RHINO MOTION CONTROLS RMCS-1120 User manual

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 1
Hybrid AC Driver [RMCS-1120]
Installation Manual and Datasheet

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 2
Hybrid AC Driver [RMCS-1120]
Key eatures
• Smooth and quiet operation at all speeds and e tremely low motor heating
• Industrial grade performance for an alternating current servo motor
• Field oriented control based low voltage servo loop
• Fully configurable position and velocity loop
• Input supply voltage from 12VDc to 50VDC
• Delivers up to 7amps of continuous current
• Selectable gear-ratio for encoder with counts from 4000 to 10000 per revolution
• PULSE, DIRECTION and ENABLE inputs with opto-isolated interface
• Short-circuit protection for the motor outputs, over-voltage and under-voltage protection
• LED indication for power and error states
Description
Thank you for purchasing RMCS-1120, Hybrid AC Driver. RMCS-1120 is Rhino Motion Controls
introductory hybrid low voltage AC drive designed for smooth and quiet operation without compromising
on torque and control at higher speeds. It has short-circuit protection for the motor outputs, over-voltage
and under-voltage protection and will survive accidental motor disconnects while powered-up.
The RMCS-1120 delivers a low-voltage servo performance using a field oriented control (FOC) current
loop for two-phase hybrid PMSM motors. It also provides a fully configurable position and velocity loop
with feed-forward variables to achieve close to zero lag in servo performance.
Two phase PMSM servo systems give an advantage of higher speed, faster response and very low motor
heating.
The RMCS-1120’s FOC control gains are calibrated on start-up based on motor characteristics and also
adjusted dynamically while the motor is in motion. This control algorithm makes it capable of achieving
better torque at higher speeds in comparison to comparable drives in its range.
The PULSE/STEP, DIRECTION and ENABLE inputs are optically isolated. Both inputs work with 2.5V, 3.3V
or 5V logic drive signals. The input drive current is 5mA at 2.5V so almost all logic family (74LS, 74HC,
etc.) can be used to drive these inputs.
The RMCS-1120 hybrid AC drive is warranted to be free of manufacturing defects for si months from the
date of purchase. Please see the section on service, support and warranty at the end of this document.

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 3
Hybrid AC Driver [RMCS-1120]
Technical Specifications
Specification
Min
Max
Units
Comment
s
Supply Voltage
12
5
0
Volts DC
Between +Ve and ND
Phase Current
0.5
7
Amps
As demanded by load
Servo Loop Speed
500
1000
Hz
Power Dissipation
0
15
Watts
—
Short
-
Circuit Current
7
10
Amps
In case of motor terminal short
PUL and
DIR Voltage
2.5
7
Volts DC
Between + and
–
input pins
Ambient Temp.
0
70
Celsius
Humidity
0
95%
Non condensing
Step Frequency
—
200
kHz
Direction Setup time
500
—
ns
Steps is clocked on positive edge
Mechanical Specifications
Specification
Details
Dimensions (L * W * H)
110mm * 77mm *33mm
Weight
155gms
Heat Sink
Anodized Aluminum 3mm thickness
Mounting Screw Holes
3.6mm minimum diameter

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 4
Hybrid AC Driver [RMCS-1120]
Caution
• Read this document carefully before installing and using you drive
• Inputs voltage to the drive must not e ceed the ma imum of 50VDC or it may damage the drive
• Reversing polarity power supplied to the drive will damage the drive or power supply
• Connecting the power supply wires to the terminals outputs of the motor coils will damage the
drive
• Short-circuiting the motor terminals to +Ve power or to each other or to GND may damage the
drive
• E cess humidity or condensation on the drive may damage the drive
• Voltage in e cess of 7V between the PULSE+ and PULSE- or DIR+ and DIR- or ENA+ and ENA-
input terminals may damage the opto-isolators
• Reverse voltage in e cess of 7V between the PULSE- and PULSE+ or DIR- and DIR+ or ENA+ and
ENA- input terminals may damage the opto-isolators
• Heat sink is designed to dissipate heat from the drive circuitry as long as the ambient temperature
is less that 70 degrees Celsius. Ambient temperature in e cess of that may damage the drive
• Do not un-plug the terminals of the motor while the drive is powered up and running
Power and Motor Terminal Assignments
Terminal No.
Terminal Name
Description
Terminal 1
A
+
Motor Coil Phase A
+
Terminal 2
A
-
Motor Coil Phase A
-
Terminal 3
B
+
Motor Coil Phase B
+
Terminal 4
B
-
Motor Coil Phase B
-
Terminal 5
+V
Power +
Ve (1
2
VDC to 5
0VDC Max wrt. ND)
Terminal 6
ND
Power
round or
Power
–
Ve

