Page 1
Standalone MMC
Hardware Manual
Version 15.0
TM
G & L Motion Control Inc.
Page 2
Page 3
NOTE
Progress is an on-going commitment at G & L Motion Control Inc. We continually strive to offer the
most advanced products in the industry; therefore, information in this document is subject to change
without notice. The illustrations and specifications are not binding in detail. G & L Motion Control
Inc. shall not be liable for any technical or editorial omissions occurring in this document, nor for any
consequential or incidental damages resulting from the use of this document.
DO NOT ATTEMPT to use any G & L Motion Control Inc. product until the use of such product is
completely understood. It is the responsibility of the user to make certain proper operation practices
are understood. G & L Motion Control Inc. products should be used only by qualified personnel and
for the express purpose for which said products were designed.
Should information not covered in this document be required, contact the Customer Service
Department, G & L Motion Control Inc., 672 South Military Road, P.O. Box 1960, Fond du Lac, WI
54936-1960. G & L Motion Control Inc. can be reached by telephon e at (92 0) 921–710 0 or (800 ) 5584808 in the United States or by e-mail at glmotion.support@danahermotion.com
Release Date: 09-01-06
Catalog Part Number M.1300.7620
Printed Part Number M.3000.0067
Electronic Part Number M.3000.0066
© 1999-2006 G & L Motion Control Inc.
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Belden® is a registered trademark of Cooper Industries, Inc.
IBM is a registered trademark of International Business Machines Corp.
Windows 95, 98, NT, Microsoft, and MS-DOS are registered trademarks of Microsoft Corporation.
MOD HUB is a trademark of Contemporary Control Systems, Inc.
ARCNET® is a registered trademark of Datapoint Corporation.
ST is a trademark of AT&T Bell Labs.
Temposonics™ is a trademark of Contemporary Control Systems, Inc.
DeviceNet™ is a trademark of Open DeviceNet™ Vendor Association. Inc.
Pentium and PentiumPro are trademarks of Intel Corporation.
PiC900, PiCPro, MMC, PiCServoPro, PiCTune, PiCProfile, LDO Merge, PiCMicroTerm and PiC Programming Pendant are
trademarks of G & L Motion Control Inc.
Page 5
Table of Contents: MMC Hardware Manual
1 Introduction to the Standalone MMC.................................................................... 1
1.1 Overview....................................................................................................... 1
1.2 Contents of This Manual............................................................................... 1
1.3 Software and Manuals .................................................................................. 2
1.3.1 Required Software and Manuals ......................................................... 2
1.3.2 Suggested Manuals ............................................................................. 2
1.4 G&L Motion Control Support Contact......................................................... 2
2 Safety Precautions.................................................................................................. 3
2.1 System Safety ............................................................................................... 3
2.1.1 User Responsibility ............................................................................. 3
2.1.2 Safety Instructions .............................................................................. 3
2.2 Safety Labels................................................................................................. 4
2.2.1 Hazard Warning .................................................................................. 4
2.2.2 Danger, Warning, or Caution Warning ............................................... 5
2.2.3 Hot Surface Warning .......................................................................... 5
2.3 Safety First.................................................................................................... 6
2.4 Safety Inspection........................................................................................... 6
2.4.1 Before Starting Operations ................................................................. 6
2.5 After Shutdown............................................................................................. 6
2.6 Operating Safely ........................................................................................... 6
2.7 Electrical Service & Maintenance Safety..................................................... 7
2.8 Safe Cleaning Practices ................................................................................ 8
3 Installation, Operation, & Maintenance................................................................. 9
3.1 Mounting the MMC Control......................................................................... 9
3.2 Adding an Option Module to the MMC Control.......................................... 10
3.3 Dimensions and Mounting of MMC with Option Modules Attached.......... 12
3.4 System Power and Environment Requirements............................................ 13
3.4.1 General Power and Environment Requirements ................................. 13
3.4.2 Control Cabinet Specifications ........................................................... 14
3.4.3 Power Distribution Diagram ............................................................... 14
3.4.4 Grounding the System ........................................................................ 16
3.4.5 Controlling Heat Within the System ................................................... 17
3.4.6 Handling an MMC .............................................................................. 18
3.5 System Wiring Guidelines............................................................................ 19
3.5.1 Recommended Signal Separation ....................................................... 19
3.5.2 Differential Devices for Analog and Encoder Signals ........................ 22
3.6 Starting an Application................................................................................. 23
3.7 Basic Setup and Maintenance Procedures .................................................... 24
3.8 System Status Lights..................................................................................... 24
3.8.1 Power Status ....................................................................................... 25
3.8.2 Battery Status ...................................................................................... 25
3.8.3 Scan Status .......................................................................................... 25
3.8.4 Power-up Diagnostics Status .............................................................. 25
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3.8.5 Run-time Diagnostic Status ................................................................ 26
3.8.6 Diagnostic Error Codes ....................................................................... 27
4 Standalone MMC Control...................................................................................... 29
4.1 Introduction................................................................................................... 29
4.2 Features......................................................................................................... 29
4.3 Overview....................................................................................................... 29
4.4 Major Components ....................................................................................... 30
4.4.1 Machine Control Board ...................................................................... 31
4.4.2 Motion Control Board ......................................................................... 32
4.4.2.1 Analog Servo board............................................................. 32
4.4.2.2 SERCOS board.................................................................... 33
4.5 Power Supply Requirements......................................................................... 33
4.6 Machine Control Connection & Operation................................................... 37
4.6.1 PiCPro Port ......................................................................................... 38
4.6.2 Block I/O Port ..................................................................................... 39
4.6.3 User Port ............................................................................................. 43
4.6.4 General I/O Port .................................................................................. 49
4.6.4.1 DC Output Operation........................................................... 53
4.6.4.2 DC Input Operation ............................................................. 56
4.6.5 Power Connection ............................................................................... 57
4.7 Analog Motion Control Connections & Operation....................................... 59
4.7.1 Axis I/O Ports ..................................................................................... 59
4.7.1.1 Axis I/O Port DC Outputs ................................................... 64
4.7.1.2 Axis I/O Port DC Input........................................................ 66
4.7.1.3 Axis I/O Port Analog Output............................................... 67
4.7.1.4 Axis I/O Port Encoder Input................................................ 67
4.7.2 Aux I/O Port ........................................................................................ 68
4.7.2.1 Isolated Breakout Box Details............................................. 74
4.7.2.2 Aux I/O Port Fast Inputs...................................................... 76
4.7.2.3 Aux I/O Port DC Inputs....................................................... 77
4.7.2.4 Aux I/O Port Encoder Input................................................. 79
4.7.2.5 Aux I/O Port Analog Input.................................................. 80
4.8 SERCOS Motion Control Connections & Operation ................................... 81
4.8.1 SERCOS Receive and Transmit Ports ................................................ 81
4.8.2 Loader Port ......................................................................................... 83
4.9 Replacing the MMC Battery......................................................................... 85
4.10 Specifications ............................................................................................. 87
5 Standalone Digital MMC Control.......................................................................... 91
5.1 Introduction................................................................................................... 91
5.2 Features......................................................................................................... 91
