indicated by the following symbols.
Indicates a potentially hazardous situation which, if not handled
properly, may result in injury or property damage.
Indicates an imminently hazardous situation which, if not handled
properly, may result in death or serious injury.
Warning
Caution
Ex. "No disassemble"
Indicates a prohibited action
(what must not be done).
Indicates a necessary action
(what must be done). Ex. "Grounding"

PR-004
Warning
Never touch the rotating part of the motor while operating.
The failure could result in injuries.
Take a measure for safety to keep away contact by personel.
Do not touch the motor and driver while power is ON or for some time after
power-OFF.
Temperatures may be high and you may get burnt.
Do not change the wiring while power is ON.
Be sure to remove wiring and unplug a connector after power-OFF.
The failure could result in electric shocks, runaway or damages.
Do not give damage to, apply excessive force to, place something heavy upon,
or pinch the cable.
Do not pull the cable by too much power. The failure could result in damages to connection
section, or electric shocks.
Never disassemble, modify, or repair the product.
Do not open the cover of the product, or disassemble or modify the parts inside.
The failure could result in re, electric shocks, malfunction or injuries.
Do not install the product on or near combustibles.
Attach the product to noncombustible matter such as metal. The failure could result in re.
Do not tamper with water, corrosive gas, inammable gas, ammable
material, or electrically conductive material such as screw or metal piece.
Do not insert metal pieces into the venting holes of enclosure.
The failure could result in re, electric shocks, or damages.
Be sure to ground the terminal of the earth wire.
Securely ground to prevent electric shocks and to stabilize the potential in the control circuit.
Caution (environment)
Keep or use the product under the following environmental conditions.
Ambient temperature / Working : 0 to 40 , Storage : -20 to 60 (non freezing)
Ambient humidity : Below 90%RH (non condensing)
Vibration / Shock resistance : Below 9.8ms-2 (1G) / Below 98ms-2 (10G)
Avoid store or use in such an environment where the product is exposed to oil or water.
(It is not waterproof structure.)
Indoor use only (no direct sunlight). No corrosive gas, inammable gas, oil mist or dust.

PR-005
Caution (transportation)
The product is precision mechanical equipment.
Do not drop or give any strong impact to the product.
The failure could result in damages or malfunction.
Do not hold the cables or motor shaft when transporting the product.
The failure could result in damages or malfunction.
Do not climb, stand, or put heavy objects on the product.
The failure could result in damages or malfunction.
Do not stack in excess of the specied number of products.
The failure could result in damages or malfunction.
Caution (installation)
When installing a pulley or coupling to the machine, do not hammer on
the motor shaft.
The failure could result in damages or malfunction..
Be sure to x the product on the machine rmly.
If xation is not tight enough, the product may come off while operating.
Be sure to make precise centering between the motor shaft and the machine.
Deviation from the center could result in vibration or damages.
The load inertia moment should be below the recommended load inertia
moment ratio of the motor being used.
If it is too large, desired performance may not be attainable.
Carefully consider the heat radiation of the product, and make sure to
install it in the condition with proper airow.
Be sure to avoid interference with the heat radiation of motor and driver.
Do not block up a venting hole in the enclosure of driver.
The failure could result in abnormal temperature.

PR-006
Caution (wiring)
Wiring must always be performed properly and reliably.
Ensure that terminal connection or porarity (+, -) is correct.
The failure could result in damages or malfunction.
Carefully consider the cable clamping method, and make sure that bending
stress and the stress of the cable’s own weight are not applied on the cable
connection section.
The failure could result in damages or burst.
Do not apply a voltage exceeding the specied voltage to the input terminal.
The failure could result in damages or burst.
Do not modify the connector or terminals, etc., on the end of the cable.
The failure could result in damages or burst.
Caution (usage)
Provide an external emergency stop circuit to ensure that operation can be
stopped and power switched off immediately.
When a trouble occurs, shutoff the power immediately.
Before operation, check the parameter settings to ensure that there are no
operation errors. Connect a load to the products after the successful
trial-operations.
Improper settings may cause some machines to perform unexpected operation,
resulting in damages.
Do not apply a load exceeding the tolerable load onto the motor shaft.
The failure could result in break of the shaft.
Do not turn on or off the power frequently.
The failure could result in degradation of circuit element.
Do not change the parameter settings excessively.
The failure could result in instable or unexpected operation.