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 5
Hybrid AC Driver [RMCS-1120]
Encoder Terminal Assignments
Terminal No.
Terminal Name
Wire Colour
Description
Terminal 1
ND
BLACK
Power
round or
Power
–
Ve
Terminal 2
+V
RED
Power +Ve
(5VDC wrt. ND)
Terminal 3
A
-
REEN
Motor Coil Phase A
-
Terminal 4
A+
YELLOW
Motor Coil Phase A+
Terminal 5
B
-
WHITE
Motor Coil Phase B
-
Terminal 6
B+
BLUE
Motor Coil Phase B+
Pulse and Direction Input Assignments
Terminal No.
Terminal Nam
e
Description
Terminal 1
ENA
-
Enable (Motor Free)
-
Ve optically isolated input
Terminal 2
ENA+
Enable (Motor Free) +Ve optically isolated input
Terminal 3
DIR
-
Direction
-
Ve optically isolated input
Terminal 4
DIR+
Direction +Ve optically isolated input
Terminal 5
PUL
-
Pulse
-
Ve optically isolated input
Terminal 6
PUL+
Pulse +Ve optically isolated input

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 6
Hybrid AC Driver [RMCS-1120]
Switch Selection Table for Step Selection
Resolution
SW1
SW2
1/4
ON
ON
1/5
OFF
ON
1/2
ON
OFF
1x
OFF
OFF
1 = Encoder Counts Per Revolution (CPR)
Switch (3): Sets EEPROM permissions
SW3 ON – EEPROM Data Locked
SW3 OFF – EEPROM Data Unlocked
Switch (4): Sets Direction
SW4 ON – Forward Direction
SW4 OFF – Reverse Direction
RS-485 Command Port
A 2pin command port is available on the drive for debug and tuning routines. The communication is based
on Modbus RTU, the drive works as Modbus Slave and its register map is given in the Modbus Register
Table.
When connected it to a computer the drive parameters can be accessed by simple commands using any
Modbus Master Poll Software. An additional hardware to e ecute this process would be a USB to RS485
Converter. The baud rate of 115200 bps is default with 8 bit data, 1 stop bit and no parity.
The Modbus RTU Functions 03 (Read Multiple Registers), 05 (Write Single Coil) and 06 (Preset Single
Register) are used to control the drive.

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 7
Hybrid AC Driver [RMCS-1120]
For e ample, some valid Control Query Frames for Drive would be like:
1. 0 01, 0 03, 0 00, 0 00, 0 00, 0 0F, CRC16 – This Query will e pect a read of 15 Slave Registers
starting from address 0 0000 as a response from Drive with Slave Address 0 01.
2. 0 00, 0 05, 0 00, 0 00, 0 00, 0 00, CRC16 – This Query will set all the Slave Drives’ Parameters
to their default values.
3. 0 01, 0 06, 0 20, 0 04, 0 00, 0 00, CRC16 – This Query will Set Value 0 0000 to the Register at
address 0 2004 of Drive, that will start the Motor.
Modbus Register Table
Parameter
Description
Address
Decimal
Address
Data Type
Default
Max
PP_ AIN
Position P ain
0X0000
0
Signed
256
30000
PFF_ AIN
Feed
Forward ain
0X0001
1
signed
50
30000
PD_ AIN
Position D ain
0X0002
2
signed
300
30000
PV_ AI
N
Velocity P ain
0X0003
3
signed
600
30000
IV_ AIN
Velocity I ain
0x0004
4
signed
80
1000
DV_ AIN
Velocity D ain
0X0005
5
signed
300
30000
C_LIMIT
Current Limit
0X0006
6
signed
2400
4000
CP_ AIN
Current P ain
0X0007
7
signed
100
1000
CI_ AIN
Current I ain
0X0008
8
signed
100
1000
C_TRI ER
Current Trigger
Level
0X0009
9
signed
1200
4000
FLT_TIME_CN
ST
Input Filter Time
0X000A
10
signed
0
100
PFA_ AIN
Acceleration FeedF
0X000B
11
byte
7
100
I_MUL
Input Multiplier
0X000B
11
byte
1
8
SLVADDR
Modbus Slave
Address
0X000C
12
byte
1
247
ENC_PPR
Encoder CPR
0X000D
13
signed
4000
10000
M_POLES
Motor Poles Count
0X000E
14
byte
50
100