5.3 Overview....................................................................................................... 91
5.4 Power Supply Requirements......................................................................... 92
5.5 Connectors & Operation............................................................................... 93
5.5.1 Block I/O Port ..................................................................................... 95
5.5.2 User Port ............................................................................................. 98
5.5.3 PiCPro Port ......................................................................................... 104
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5.5.4 Ethernet Port ....................................................................................... 106
5.5.5 Digital Link Ports ................................................................................ 108
5.5.6 User USB Port .................................................................................... 111
5.5.7 User USB Port .................................................................................... 111
5.5.8 Power Connection ............................................................................... 111
5.6 Replacing the MMC Battery......................................................................... 112
5.7 Specifications ............................................................................................... 114
6 MMC Ethernet TCP/IP Option Module................................................................. 117
6.1 Introduction................................................................................................... 117
6.2 Connections .................................................................................................. 118
6.2.1 The Ethernet Port ................................................................................ 119
6.2.2 The RS232 COMM Ports ................................................................... 121
6.3 LEDs............................................................................................................. 123
6.4 Firmware Update .......................................................................................... 124
6.5 Theory of operation ...................................................................................... 124
6.6 Specifications Table...................................................................................... 126
6.7 Useful Internet Links .................................................................................... 126
7 MMC DeviceNet
TM
Option Module........................................................................ 129
7.1 Introduction................................................................................................... 129
7.2 Connections .................................................................................................. 130
7.2.1 The DeviceNet Port ............................................................................ 131
7.2.2 The Configuration (RS232) Port ......................................................... 131
7.3 LEDs............................................................................................................. 132
7.4 Theory of Operation...................................................................................... 133
7.5 Specifications................................................................................................ 134
8 MMC Profibus Option Module.............................................................................. 135
8.1 Introduction................................................................................................... 135
8.2 Connections .................................................................................................. 136
8.2.1 The Profibus Port ................................................................................ 137
8.2.2 The Configuration (RS232) Port ......................................................... 137
8.3 LEDs............................................................................................................. 138
8.4 Theory of Operation...................................................................................... 139
8.5 Specifications for Profibus Module.............................................................. 140
9 MMC Axis I/O Option Module ............................................................................. 141
9.1 Specifications................................................................................................ 142
10 MMC 32In/32Out Option Module....................................................................... 145
10.1 Introduction................................................................................................. 145
10.2 Connections & Operation ........................................................................... 147
10.2.1 DC Output Operation ........................................................................ 150
10.2.2 DC Input Operation .......................................................................... 153
10.3 Specifications.............................................................................................. 155
11 CE and EMC Guidelines...................................................................................... 157
11.1 Background on EMC (Electromagnetic Compatibility) Compliance......... 157
11.2 Background on Low Voltage Compliance.................................................. 157
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11.3 RFI Emission and Immunity....................................................................... 158
11.4 Classes of EMC Operating Environments.................................................. 159
11.5 Conformance with the EMC Directive....................................................... 160
11.6 Conformance With the Low Voltage Directive.......................................... 160
11.7 Changes to the PiC Products....................................................................... 160
11.7.1 Changes Affecting the User .............................................................. 161
11.8 Using CE/EMC and Non-CE/EMC Modules ............................................ 164
11.9 Declarations of Conformity ........................................................................ 166
Appendix A - Operation Details............................................................................... 171
A.1 Introduction.................................................................................................. 171
A.2 DC Inputs..................................................................................................... 171
A.3 DC Outputs .................................................................................................. 173
A.3.1 Inductive Loads .................................................................................. 174
A.4 Encoder Inputs ............................................................................................. 175
INDEX..................................................................................................................... 179
iv MMC Hardware Manual G & L Motion Control Inc.
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Introduction to the Standalone MMC
1 Introduction to the Standalone MMC
1.1 Overview
The Standalone Machine and Motion Control (MMC) product line consists
of three distinct products:
• The Standalone MMC Control, which is available in two configu-
rations to control:
• Analog Interfaced drives (such as the Analog Interfaced
MMC-SD) via a +10V analog output.
• SERCOS Interfaced drives.
• The Standalone Digital MMC Control, which controls Digital
Interfaced drives (such as the Digital MMC-SD) via a digital connection (Digital Link).
• MMC Option Modules, which provide various added functional-
ity to the Standalone MMC Control and the Standalone Digital
MMC Control.
Unless otherwise noted, all of the information in this manual applies to both
the Standalone MMC Control and the Standalone Digital MMC Control.
1.2 Contents of This Manual
This manual includes the following major topics:
• Information to safely operate and maintain the equipment in a
safe manner.
• User responsibilities for product acceptance and storage.
• Power and environmental information for general power, control
cabinet, grounding, heat control and handling.
• Procedures for mounting, wiring, and connecting the MMC Con-
trol.
• The function, location, and signal descriptions of connectors on
the MMC Control.
• Physical, electrical, environmental and functional specifications/
dimensions.
• Description of the minimal maintenance necessary.
• A troubleshooting chart of potential problems and possible solu-
tions.
G & L Motion Control Inc. MMC Hardware Manual 1
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Introduction to the Standalone MMC
• Part numbers and descriptions for the MMC Control, MMC
Option Modules, and related equipment.
1.3 Software and Manuals
1.3.1 Required Software and Manuals
• For use with the Standalone MMC Digital Control, V16.0 or
higher of one of the following, and for use with the Standalone
MMC Control, V11.0 or higher of one of the following:
• Professional Edition
• MMC Limited Edition
• Monitor Edition
1.3.2 Suggested Manuals
• Function/Function Block Reference Guide
• Motion Application Specific Function Block Manual
• Ethernet Application Specific Function Block Manual
• General Purpose Application Specific Function Block Manual
1.4 G&L Motion Control Support Contact
Contact your local G&L Motion Control representative for:
• Sales and order support
• Product technical training
• Warranty support
• Support service agreements
G&L Motion Control Technical Support can be reached:
• In the United States, telephone (800) 558-4808
• Outside the United States, telephone (920) 921-7100
• E-mail address, glmotion.support@danahermotion.com
2 MMC Hardware Manual G & L Motion Control Inc.
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Safety Precautions
2 Safety Precautions
READ AND UNDERSTAND THIS SECTION IN ITS ENTIRETY
BEFORE UNDERTAKING INSTALLATION OR
ADJUSTMENT OF MMC CONTROL EQUIPMENT
The advice contained in this section will help users to operate and maintain the
equipment in a safe manner at all times.
PLEASE REMEMBER THAT SAFETY IS EVERYONE'S RESPONSIBILITY
2.1 System Safety
The basic rules of safety set forth in this section are intended as a guide for
the safe operation of equipment. This general safety information, along with
explicit service, maintenance and operational materials, make up the
complete instruction set. All personnel who operate, service or are involved
with this equipment in any way should become totally familiar with this
information prior to operating.