PR-007
Caution (corrective actions)
If any alarm has occurred, eliminate its causes of alarm and secure the safety
before restarting the operation.
The failure could result in damages or burst.
When it is assumed that a hazardous condition may take place at the
occurrence due to a product fault, use an external holding brake mechanism.
If any alarm has occurs, the motor goes into free-run state.
If any product fault has occurred, shutoff the power immediately and do not
turn on the power.
The failure could result in damages or burst.
Caution (maintenance, inspection)
Only persons who are trained and qualied to work or on electrical
equipment are permitted to maintain or inspect the product.
Incorrect handling or operation could cause electric shocks or damages.
Do not perform a dielectric voltage-withstand test.
The failure could result in destruction of circuit element.
About processing of waste
This product should be treated as an industrial waste when it is disposed.
Muscle Corporation is not responsible for any damages resulting
from modications or repairs made to the product.

IN-001
INDEX
Chapter 1
Functions and Structure ���������������������������������������������������001
1.1. Overview ��������������������������������������������������������������������001
1.2. Block Diagram ���������������������������������������������������������������002
1.3. Product Code Scheme �������������������������������������������������������002
1.4. Parts Description ������������������������������������������������������������003
1.5. Motor's Rotating Direction ����������������������������������������������������003
1.6. Status LED ������������������������������������������������������������������004
1.7. Control Type �����������������������������������������������������������������005
1.7.1. Pulse Type (P Type) �����������������������������������������������������005
1.7.2. Computer Type (C Type) �������������������������������������������������005
1.7.3. Interpolation Type (R Type) ����������������������������������������������005
Chapter 2
Installation ����������������������������������������������������������������006
2.1. Operating Condition ����������������������������������������������������������006
2.2. Mounting to Machinery �������������������������������������������������������006
2.2.1. General Notes �����������������������������������������������������������006
2.2.2. Coupling / Centering ����������������������������������������������������007
2.2.3. Allowable Shaft Load ����������������������������������������������������007
2.2.4. Notes for Shaft Load ����������������������������������������������������008
2.3. Notes for Cabling ������������������������������������������������������������009
Chapter 3
Wiring and Connections ���������������������������������������������������� 010
3.1. Typical Connection Example �������������������������������������������������� 010
3.2. Connector Pin Layout and Functions ������������������������������������������ 011
3.3. Connecting to Power Supply �������������������������������������������������� 013
3.4. Connecting to Equipments ���������������������������������������������������� 014
3.4.1. Connection for Host Communication �������������������������������������� 014
3.4.2. Connection for Pulse Input ����������������������������������������������� 015

IN-002
3.4.3. Digital Input/Output ����������������������������������������������������� 016
3.4.4. Connection for Analog Input/Output �������������������������������������� 016
3.4.5. +5V Output ������������������������������������������������������������� 016
3.5. I/O Circuit ������������������������������������������������������������������ 017
3.6. Connection Example ��������������������������������������������������������� 018
Chapter 4
Communication Functions ������������������������������������������������� 019
4.1. Communication Software Overview ������������������������������������������� 019
4.2. Conrming Communication ��������������������������������������������������� 019
4.3. Communication Method ������������������������������������������������������ 021
4.4. Communication Time ���������������������������������������������������������022
4.4.1. Transmission Time �������������������������������������������������������022
4.4.2. Response Time ����������������������������������������������������������023
Chapter 5
Operating the Motor �������������������������������������������������������024
5.1. Basic Motion ����������������������������������������������������������������� 024
5.2. Multiple Axes Control Motion �������������������������������������������������025
Chapter 6
Input/Output Functions ���������������������������������������������������026
6.1. Input / Output Functions �����������������������������������������������������026
6.1.1. Digital Input �������������������������������������������������������������026
6.1.2. Digital Output ����������������������������������������������������������� 027
6.1.3. Analog Input �������������������������������������������������������������028
6.1.4. Analog Output �����������������������������������������������������������029
6.2. I/O Signal according to Control Type ������������������������������������������029
6.2.1. Pulse Input ��������������������������������������������������������������029
Chapter 7
Various Other Functions ���������������������������������������������������030
7.1. Origin Search ����������������������������������������������������������������030
7.2. Push Motion �����������������������������������������������������������������030
7.3. Manual Jog and Feed ��������������������������������������������������������� 031
7.4. Torque Control ��������������������������������������������������������������� 031

IN-003
7.5. Arithmetic/Logical Operation Function ���������������������������������������� 031
7.6. PLC Function ���������������������������������������������������������������� 031
7.7. Reversal of Coordinate �������������������������������������������������������032
7.8. Circular / Linear Interpolation (optional) ���������������������������������������032
7.9. Protection/Safety Features ���������������������������������������������������032
Chapter 8
Maintenance and Inspection �����������������������������������������������033
8.1. Maintenance �����������������������������������������������������������������033
8.2. Troubleshooting ��������������������������������������������������������������034
8.2.1. Communications ���������������������������������������������������������034
8.2.2. Motor �������������������������������������������������������������������034
8.2.3. Motion ������������������������������������������������������������������034
Chapter 9
Characteristics �����������������������������������������������������������035
9.1. Basic Specications ����������������������������������������������������������035
9.2. Electric Specications �������������������������������������������������������� 037
9.3. Dimensions ������������������������������������������������������������������038
Chapter 10
Peripherals ���������������������������������������������������������������042
10.1. Cables ����������������������������������������������������������������������042
Revision History ����������������������������������������������������������045

