Intelligent Motion Systems MDI42 AC Specification Manual

42 TM 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 Confi guration** • 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 identifi er. The MDrive42AC Plus2 Motion Control is available with optional closed loop control. This increases functionality by adding stall detection, position mainte- nance and fi nd index mark. The closed loop confi guration 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 Plus2 Motion 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 fi xed to the internal step clock. A sealed version designed to meet IP65 specifi cations 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**. In ter face con nec tions are ac com plished 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 of fers de sign ers a cost effec- tive, full featured programmable motion con trol ler in te grat ed 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 fl ow through the motor, resonance is sig- nifi cantly 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 Plus2 Motion Control system adds a versatile array of func tions by com bin ing a full featured pro gram - ma ble mo tion controller with our com pact and cost ef fec tive MDrive42AC Micro- stepping products, adding little cost and no increase in size. Stan dard of fer ings include up to 8 general pur pose I/O lines (sourcing or sinking) that operate to +24 VDC, one 10 bit analog in put, electronic gearing, high speed position capture input/trip output, microstep res o lu tions up to 51,200 steps per rev o lu tion, 0 to 5 MHz step clock rate, and a full fea tured easy- to-program in struc tion set. The MDrive42AC Plus2 Motion Control system com mu ni cates over RS-422/485 which al lows for point-to-point or multiple unit con fi g u ra tions utilizing one com mu - ni ca tion port. Addressing and hard ware support multiple uniquely addressed units com mu ni cat ing over a single line. new

MDrive42AC 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-sec2 / 6.5 kg-cm2 14.07 lb / 6.38 kg DOUBLE LENGTH 2294 oz-in / 1620 N-cm 84 oz-in / 59 N-cm 0.1833 oz-in-sec2 / 13.0 kg-cm2 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 Confi guration 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 Confi guration (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-Defi ned Note: µstep/rev 2X the encoder count/rev minimum Counters Type Position, En cod er/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 109 Steps 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 SPEC I FI CA TIONS † Designed for line-neutral systems. ‡ Adjusting the microstep resolution can increase the range.

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 Torque in 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

Planetary Gearbox for MDrive42Plus Dimensions in Inches (mm) Permitted Output Torque (oz-in/Nm) Gearbox Effi ciency 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 fi ner positional resolutions. These effi cient, 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 confi gurations. 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)

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. +00 (1) 860 295-6102 - Fax +00 (1) 860 295-6107 e-mail: [email protected] http: //www.imshome.com U.S.A. SALES OFFICES Eastern Region Tel. 862 208-9742 - Fax 973 661-1275 e-mail: [email protected] Central Region Tel. 260 402-6016 - Fax 419 858-0375 e-mail: [email protected] Western Region Tel. 602 578-7201 e-mail: [email protected] IMS ASIA PACIFIC OFFICE 30 Raffl es Pl., 23-00 Caltex House, Singapore 048622 Tel. +65/6233/6846 - Fax +65/6233/5044 e-mail: [email protected] IMS EUROPEAN SALES MANAGEMENT 4 Quai Des Etroits 69005 Lyon, France Tel. +33/4 7256 5113 - Fax +33/4 7838 1537 e-mail: [email protected] IMS UK Ltd. Sanderson Centre, 15 Lees Lane Gosport, Hampshire PO12 3UL Tel. +44/0 2392-520775 - Fax +44/0 2392-502559 e-mail: [email protected] TECHNICAL SUPPORT Tel. +00 (1) 860 295-6102 - Fax +00 (1) 860 295-6107 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. – F Optional 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 Plus2 Motion Control CONNECTING QuickStart Kit For rapid design verifi cation, 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 con vert er 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 fl ying 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 Effi cient, 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