2.1.1 User Responsibility
It is the responsibility of the user to ensure that the procedures set
forth here are followed and, should any major deviation or change
in use from the original specifications be required, appropriate
procedures should be established for the continued safe operation
of the system. It is strongly recommended that you contact your
OEM to ensure that the system can be safely converted for its new
use and continue to operate in a safe manner.
2.1.2 Safety Instructions
1. Do not operate your equipment with safety devices bypassed
or doors removed.
2. Only qualified personnel should operate the equipment.
3. Never perform service or maintenance while automatic con-
trol sequences are in operation.
4. To avoid shock or serious injury, only qualified personnel
should perform maintenance on the system.
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Safety Precautions
2.2 Safety Labels
5. ATTENTION - DANGER TO LIFE
Do not touch the main power supply fuses or any components
internal to the power modules while the main power supply
switch is ON. Note that when the main power switch is OFF,
the incoming supply cable may be live.
6. GROUNDING (Protective Earth)
The equipment must be grounded (connected to the protective
earth connection) according to OEM recommendations and to
the latest local regulations for electrical safety . The grounding
(protective earth) conductor must not be interrupted inside or
outside the equipment enclosures. The wire used for equipment grounding (connection to protective earth) should be
green with a yellow stripe.
7. If there is any doubt at all as to the safety of the equipment,
you should set the main power switch to OFF and contact
your OEM for advice.
The purpose of a system of safety labels is to draw attention to objects and
situations which could affect personal or plant safety. It should be noted that
the use of safety labels does not replace the need for appropriate accident
prevention measures. Always read and follow the instructions based upon the
level of hazard or potential danger.
2.2.1 Hazard Warning
Danger Electric
Shock Risk
When you see this safety label on a system, it gives a warning of a
hazard or possibility of a hazard existing. The type of warning is
given by the pictorial representation on the label plus text if used.
The label color is yellow with black text and graphics. To ignore
such a caution could lead to severe injury or death arising from an
unsafe practice. If voltage levels are included in the text they must
indicate the maximum level of the hazard in normal or fault
condition.
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Safety Precautions
2.2.2 Danger, Warning, or Caution Warning
Symbol plus DANGER,
WARNING or CAUTION
When you see this safety label on a system, it gives a warning of a
hazard or possibility of a hazard existing. This type of warning is
given by the pictorial representation on the label plus text if used,
and provides information intended to prevent potential injury and/
or equipment damage.
2.2.3 Hot Surface Warning
Hot Surface
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Safety Precautions
2.3 Safety First
G&L Motion Control equipment is designed and manufactured with
consideration and care to generally accepted safety standards. However, the
proper and safe performance of the equipment depends upon the use of sound
and prudent operating, maintenance and servicing procedures by trained
personnel under adequate supervision.
For your protection, and the protection of others, learn and always follow
these safety rules. Observe warnings on machines and act accordingly. Form
safe working habits by reading the rules and abiding by them. Keep these
safety rules handy and review them from time to time to refresh your
understanding of them.
2.4 Safety Inspection
2.4.1 Before Starting Operations
1. Ensure that all guards and safety devices are installed and
operative and all doors which carry warning labels are closed
and locked.
2. Ensure that all personnel are clear of those areas indicated as
potentially hazardous.
3. Remove (from the operating zone) any materials, tools or
other objects that could cause injury to personnel or damage
the system.
4. Make sure that the control system is in an operational condition.
5. Make certain that all indicating lights, horns, pressure gauges
or other safety devices or indicators are in working order.
2.5 After Shutdown
Make certain all controlled equipment in the plant is safe and the associated
electrical, pneumatic or hydraulic power is turned off. It is permissible for
the control equipment contained in enclosures to remain energized provided
this does not conflict with the safety instructions found in this section.
2.6 Operating Safely
1. Do not operate the control system until you read and understand the
operating instructions and become thoroughly familiar with the system
and the controls.
2. Never operate the control system while a safety device or guard is
removed or disconnected.
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Safety Precautions
3. Where access to the control system is permitted for manual operation,
only those doors which provide that access should be unlocked. They
should be locked immediately after the particular operation is completed.
4. Never remove warnings that are displayed on the equipment. Torn or
worn labels should be replaced.
5. Do not start the control system until all personnel in the area have been
warned.
6. Never sit or stand on anything that might cause you to fall onto the control equipment or its peripheral equipment.
7. Horseplay around the control system and its associated equipment is
dangerous and should be prohibited.
8. Know the emergency stop procedure for the system.
9. For maximum protection when carrying out major servicing requiring
the system to be powered down, the power source should be locked
using a lock for which only you have the key. This prevents anyone
from accidentally turning on the power while you are servicing the
equipment.
10. Never operate the equipment outside specification limits.
11. Keep alert and observe indicator lights, system messages and warnings
that are displayed on the system.
12. Do not operate faulty or damaged equipment. Make certain proper service and maintenance procedures have been performed.
2.7 Electrical Service & Maintenance Safety
1. ALL ELECTRICAL OR ELECTRONIC MAINTENANCE AND
SERVICE SHOULD BE PERFORMED BY TRAINED AND
AUTHORIZED PERSONNEL ONLY.
2. It should be assumed at all times that the POWER is ON and all conditions treated as live. This practice assures a cautious approach which
may prevent accident or injury.
3. To remove power:
LOCK THE MAIN SWITCH IN THE OPEN POSITION.
USE A LOCK TO WHICH ONLY YOU HAVE THE KEY.
4. Make sure the circuit is safe by using the proper test equipment. Check
test equipment regularly
5. Capacitors take time to discharge. Care should be taken in manual discharging of capacitors
6. There may be circumstances where troubleshooting on live equipment
is required. Under such conditions, special precautions must be taken:
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Safety Precautions
• Make sure your tools and body are clear of the areas of equipment
which may be live.
• Extra safety measures should be taken in damp areas.
• Be alert and avoid any outside distractions.
• Make certain another qualified person is in attendance.
7. Before applying power to any equipment, make certain that all personnel are clear of associated equipment.
8. Control panel doors should be unlocked only when checking out electrical equipment or wiring. On completion, close and lock panel
doors.
9. All covers on junction panels should be fastened closed before leaving any job.
10. Never operate any controls while others are performing maintenance
on the system.
11. Do not bypass a safety device.
12. Always use the proper tool for the job.
13. Replace the main supply fuses only when electrical power is OFF
(locked out).
2.8 Safe Cleaning Practices
1. Do not use toxic or flammable solvents to clean control system
hardware.
2. Turn off electrical power (lock out) before cleaning control system
assemblies.
3. Keep electrical panel covers closed and power off when cleaning an
enclosure.
4. Always clean up spills around the equipment immediately after they
occur.
5. Never attempt to clean a control system while it is operating.
6. Never use water to clean control equipment unless you are certain that
the equipment has been certified as sealed against water ingress. Water
is a very good conductor of electricity and the single largest cause of
death by electrocution.