IN-004
Explanation of icon
Icons used in this User's Guide.
Warningsandnotices
Importantpoints
Supplementalexplanations
Bundled Items
CM2 package includes CM2 and following cables.( : Refer to 3.1)
# Cable Application
accessory
power supply
cable
400mm
one side connector
accessory
communication
cable
400mm
one side connector
accessory
I/O cable
400mm
one side connector
a
b
c
ca

001
1.1. Overview
The COOL MUSCLE 2 (CM2) is the world smallest integrated AC servo system that combines motor,
encoder, driver, controller, PLC and power supply. The use of its own program language " CML " ( COOL
MUSCLE Language ) allows easy creation and control of motion. CML is a powerful motion programming
language that simplies and supports PTP motion, interpolation function* and torque control. CM2 provides the
highest system solution. (*optional)
Features of CM2
Motor
CM2 is based on an AC servo motor allowing for high speed, Max.8000min.
100W, 200W and 400W models are available.
Encoder
Muscle's unique magnetic encoder gives CM2 a Max. 50,000 ppr, and realizes the smooth motion and
high-accuracy positioning.
Driver
An ultra compact driver incorporates closed loop vector control.
Muscle's unique control technology eliminates the servo tuning.
Controller
Various kinds of motion as PTP motion, interpolation function (optional) and torque control are supported.
Muscle's original OS is built in.
Integrated PLC Function
CM2 has 6 inputs and 4 outputs.
A totally new integrated AC servo system incorporates PLC function as arithmetic / logical operation and
more.
Integrated Power Supply
Motor control/drive power supply is built in!
CM2 can be connected directly to AC100V-240V power source without conversion.
Communication
Two RS-232C ports.
Multi-axis network can be easily created by the daisy chain connection.
Functions and Structure
Chapter 1

002
Chapter 1FunctionsandStructure
1.2. Block Diagram
1.3. Product Code Scheme
Product code scheme is described as below.
CM2-C-56B10A-R
CM2 Model numbers are as below.
Cool Muscle 2 names Model #
COOLMUSCLE2 CM2 56 100W *Type CM2-*-56B10A-*
COOLMUSCLE2 CM2 56 200W *Type CM2-*-56B20A-*
COOLMUSCLE2 CM2 60 100W *Type CM2-*-60A10A-*
COOLMUSCLE2 CM2 60 400W *Type CM2-*-60A40A-*
Motor Output
10 100W
20 200W
40 400W
Control Type
PPulse
CComputer
R Interpolation
Motor size
56 56mm
60 60mm
Motor
Series
CM2
Power
Unit
Controller
Motor
Driver
(Amplifier)
Magnetic Encoder
(Detect Speed and
Position)
Input/Output
Interface
Communication
Interface
DC-DC
Converter
Driver Interface
Power Supply
Input
Communication
Line
Input/Output
Signal
Motor
Output
Shaft end (*Option)
RRound shaft
KKeyway *
DD-cut *
WDouble D-cut *

003
Chapter 1FunctionsandStructure
1.4. Parts Description
Each part of CM2 is as below.
1.5. Motor's Rotating Direction
The rotationg direction means as drawn in right.
CW (Clockwise) :
Facing to the output shaft, the motor shaft rotates in
Clockwise direction.
CCW (Counterclockwise) :
Facing to the output shaft, the motor shaft rotates in
Counterclockwise direction.
Driver
Case
Flange
Shaft
Mounting
holes
(4 corners)
LED Cover
Status LED
I/O
Connector
Slave Connector
I/O Cable
Host Connector
Power Supply Cable
Power Supply
Connector

004
Chapter 1FunctionsandStructure
1.6. Status LED
Status LED lights as follows by the status of CM2. (Status LED can be inactivated by parameter setting)
Status LED Pattern of lighting / blinking Status of CM2
Blue Lighting
Light
ON
Light
OFF
Servo ON
Red
Lighting ON
OFF
Motor free
by CML command
or input function
Blinking
once
ON
OFF
Overow of
position error
Blinking
twice
ON
OFF
Over voltage
Blinking
3times
ON
OFF
Overload
Blinking
4times
ON
OFF
Temperature error of
driver
Blinking
5times
ON
OFF
Push motion error
Blinking
6times
ON
OFF
Emergency stop
5 SEC
0.5
SEC