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 8
Hybrid AC Driver [RMCS-1120]
Where,
PP_ AIN
Position Error Proportional ain in Position Control Loop
PFF_ AIN
Input Velocity Feedforward
ain in Position Control Loop
PD_ AIN
Position Error (Derivative) Damping ain in Position Control Loop
PV_ AIN
Velocity Error Proportional ain in Velocity Control Loop
IV_ AIN
Velocity Error Integral ain in Velocity Control Loop
DV_ AIN
Velocity
Error (Derivative) Damping ain in Velocity Control Loop
C_LIMIT
Current Command Limit Variable to reduce overheating in specific applications
CP_ AIN
Current Error Proportional ain in Current Control Loop
CI_ AIN
Current Error Integral ain in Current
Control Loop
C_TRI ER
Overload Current Trigger Level setting for LED Display
FLT_TIME_CNST
Input Pulse Train IIR filter Time Constant setting
PFA_ AIN
Input Acceleration Feedforward ain In Position Loop
I_MUL
Input Pulse Train Multiplier to reduce
Output Speed
SLVADDR
Slave Address of Device for Modbus RTU Communication
ENC_PPR
The Encoder CPR setting for the Motor
M_POLES
The Number of Poles in the Motor
Note: The Current Limit and the Current Trigger Level are application specific parameters.
Additional Commands
Parameter
Description
Address
Decimal
Address
Data Type
Default
Max
V_COMD
Velocity Command
0X2
000
8192
Signed
0
200
A_COMD
Acceleration
Command
0X
2001
8193
signed
25
1000
M_COMD
Motion Command
0X
2002
8194
signed long
0
-
M_STATE
Motion Status
0X2004
819
6
signed
4
-
P_ERROR
Position Error
0x
2005
819
7
signed
-
-
C_POS
Current 32
bit POS
0X
2006
819
8
S
igned
long
-
-
C_Angle
Current Angle
0X
200
8
8
200
signed
-
-

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 9
Hybrid AC Driver [RMCS-1120]
(CPR)
C_Speed
Current Speed
0X
200
9
820
1
signed
-
-
C_Current
Current Input
Current
0X
200
A
820
2
signed
-
-
C_Calibrate
Current loop
calibrated level
0
X200
B
820
3
signed
-
-
C_Error
Realtime error
status
0X200C
8204
Signed
0
Where,
V_COMD
The maximum Velocity setting for Trapezoidal Motion
Profile (15rpm / unit)
A_COMD
The Acceleration Slope setting for Trapezoidal Motion Profile (30rpm/s2 / unit)
M_COMD
The Displacement required for the Motion Profile in Encoder Steps (32bit signed)
M_STATE
The state of the Motion Profile State Machine
P_ERROR
The Position Error between Commanded and Current Position (Realtime)
C_POS
The Current Encoder Position (16 bit) (Realtime)
C_Angle
The Commutation Angle of the Shaft (Encoder CPR) (Realtime)
C_Speed
The Speed of the Motor (30rpm/step) (Realtime
)
C_Current
The Current Command iven to Current Loop (Realtime)
C_Calibrate
The Startup Current Loop Calibration Value
C_Error
ives the status of the error when motor is automatically disabled due to fault
Note: The motion command value 4000 corresponds to one full rotation of motor. The programmer can
have multiples of 4000 to achieve specific number of rotations. For e ample, if 8 rotations are required,
this value would be 32000 (4000 multiplied by 8). If the motion command value is negative, it will run the
motor in opposite direction.