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Installation, Operation, & Maintenance
3 Installation, Operation, & Maintenance
3.1 Mounting the MMC Control
Mount the unit to your cabinet using the mounting slots on the MMC as
shown. (Note: the Standalone MMC Digital Control requires a minimum of
1/2 in clearance on the left side, for proper fan air movement). The MMC
unit must be mounted vertically. The recommended size of mounting
hardware is #10 bolts with #10 star washers (to ensure proper ground
connection) as shown in Figure 3-1 below.
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Installation, Operation, & Maintenance
Figure 3-1: MMC Mounting Dimensions
8.75" (222.25 mm)
1.05" (26.67 mm)
MMC
.218" (5.54 mm)
Note: Unit is 5.3”
(134.62 mm) deep.
Side Cover
.040" Thickness
Screw Head
.080" Thickness
NOTE: Add the side
cover and screw head
thicknesses to the
unit’s dimensions for
total width.
9.59" (243.59 mm)
1.00"
.55"
(13.97 mm)
(25.4 mm)
2.10" (53.34 mm)
.500" (12.70 mm) clearance required
for Standalone Digital MMC Control
.55" (13.97 mm)
3.2 Adding an Option Module to the MMC Control
Several Option Modules are available to add functionality to the MMC
system. These modules are described in the later sections of this manual.
The standard Standalone MMC Control (MMC-A2, MMC-A4, and MMCS8) accepts up to two MMC Option Modules. The Standalone MMC Control
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Installation, Operation, & Maintenance
Plus (MMC-A2 Plus and MMC-A4 Plus), as well as the Standalone Digital
MMC Control (MMC-D32 and MMC-D64), accepts up to four MMC Option
Modules.
Option modules are shipped with a 50-pin square post connector and screws
needed to attach the module to the MMC (or to another option module).
Follow the procedure below to add an option module to the MMC (or to
another option module).
1. Place the MMC and the option module on a static free surface. Ground
yourself using a properly grounded wrist strap before you begin. These
are standard precautions before handling any electronic components.
2. Remove the five screws securing the MMC cover using a #1 Phillips
screwdriver and set them aside. There are two screws on the top, two
screws on the bottom, and one screw on the side of the module.Lift the
side cover off and set aside.
3. Locate the 50-pin square post socket at the top of the MMC board.
Press one side of the 50-pin square post male connector into this socket
ensuring that the pins are aligned and it is firmly seated.
4. Pick up the option module. Line up the socket on the option module
with the male end of the connector extending from the MMC ensuring
that the pins are aligned. Press firmly into place. Be sure to align the
screw tabs on the top and bottom of the option module with the screw
slots on the top and bottom of the MMC module so that the modules
slide together easily.
5. Screw four screws (of the five included in your package) into the screw
tabs to attach the option module to the MMC.
6. Lay the unit on the bench. Place the cover you set aside in Step 3 on the
option module. Be sure to align the screw tabs on the top and bottom of
the cover with the screw slots on the top and bottom of the option module.
7. Screw the five screws removed in Step 2 back into place to secure the
cover.
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Installation, Operation, & Maintenance
Figure 3-2: Location of Screws on the MMC Control
(MMC A-4 Servo Unit Shown)
Top Screws
Cover Side of Module
Side Screw
4
2
+
M
O
C
Bottom Screws
3.3 Dimensions and Mounting of MMC with Option Modules Attached
After attaching option modules to the MMC module, mount the unit to your
cabinet using the mounting slots on the MMC and the option module. The
recommended size of mounting hardware is #10 bolts with #10 star washers
(to ensure proper ground connection).
12 MMC Hardware Manual G & L Motion Control Inc.
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Installation, Operation, & Maintenance
Figure 3-3: MMC Mounting Dimensions with 2 Option Modules Attached
.218" (5.54 mm)
9.59" (243.59 mm)
8.75" (222.25 mm)
1.05" (26.27 mm)
MMC
Module
1.69" (42.93 mm)
(32.51 mm)
Option
Module
1.28"
Option
Module
Note: Unit is 5.3”
(134.62 mm) deep.
Side Cover
.040" Thickness
Screw Head
.080" Thickness
NOTE: Add the side
cover and screw head
thicknesses to the unit’s
dimensions for total
width.
.55"
(13.97 mm)
1.28"
(32.51 mm)
1.28"
(32.51 mm)
.55" (13.97 mm)
1.00"
(25.4 mm)
2.10" (53.34 mm)
.500" (12.70 mm) clearance required
for Standalone Digital MMC Control
3.4 System Power and Environment Requirements
3.4.1 General Power and Environment Requirements
The MMC is suitable for operation in a pollution degree 2
environment (i.e., normally , only non-conductive pollution occurs).
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Installation, Operation, & Maintenance
You are not required to install the system rack in a control cabinet.
However a cabinet protects the system from dust and mechanical
damage and is recommended.
Power distribution is shown in Figure 3-4 on page 15. Install the
system rack away from all sources of strong electromagnetic noise.
Such noise can interfere with MMC operation.
Protect the MMC system from all the following:
• conductive fluids and particles
• corrosive atmosphere
• explosive atmosphere
The diagrams and recommendations may be modified if necessary
so the wiring conforms to current NEC standards or government
regulations.
3.4.2 Control Cabinet Specifications
The control cabinet housing the MMC:
• should have a NEMA-12 rating or better. A cabinet with this rat-
ing protects its contents from dust and mechanical damage.
• must be large enough to provide adequate air circulation for
the MMC, drives, and other components. Always allow for
adequate air flow through the MMC vents.
• must have a rigid vertical surface to mount the MMC on.
• should be positioned to allow the cabinet door to open fully
for easy access to the MMC Control.
IMPORTANT
Post warnings according to National, State, or local
codes for the voltage present in the control cabinet.
3.4.3 Power Distribution Diagram
The MMC requires an external DC power source. The power
distribution drawing that follows shows an MMC connected to an
Analog Interfaced MMC-SD Drive. The drive’s 24 VDC power is
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Installation, Operation, & Maintenance
supplied via the MMC in this example. If the drive has its own
external 24 VDC supply, the +24 V line would not be connected.
Figure 3-4: Example of 24 VDC Power Distribution to an MMC System
MAIN
DISCONNECT
AC
PLANT GROUND
EXTERNAL
24VDC
POWER SUPPLY
The DC power source is connected to the MMC system through a
3-pin connector. It plugs into the power connector of the MMC.
The ground from the power source and ground from the MMC must
be connected to the Single-Point Ground (SPG).
MMC
+24V
COM
+
SINGLE POINT
GROUND (SPG)
GROUND from another
CONTROL CABINET
CHASSIS
GROUND
Analog
Interfaced
MMC-SD Drive
+24V
COM
Motor
Power
L1
L2
GND
Devices connected to the hardware may have their own power
sources for input data or output control signals. You can use other
wiring setups, provided that each one is:
• at the correct voltage and current levels for the module and
the device.
• connected to the same Single-Point Ground that the MMC
uses.