005
Chapter 1FunctionsandStructure
1.7. Control Type
Control types of CM2 include Computer, Pulse and Interpolation allowing you to choose the appropriate type for
your application.
1.7.1.PulseType(PType)
Pulse type CM2 can replace the existing pulse controll unit.
Input methods for Pulse type include CW/CCW pulses and Pulse/ Direction style. This input method can be
selected by parameter K36. Please refer to the CML User’s Guide for more information.
1.7.2.ComputerType(CType)
The operation controlled by a command or a program are possible. C type CM2 can be operated in the
following methods.
Direct Mode
If your application requires complicated motion or arbitrary motion, you can send CML commands directly to
CM2 via PC or embedded computers as needed. Immediate motion of CM2 is triggered and executed every
time CML commands are sent from computer.
This mode is useful for debugging the programs or test runs. Please refer to the CML User's Guide for more
information.
Program Mode
CM2 operates in accordance with a pre-defined program using CML. For the application which requires
repetitive motion, it is realized by executing pre-programmed positioning program stored in CM2, eliminating
the need for an external controll unit. Pre-loaded programs in CM2 can be set to run using a switch connected
to input, PC or PLC.
Please refer to the CML User's Guide for more information.
1.7.3.InterpolationType(RType)
R type CM2 has the function of Circular/Linear Interpolation in addition to the function of Computer Type.
Circular Interpolation function can easily generate an arc trajectory only by specifying radius or center point of
circle without a complex hand calculation and describing the calculating formula.

006
Installing in an improper location or mounting to machinary incorrectly, CM2 could result in abnormal behavior
or an unpredictable accident. Please read the following cautions to ensure safe and proper use of CM2.
2.1. Operating Condition
Please refer to Section 9.1 for operating and storage conditions.
The following instructions should also be fully noted.
Indoor where there is not direct sunlight on the product.
Cooling ventilation is properly considered.
No dust, metal particles, corrosive gas, ammable gas, oil mist.
No drop of water and cutting oil.
Please note that CM2 is not environmentally sealed. Using CM2 in a place where water or oil
gets into it may cause insulation failure or short-circuit.
Use in a place where inspection and cleaning are easy to do.
*Please contact us when the motor is required for more demanding conditions.
2.2. Mounting to Machinery
2.2.1.GeneralNotes
Mounting Direction
CM2 can be mounted horizontally or vertically.
Impact / Vibration
Please avoid mounting CM2 where excessive impact and vibrations occur.
Protect CM2 from impact such as hammering during mouting. Never apply any direct impact to the motor shaft.
Installation
Chapter 2

007
Chapter 2 MountingCM2
2.2.2.Coupling/Centering
Use a coupling when connecting the motor to a machine
to avoid unnecessary load. Make sure that the motor shaft
and the machine center are properly aligned.
Use a exible coupling with high torsional stiffness. Use of
a flexible coupling with low torsional stiffness may cause
unstable motion.
When the machine center and the motor shaft are not
properly aligned, vibration may occur, resulting in damage
to the motor bearings. Please make sure to align the motor
shaft with the mashine center within the error tolerance as
the diagram in the right. Do not apply impact or force to the
motor shaft during mounting a coupling.
2.2.3.AllowableShaftLoad
Allowable Radial Load and Thrust Load onto the motor shaft
are described in 9.1, Specification. Design the machinery
to ensure that shaft load does not exceed the allowable
values.
Radial Load (Fr) : Perpendicular force applied to the
shaft end.
Thrust Load(Fs) : Parallel force applied to the shaft end.
Motor
motor axis center
machine center
Coupling
degree of parallelization
Motor
motor axis center
machine center
Coupling
degree of eccentricity

008
Chapter 2 MountingCM2
2.2.4.NotesforShaftLoad
Radial Load
Excessive radial load could damage the motor bearings.
Belt Drive
When a pulley is directly mounted onto the shaft,
take note of radial load caused by belt tension.
To prevent slipping and respond to overload, a
wide belt with strong tension tends to be used for
design on the safe side. Moreover, this tendency
may be increased by the adjustment not using a
measurement tool.
Gear drive
When a gear is directly mounted onto a motor
shaft, radial load is occurred.
The larger radial load is caused by using smaller
gears to obtain high reduction ratio. Please make
sure that the axial load is within the values of
specications.
Overhang load
When the motor shaft is overhung, a vertical force
onto the overhung part has a big influence on the
motor shaft.
Overhang load is multiplied by the leverage effect,
stressing the motor shaft bearing. The longer the
overhung length, the larger the overhang load.
Moment load is applied ( see the illustration in the
right) to the motor shaft that is overhung. A tension
force is applied to the top half of the shaft and
compression forced is applied to the bottom half of
the shaft. During the shaft rotation, these opposite
forces alternate and stress the shaft, and continued
rotation over the long term could result in break.
compression
tension
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