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 10
Hybrid AC Driver [RMCS-1120]
RS-485 Connection Setting.
Baud Rate :
115200
bps
(
Bits per second)
Data bits
: 8
P
arity
: None
Stop Bit
s : 1
Motion Profiler Status : 8196 Supported unctions:
0 : Motor Start [Start O
peration]
03 : Read Single / Multiple Registers
1: Running [Command R
unning
, Read Only
]
06 : Write Single Register
2 : Stop Motor [
D
eceleration
]
0
5 : Write Coil [Slave ID 0x00 (D
efault)]
3 : Emergency STOP [Disable]
4 : Idle [Enabled and Locked]
5 : Current ains Auto Tuning
6 : Motor Start [Absolute O
peration]
7:
Reset Position Resistors to Z
ero

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 11
Hybrid AC Driver [RMCS-1120]
Modbus RTU Master’s Command List for Setting Motion Profile
For setting any Command’s value, the Modbus Master Queries with the RTU Function 0 06. The query
frame contains 8 bytes. Some Right Shift (“>>”) and “&” operations on the input value are required in
order to tackle the data type issues.
Note: SDA stands for Slave Drive Address
Caution: The Motion Status must be IDLE before sending Motion Profiler Status Commands e cept 2 and
3.
Command Modbus Master Query rame
Velocity
SDA, 0x06, 0x20, 0x00, (Value >> 8), (Value & 0xFF), CRC16
Acceleration
SDA, 0x06, 0x20, 0x01, (Value >> 8), (Value &
0xFF), CRC16
Motion
SDA, 0x06, 0x20, 0x02
, ((Value & 0xFFFF) >> 8), (Value & 0xFF), CRC16
SDA, 0x06, 0x20, 0x03
, (Value >> 24), ((Value & 0xFFFFFF) >> 16), CRC16
Motion Status
SDA, 0x06, 0x20, 0x04, (Value >> 8), (Value & 0xFF), CRC16
Power Supply Selection
The general rule of thumb to get the most out of the motor is to drive it with a supply voltage that is at-
least 3 to 4 times its rated supply voltage. A DC regulated power supply with good low-ESR decoupling
capacitors on its output is recommended for best performance of this drive.
LED Status and Error Codes
There is a single LED on this drive for power and error status messages. In case the LED is blinking or
flickering please check all connections and powered-down, wait for 5 seconds and then power-up the drive
once again.
LED State
Message
reen LED ON and steady
Powered up and calibrated
Red LED Flickering randomly
Current Trigger Level Achieved
Red LED blinking
Short circuit on motor terminals or drive message to connection error

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 12
Hybrid AC Driver [RMCS-1120]
Guide to General Problems
Problem Symptom
Possible Reasons and Solutions
Motor is not rotating
Drive is not powered up
Motor is not connected properly to the drive
Drive is in an error state, check LED status
Pulse and Direction inputs are not connected properly or are not supplying
enough current
Motor rotates in the wrong direction
Motor Phase connections may be reversed
LED is blinking
Check LED status messages in this document and check connections and voltages
accordingly
Drive might be damaged due to incorrect installation or handling
Drive is not powering up (no LED)
Check that the connectors to the drive are tightly plugged in
Check the supply voltage is adequate and in correct polarity
Drive might be damaged due to incorrect installation or handling
Erratic Motion on Motor
Power supply voltage not stable or regulated
Motor Coil damaged or not connected to the drive correctly
Current setting on the motor too high
Control signals of Pulse or Direction are not connected properly or not supplying
enough voltage and current
Control signal interference due to power supply or environmental noise
Motor stalls during accelerating
Motor load is too high
Acceleration is too high
ain settings is too low of the Motor
Power Supply is too low for Motor or Speed
Excessive Motor or Drive Heating
Drive is damaged
Power supply voltage is too high
Not enough cooling or ventilation for motor or drive

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 13
Hybrid AC Driver [RMCS-1120]
Control Signal Connection NPN pull-down
In this connection technique all the signal +ve inputs are connected to a common high voltage VCC. The
opto-isolators LED is turned–on by a pull-down on the –Ve terminals by an NPN-transistor output

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 14
Hybrid AC Driver [RMCS-1120]
Control Signal Connection PNP pull-up
In this connection technique all the signal -ve inputs are connected to a common low voltage GND. The
opto-isolators LED is turned–on by a pull-up on the +Ve terminals by an PNP-transistor output
Control Signal Connection Differential
In this connection technique each input is differential controlled and no necessity for a common voltage

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 15
Hybrid AC Driver [RMCS-1120]
2-phase, 4-lead Motors Connections
4 lead motors are the least fle ible but easiest to wire. Speed and torque will depend on winding
inductance. In setting the drive output current, multiply the specified phase current by 1.4 to determine
the peak output current.