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Installation, Operation, & Maintenance
It is recommended that the same main disconnect switch be used
for the MMC system and for all devices in the application.
No matter how the system is installed, before you connect the MMC to the application, make sure that power
is off to the system and to the devices that are wired to the
MMC.
3.4.4 Grounding the System
The ground of the MMC power source must be connected directly
to a Single Point Ground (SPG) tie block. The tie block should be
made of brass or copper, bolted or brazed to the control cabinet. If
the tie block is bolted rather than brazed, scrape away paint or
grease at the point of contact. Put star washers between the tie
block and the cabinet to ensure good electrical contact.
IMPORTANT
Metal enclosures of power supplies, drives, etc., should also have
good electrical contact with the SPG.
CAUTION
The Single Point Ground should be the only common
point for all the ground lines. If not, ground loops may
cause current flow among components of the system
which can interfere with proper operation of the MMC.
Devices to be connected directly to the Single Point Ground
include:
• Plant safety ground.
• Chassis ground from MMC power connector.
• The metal panel or cabinet on which the MMC is mounted.
• “Common” or “0 V” lines from power supplies that provide
external power to the I/O modules and the devices to which
they are connected.
• Chassis grounds from the devices themselves, such as
device drivers, machinery, and operator interface devices.
16 MMC Hardware Manual G & L Motion Control Inc.
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Installation, Operation, & Maintenance
• AC common line from the noise filter, if any.
• The ground of the power source of the computer worksta-
tion, if any, from which you monitor the system operation.
An AC outlet in the control cabinet is recommended.
• Single point grounds from other control cabinets, if any, in
the system.
IMPORTANT
You must ensure that the “0V” or “Common” of all devices connected to the MMC are connected to Single Point
Ground (SPG). Failure to do so may result in erratic operation or damage to the MMC. Examples of devices connected to the MMC include the power source that supplies
24VDC power to the MMC and devices connected to the
MMC PiCPro Port or User Port. Note that some devices
(for example, a Personal Computer) may have their “0V”
and “Chassis” connected together internally, in which
case only one connection has to be made to SPG for that
device.
Also, you must ensure that the MMC “Chassis” connection is connected to SPG, and that the MMC is mounted
to a metal panel or enclosure that is connected to SPG.
3.4.5 Controlling Heat Within the System
The MMC hardware case is designed to promote air circulation and
dissipate heat. The MMC must be mounted vertically to take
advantage of this design. Normally no fans or air conditioners are
needed. However, if the environment outside the control cabinet is
hot or humid, you may need to use a fan, heat exchanger,
dehumidifier or air conditioner to provide the correct operating
environment.
Table 3-1: Operating Limits for the MMC
Temperature 5 to 55° C (41 to 131° F)
Relative humidity 5 to 95%, non-condensing
Make sure that components installed in the cabinet with the MMC
do not raise the temperature above system limits and that any hot
G & L Motion Control Inc. MMC Hardware Manual 17
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Installation, Operation, & Maintenance
spots do not exceed specifications. For example, when heatgenerating components such as transformers, drives or motor
controls are installed, separate them from the system by doing one
of the following:
• Place them near the top of the control cabinet so their heat
output rises away from the MMC.
• Put them in another control cabinet above or to one side of
the cabinet with the MMC. This protects the MMC from
both heat and electrical noise.
The MMC itself is a source of heat, though in most installations its
heat dissipates without harmful effects. System heat is generated
from power dissipated by:
• field side input/output components
• other components within the MMC
If the MMC is operated outside the recommended limits,
it may be damaged. This will void the warranty.
3.4.6 Handling an MMC
The case protects the MMC’ s internal circuitry against mechanical
damage in shipping and handling. However, like any electronics
device, the circuitry can be destroyed by:
• temperatures over 55° C (131° F)
• moisture condensing inside the module
• static discharge
• exposure to a magnetic field strong enough to induce a current in the circuitry
• freezing temperatures, vibration, and other hazards
CAUTION
Normally there is no need to open the case. Occasionally, a battery
must be replaced. A diagram and detailed anti-static precautions in
18 MMC Hardware Manual G & L Motion Control Inc.
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Installation, Operation, & Maintenance
the appendices are included with modules that have replaceable
components.
3.5 System Wiring Guidelines
The MMC relies on electrical signals to report what is going on in the
application and to send commands to it. In addition, signals are constantly
being exchanged within the system. The MMC is designed for use in
industrial environments, but some guidelines should be followed.
3.5.1 Recommended Signal Separation
G&L Motion Control continues to recommend separation of low
level signals (encoder, analog, communications, fast DC inputs)
from high voltage (110 Vac, 220 Vac, 440 Vac, etc.) or high current
lines (such as motor armature cables). Maintain at least one inch of
separation around signals.
Figure 3-5 below illustrates the recommended connections when
using EMC compliant products. Note that a capacitor is connected
to the 24 VDC supply. To prevent excessive conducted emissions
from a DC power source (typically 24 V) used for digital I/O, a
1000 picofarad capacitor should be used. Connect the capacitor
from the +24 VDC to COMMON at the distribution terminals.
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Installation, Operation, & Maintenance
Figure 3-5: Recommended EMC Compliant Connections
COMMUNICATIONS
AC INPUT
POWER
GND
MMC
ENCODER, ANALOG
DC INPUT/OUTPUT
Power
Connector
24V
COM
Capacitor
(.001 uf)
+
DC POWER SUPPLY
SINGLE-POINT GROUND
SINGLE-POINT GROUND
Inside a control cabinet, connect the shields of shielded cables at
the MMC. Figure 3-6 below illustrates shielded cable entering/
leaving the cabinet.
20 MMC Hardware Manual G & L Motion Control Inc.
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Installation, Operation, & Maintenance
Figure 3-6: Connecting Shielded Cable
MMC
Cabinet
Enclosure
External
Drive
The two different methods of terminating shields are used to
accommodate two different immunity requirements. Immunity
required inside an enclosure is considered lower because cables are
typically less than three meters in length and/or can be separated
from each other and from noise sources.
Immunity required external to an enclosure is considered higher
because the user may have less control over the noise environment.
Low level signal cables that can be external to an enclosure are
tested at a 2 KV level for electrical fast transients (EFT s). Low level
signals that can be less than three meters in length or can be
separated from noise sources are tested at a 1 KV level. Under the
stated conditions, there will be no disturbance of digital I/O,
encoder, or encoder operation. For analog signals, there may be
momentary disturbances but there will be self-recovery when the
noise subsides.
Do not operate transmitters, arc welding equipment, or other high
noise radiators within one meter of an enclosure that has the door
open. Continue to equip inductive devices, if they are in series with
a mechanical contact or switch, with arc suppression circuits. These
devices include contactors, solenoids and motors. Shield all cables
that carry heavy current near the system, using continuous foil wrap
or conduit grounded at both ends. Such cables include power leads
G & L Motion Control Inc. MMC Hardware Manual 21
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Installation, Operation, & Maintenance
for high-frequency welders and for pulse-width-modulated motor
drives.
Use care when wiring I/O devices to the MMC and when
plugging in cables. Wiring the wrong device to the connector or plugging a connector into the wrong location
could cause intermittent or incorrect machine operation.
3.5.2 Differential Devices for Analog and Encoder Signals
A differential device receives or sends one signal over two wires
(typically a shielded twisted pair). The input/output voltage at the
second terminal is the inverse of the first. Information is received/
sent as the difference between the two voltages.
WARNING
Figure 3-7: Differential Digital Pulse Train
SIGNAL AT A
INVERTED
SIGNAL AT A
DIFFERENTIAL
The advantages of using differential signals are:
• A differential signal is less susceptible to electromagnetic
noise. Static or other interference affects both of the twistedpair wires equally , so the difference between the normal an d
inverted voltage remains unchanged. A differential signal
can be transmitted over a much longer distance or in a much
noisier environment than a single-ended one.
• MMC hardware circuitry can detect signal loss from an
encoder if the signal is differential. The application program
can be set to shut down the application if such an error is
detected.
IMPORTANT
Always use differential drivers with differential inputs.
22 MMC Hardware Manual G & L Motion Control Inc.
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3.6 Starting an Application
To start an application:
1. Turn off the main disconnect switch in the control cabinet. If
some devices are not powered from the control cabinet, turn
them off also.
2. Connect the connectors according to your diagrams.
3. Turn on power to the system. The MMC goes through the fol-
lowing sequence:
• The Power light (labeled “P”) goes on and stays on.
• The Diagnostic light (labeled “D”) goes on briefly, then
goes off.
• If there is an application in the MMC’s memory, the ladder
starts scanning and the Scan light (labeled “S”) goes on. If
there is not an application in the MMC’s memory, use the
download command in the PiCPro software to place it there.
Installation, Operation, & Maintenance
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Installation, Operation, & Maintenance
3.7 Basic Setup and Maintenance Procedures
Table 3-2 below summarizes how to proceed when performing certain
maintenance and/or setup functions.
Table 3-2: Maintenance Procedure Summary
In order to:
Turn off the entire application. Turn off main disconnect (which should
Wire the I/O to the application. Turn off main disconnect (which should
Change the battery. Turn off main disconnect (which should
Connect/disconnect the MMC with the
computer workstation through the
PiCPro port.
also turn off all external power supplies to
the application); unplug the DC power to
the MMC.
also turn off all external power supplies to
the application); unplug the DC power to
the MMC.
also turn off all external power supplies to
the application); unplug the DC power to
the MMC.
Turn off main disconnect (which should
also turn off all external power supplies to
the application); unplug the DC power to
the MMC.
Connect/disconnect the MMC with an
operator interface through the User port.
Download an application program into
the memory.
Stop the scan. From the workstation - use the Stop Scan
Turn off main disconnect (which should
also turn off all external power supplies to
the application); unplug the DC power to
the MMC.
Make sure power is on (check the P light).
commands in the PiCPro software.
3.8 System Status Lights
Three lights on the front of the Control (Scan, Power, and Diagnostic labeled
“S”, “P”, and “D”), shown in Figure 3-8, provide diagnostic and operational
24 MMC Hardware Manual G & L Motion Control Inc.
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Installation, Operation, & Maintenance
information including power supply status, battery status, diagnostic status,
and system status.
Figure 3-8: Status Lights
SPD
3.8.1 Power Status
The green Power light (P) indicates that the power supplies internal
to the MMC are working properly. If the power light (P) does not
go on, or goes off during operation of the system, check that the
proper voltage is present at the MMC power connector . If it is, turn
off the main disconnect switch and replace the MMC.
3.8.2 Battery Status
If the green Power light (P) on the Standalone MMC Control starts
flashing, the battery must be replaced. Follow the battery
replacement procedure in Section 4.9 on page 85. Note that the
Standalone Digital MMC Control does not use the Power light to
report a low battery condition, but rather uses a Diagnostic light
error code (Section 3.8.6 on page 27) to report this condition.
3.8.3 Scan Status
The green Scan light (S) indicates that the application program is
running. If the Scan light does not go on:
1. Check that the power light (P) is ON.
2. Check that the diagnostic light (D) is OFF.
3. Verify that there is a Ladder in the MMC’s application mem-
ory.
Whenever the scan light is out, the discrete outputs go to the OFF
state and the analog outputs are zeroed.
3.8.4 Power-up Diagnostics Status
When the system is powered up, it tests itself and reports the results
of the tests using the yellow Diagnostic light (D).
When power is applied to the MMC, the Diagnostic light comes on
briefly while its diagnostic tests are running. After the power-up
G & L Motion Control Inc. MMC Hardware Manual 25
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Installation, Operation, & Maintenance
diagnostics run, the Diagnostic light will be in one of the following
states:
• off, indicating that the MMC is operating correctly.
• on, indicating that the power-up diagnostics found a hardware problem with the MMC.
Power-up diagnostics are run only when the system is powered up. It
is possible that a failure might occur during operation. If so, the Diagnostic light remains off. If you suspect that the MMC might be defective, cycle power to run diagnostics again.
3.8.5 Run-time Diagnostic Status
When the application is running (the Scan light is on), the Control
constantly monitors the system for proper operation, and the yellow
Diagnostic light (D) will be in one of the following states:
NOTE
• off, indicating that the MMC is operating correctly.
• flashing a three digit error code (see Section 3.8.6 on page
27)
• continuously pulsing from bright to dim, indicating one of
the following:
• The Servo Setup Function used in the ladder was
compiled with a PiCPro version prior to 16.0.
Recompile the Servo Setup Function, then compile
and download the ladder with PiCPro 16.0 or
greater.
• The application has accessed an array element
beyond the defined array boundary. Avoid this practice.
• A UDFB is not preceded by the recommended
Enable/OK lines. Precede UDFBs with Enable/OK
lines as recommended in the Software Manual.
• An internal software error has occurred. Consult the
factory.
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Installation, Operation, & Maintenance
3.8.6 Diagnostic Error Codes
While the MMC is running, the Diagnostic light (D) on the CPU
module will flash a three digit code signal if there is an error. For
example, if there is a long pause-flash-pause-flash-flash-pauseflash-flash-flash-long pause, the code is 123. The errors are
described below.
Table 3-3: Diagnostic Light Error Codes
Code Error Description
123 Scan too long A ladder scan loss has occurred because the CPU
takes more than 200 ms to scan the application
program.
124 Excessive overhead The system overhead update time is excessive.
Consult the factory.
125 Insufficient memory There is insufficient memory on the CPU to run the
current program.
222 Driver error No driver support on the CPU for the Option module.
Update your system EPROMs.
22_ Master rack error An Option Module in the master rack (or the Motion
Control Board in a Standalone MMC Control) do not
match what was declared in the hardware master
declaration table. The number of flashes in the third
digit (_) identifies the slot number that is in error . The
first Option Module is Slot 3.
3_ _ Expansion rack error The Block I/O modules installed do not match what
was declared in the expansion hardware declaration
table.