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 16
Hybrid AC Driver [RMCS-1120]
Configuration through PC software
To configure the drive easily a Windows software is available here
http://rhinomc.com/downloads/Hybrid_Servo_Tuner_Setup_Modbus.exe
The software is compatible with Windows XP and later operating systems including Windows 7, 8 and 10.
Both 32 bit and 64 bit versions are supported. Software must be installed with Admin rights, however
after installing it can be used normally without Admin rights. Software will be installed for all users by
default.
After running the setup you will get the welcome screen. Click Ne t.

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 17
Hybrid AC Driver [RMCS-1120]
Then it will show the install path and shortcut folder in start menu. Click ne t and then finish on the ne t
screen to finish the installation.
To start the software you can go to Start Menu - Rhino Hybrid Servo Tuner Modbus
Alternatively you can also start from the shortcut created on your desktop.
After opening you will see the following screen

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 18
Hybrid AC Driver [RMCS-1120]
To connect this software to drive you will need a USB to
RS485 or Serial to RS485 converter as shown in image
below.
D+ and D- Lines needs to be connected between drive and
converter. After connecting and installing the driver you
need to make sure that hardware or virtual Com port is
between the range of Com1 to Com32. Com Port beyond
this range are incompatible with the software. You may
change the COM port from device manager.
You may connect multiple drives on same paralleled
connection to D+ and D- lines.

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 19
Hybrid AC Driver [RMCS-1120]
Once the drive is connected through converter and drivers are installed there should be a COM port for the
connection. It should be selected in the software in the 'Modbus Serial Port Connection' section.
If the Com port for your connection is not visible, clicking on the dropdown will refresh the list of available
ports. Click Connect button to connect to the specified com port.
Once the connection is done, you will also need to select
the slave address to communicate with drive. Slave address
can be from 1 to 247.
If you don't know the slave addresses for connected drives
you may click the Search button for Available Slaves. It will
search from 1 to 247 slaves for response. If it gets a
response the slave will be added in drop down. You can see
the progress in status bar. It will take a lot of time to scan
all devices. You may press cancel when all connected
devices are found. Once the process is finished you can
select any slave address from the drop down of Available
Slaves to communicate to it.
Once a valid slave address is selected the drive will start
communicating to software and the connection status
indicator will turn green. It will also change colors between
green and yellow-green to indicate communication. Also the
software will load all the parameters stored in drive.
You may also change the update interval through drop
down. Lower the interval - faster the communication will
be. However it will also consume more CPU. If you are
running a slow PC or the software slows down your PC you
may increase it. Ideally 10 to 50 ms interval will suite most
PCs.

RHINO MOTION CONTROLS
RMCS-1120
Hybrid Servo Driver with Modbus RTU communication
(Ma . 50Vdc and 7A per phase)
http://www.rhinomc.com
Page 20
Hybrid AC Driver [RMCS-1120]
On the Parameters section you can see all the parameters
loaded from the currently connected drive. If you change
the slave address, the parameters will be loaded for the new
slave.
You may also click 'Read Parameters' button at any point to
read the parameters from drive.
Description of each parameter can be seen by hovering the
mouse cursor over it. If it isn't showing the tooltip you can
enable it from Help menu.
You may change the parameters by typing into the te tbo .
You can save it to the drive by pressing enter. You may also
change multiple parameters and click 'Write Parameters'
button to save all parameters. Only the parameters which
are changed will be written.
You can save all the parameters for a particular drive to a
file and load it when required. On opening such saved file all
the parameters will be written to the drive and drive will
immediately start responding according to the new
parameters.
In case you have set the parameters wrongly and you want
to reset it, you may click the 'Reset Parameters of All Drives
on Modbus' button. This will reset all the drives connected
on modbus. Its recommended that you do this only when
one drive is connected because otherwise it will reset the
slave address of each connected drive to 1, this will
make all the drive communicating simultaneously to the
software and it may show wrong values or misbehave.
Ideally you should connect drives one by one and change
their slave addresses to greater than 1 value. After all your
drive are programmed with different slave addresses you
may connect them all to the modbus lines and configure
through the software.
After connecting a new motor or resetting the parameters its
recommended to click the 'Current Gains Auto Tune' button
once. This will set the current gains according to the motor
characteristics.