The number of flashes in the second and third digits
indicates the block I/O module (01 through 77). The
second digit will flash a 1 - 7, 10 for 0. The third digit
will flash a 1 - 9, 10 for 0.
For example, if the second digit flashes 3 times and
the third digit flashes 10 times, the module 30 is being
reported.
621 Low Battery The MMC has detected that the on-board battery is
low and needs to be replaced as soon as possible (Not
for Standalone Digital MMC Control).
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Installation, Operation, & Maintenance
28 MMC Hardware Manual G & L Motion Control Inc.
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4 Standalone MMC Control
4.1 Introduction
This section contains information on the Standalone MMC Control hardware only.
Information on the Standalone Digital MMC Control is contained in Section 5 on page
91. Block I/O information can be found in the Block I/O Hardware Manual. Software
information can be found in the PiCPro online help, the Function/Function Block
Reference Guide, ASFB Manuals or on-line.
4.2 Features
• 32-bit RISC Processor
• 2 Mbytes of flash memory
• 256 Kbytes of Application Memory
Standalone MMC Control
• 128 Kbytes of User RAM Memory
• PicPro RS232 port, baud rates up to 57.6 Kbaud
• User RS232/RS485 port, R TS/CTS handshaking, baud rates up to
19.2 Kbaud
• Battery-backed time-of-day clock
• Application stored in battery-back RAM
• Block I/O port for I/O expansion
• Up to 4 MMC Option Modules can be user-installed
• One, two, four, and 16 axis analog versions available
• SERCOS version available
• UL Listed and CE Marked.
4.3 Overview
The MMC Control offers a complete solution to both machine and motion
control in a standalone unit. The Standalone MMC family includes these
models:
• MMC-A2 (2 1/2 axis analog servo control)
• MMC-A2 Plus (2 1/2 axis analog servo control, expandable)
• MMC-A4 (4 1/2 axis analog servo control)
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Standalone MMC Control
The PiCPro programming tool used with the PiC family of controls is also
used to program the MMC. The built-in I/O [28 inputs (24 VDC) and 16
outputs (24 VDC)] can be expanded using G&L Motion Control serially
distributed block I/O. There are also eight (four) low current DC and four
(two) DC inputs on the Axis connectors of the MMC-A4 and MMC-A2.
Field-installable options for the MMC include an Ethernet TCP/IP interface,
a DeviceNet™ master interface, a Profibus module, a 4-channel Analog
Output Module, and a 32 In/32 Out I/O Module.
4.4 Major Components
The major components of an MMC Control include a Machine Control board
and a Motion Control board contained within a metal enclosure. External
connections for the boards are located on the face of the enclosure.
Add-on modules are also available to expand the MMC Control:
• MMC-A4 Plus (2 1/2 axis analog servo control, expandable)
• MMC-S8 (8 axis SERCOS control)
• A maximum of two MMC Expansion Modules may be added to
the MMC-A2 and MMC A-4:
• Communications Option Modules (Ethernet, Profibus, or
DeviceNet).
• 32 In/32 Out DC I/O Option Modules.
• A maximum of four MMC Expansion Modules may be added to
the MMC-A2 Plus and MMC A-4 Plus:
• Up to two MMC Communications Option Modules (Ether-
net, Profibus, or DeviceNet).
• Up to four MMC Axis I/O Option Modules.
• Up to four MMC 32 In/32 Out Option Modules.
30 MMC Hardware Manual G & L Motion Control Inc.
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Figure 4-1: The MMC Control Units
Standalone MMC Control
Axis 4 Port
Axis 3 Port
Axis 2 Port
Axis 1 Port
Auxiliary
I/O Port
Analog Motion
Control Side
LEDs
PicPro Port
Block I/O
Port
User Port
General I/O
Port
Power
Connection
Machine Contro l
Side
(Common to all
MMC Controls)
RECV
XMIT
LOADER
SERCOS Motion
Control Side
LEDs
PicPro
Port
Block I/O
Port
User
Port
General I/O
General I/O
Port
Port
Power
Connection
Machine Control
Side
(Common to all
MMC Controls)
MMC-A4 (or MMC-A2) Servo Control
MMC SERCOS Control
(One-Ring Port)
4.4.1 Machine Control Board
A Machine Control Board and it’s related external connections are
located on the right side of the control. The Machine Control Board
contains the CPU. Ladder logic programming is used for machine
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Standalone MMC Control
4.4.2 Motion Control Board
control. This board also provides a PiCPro Port (RS-232 serial
interface for communicating with a computer), User Port (RS-232/
RS-485 serial interface for communicating with a serial device),
Block I/O Port (proprietary serial interface for communicating with
Block I/O Expansion Modules), and a General I/O Port (16 DC outputs and 16 DC inputs).
Table 4-1: Available Machine Control General I/O
Available I/O 2 1/2 Axis 4 1/2 Axis
GEN I/O Port DC Inputs 16 16
GEN I/O Port DC Outputs 16 16
The Motion Control Board and it’s related external connections are
located on the left side of the control. The motion control side of the
MMC unit can be either an Analog Servo board or a SERCOS
board.
4.4.2.1 Analog Servo board
The Analog Servo board provides conventional analog/
digital interfacing for two or four drives.
The typical signals needed to interface to an analog
drive are provided by the analog servo module. The
drive command is in the form of an analog voltage
(±10V). Feedback is accepted from quadrature type
encoders with differential outputs. Digital I/O (+24
VDC) is used for drive signals such as enable, reset, and
fault. Fast inputs are provided for each encoder input
and can be configured to latch encoder position under
various conditions.
The analog servo board is offered in both 2 1/2 and 4 1/2
axis configurations. An axis is considered to be an
analog output with a corresponding encoder input. In
each configuration shown in the following table, note
that there is an extra encoder input. This is referred to as
a half axis.
32 MMC Hardware Manual G & L Motion Control Inc.
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Table 4-2: Available Analog Servo Board I/O
Available I/O 2 1/2 Axis 4 1/2 Axis
Analog Inputs 1 1
Analog Outputs 2 4
Encoder Inputs 3 5
Axis DC Inputs 2 4
Axis DC Outputs 4 8
Axis Fast DC Inputs 3 5
AUX I/O Port DC
Inputs
4.4.2.2 SERCOS board
The SERCOS Motion Control board provides a fiber
optic input and output for one SERCOS ring. There is
also a serial port for field upgrades of the board’s
FLASH memory.
Standalone MMC Control
612
4.5 Power Supply Requirements
An MMC system consists of a main module (Analog Servo or SERCOS
based) and up to four option modules. An external 24 Vdc supply is required
to power the MMC’s internal circuitry and external I/O. The 24 Vdc is
distributed internally to three different buses or sections. When you size your
power supply, you must ensure that the supply is large enough to handle the
total load and that the maximum current capability of each bus is not
exceeded. Table 4-3 below shows the distribution of the 24 Vdc power within
the MMC system:
Table 4-3: MMC 24 Vdc Power Distribution
Power Bus Supplying Current To: Maximum Current
1 Module Circuitry 3 A
2 General I/O 5 A
3 Module I/O 1 A
In most cases, one power supply can be used for the entire control system.
However, depending upon the modules, drives, and external I/O used in your
application, you may split the power distribution into two or more power
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Standalone MMC Control
supplies. For example, the Axis I/O on an MMC A2 module can be powered
from the MMC, from the drive, or from another external power supply.
Refer to Table 4-4 to size the power supply required by your application.
Refer to Table 4-5 to calculate the maximum current required for a
theoretical 4 axes MMC.
A possible ignition hazard within the MMC exists if the maximum
currents listed for Bus 2 or Bus 3 are exceeded or if excessive current
is drawn at the 24 V line going into the MMC. If these currents might
be exceeded (due to improper wiring or external device failure), circuit breakers or fuses should be used in series with the 24 Vdc going
to and coming from the MMC. Specifically, the circuit breakers or
fuses should be sized for 10 A total on the 24 Vdc line coming into
the MMC, 1 A total from the +24 Vdc OUT pins of the AXIS and
AUXILIARY I/O connectors, and 5 A total from the I/O 24V pins of
the GENERAL I/O connector. For maximum protection, use fast
blow fuses. When using molded cables supplied by G&L Motion
Control to connect the MMC to the drives, no overload protection is
required.
CAUTION
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Table 4-4: 24 VDC Power Supply Sizing Worksheet
Line MMC Module
1 MMC-A2 or MMC-A4 (PLUS) 250
2 MMC SERCOS (PLUS) 300
3 Axis I/O Option Module 100
4 MMC Ethernet Option Module 200
5a MMC DeviceNet Option Module 100
5b MMC 32 In/32 Out Option Module 100
6 Subtotal, Power Bus 1 (Add Column A (3000 mA max)
MMC Component
Line
7 General Inputs 7.5 7.5
8 General Outputs 250
9 250
10 250
11 250
12 250
13 Subtotal, Power Bus 2 (Add Column A, Lines 7-12, 5000 mA max)
14 Axis inputs 7.5 7.5
15 Axis outputs 100
16 100
17 100
18 100
19 Auxiliary inputs 7.5 7.5
20 Fast inputs 7.5 7.5
21 Current supplied by AUX +24 VDC
22 Subtotal Power Bus 3 (Add Column A, Lines 14-21, 1000 mA max)
23 MMC Power (Add Column B, Lines 6, 13, and 22, 10,000 mA max)
24 Other (i.e. block I/O)
25
26
27 Subtotal (Add Column A, Lines 24-26
28 Total Power (Add Column A, Lines 23 and 27)
(Lines 7-12 are for General I/O
Port,
Lines 14-21 are for Axis I/O Ports)
Out pins
Max
Current
(mA)
Current
(mA)
(450)
(500)
Actual
Current
(mA)
# of
Units
Number
of I/O
Standalone MMC Control
Col A
Subtotal
(mA)
Col A
Subtotal
(mA)
Col B
Current
(mA)
Col B
Current
(mA)
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Standalone MMC Control
Table 4-5: 24 VDC Power Supply Sizing Example
Line MMC Module
1 MMC-A2 or MMC-A4 (PLUS) 250
2 MMC SERCOS (PLUS) 300
3 Axis I/O Option Module 100
4 MMC Ethernet Option Module 200
5a MMC DeviceNet Option Module 100
5b MMC 32 In/32 Out Option Module 100
6 Subtotal, Power Bus 1 (Add Column A (3000 mA max) 250
MMC Component
Line
7 General Inputs 7.5 7.5 16 120
8 General Outputs 250 200 5 1000
9 250 100 9 900
10 250
11 250
12 250
13 Subtotal, Power Bus 2 (Add Column A, Lines 7-12, 5000 mA max) 2020
14 Axis inputs 7.5 7.5 4 30
15 Axis outputs 100 50 8 200
16 100 100
17 100 60
18 100
19 Auxiliary inputs 7.5 7.5 120
20 Fast inputs 7.5 7.5 6 45
21 Current supplied by AUX +24 VDC
22 Subtotal Power Bus 3 (Add Column A, Lines 14-21, 1000 mA max) 955
23 MMC Power (Add Column B, Lines 6, 13, and 22, 10,000 mA max) 3225
24 Other (i.e. block I/O)
25
26
27 Subtotal (Add Column A, Lines 24-26 0
28 Total Power (Add Column A, Lines 23 and 27) 3225
(Lines 7-12 are for General I/O
Port,
Lines 14-21 are for Axis I/O Ports)
Out pins
Max
Current
(mA)
Current
(mA)
(450)
(500)
Actual
Current
(mA)
# of
Units
1250
Number
of I/O
Col A
Subtotal
(mA)
Col A
Subtotal
(mA)
400
Col B
Current
(mA)
Col B
Current
(mA)
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Standalone MMC Control
4.6 Machine Control Connection & Operation
This section provides theory-of-operation and connection information on the
Machine Control board, which is located on the right side of an MMC
Control.
Three lights on the front of the Control (Scan, Power, and Diagnostic)
provide operational and diagnostic information, as described in Section 3.8
on page 24.
The Machine Control Board does the following:
• Performs diagnostic tests.
• Checks the battery.
• Performs routine maintenance tasks.
• Executes the application program.
• Communicates with the I/O.
• Maintains communication with the workstation through the
PiCPro port.
• Maintains communication with the user interface device through
the user port. (Details for this communication depend partly on
the type of interface device. Refer to the manual that comes with
the device.)
• Provides Block I/O expansion capability.
The MMC has a flash chip on board that allows you to load an application
program into it. This is standard on the MMC. Having the application in the
standard flash chip ensures that you will not lose the application if the battery
fails. On power up, the application is transferred from the flash chip to RAM
as it is when directly downloaded from PiCPro.
To place the application in flash:
1. Compile the application into a hex file in PiCPro.
2. Use the Download Hex command in PiCPro to download the
application into flash.
Even though you have placed an application in flash, you can still download
and run a different application from PiCPro. However, when you cycle
power on the MMC, the application in flash will always be placed into RAM.
G & L Motion Control Inc. MMC Hardware Manual 37
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Standalone MMC Control
4.6.1 PiCPro Port
Function Notes Pin
Receive Data RS232-level signal that receives serial data from
Transmit Data RS232-level signal that transmits serial data to the
Signal Ground Provides the return path for signals 5
Data Terminal Ready Always high (tied to +12V through 1K resistor) 4
Request-to-send Always high (tied to +12V through 1K resistor) 7
Shield Ground Provides a path for shield current through the chas-
The 9-pin male D-sub PiCPro Port connector (labeled “PiCPro” on
the front of the Control) provides serial communication between
the Control and a computer for the PiCPro programming interface.
• Pin descriptions for are provided in Table 4-6
• Pin assignments are provided in Table 4-7
• The available PiCPro Port to PC cable is described in Table
4-8
Table 4-6: PiCPro Port Pin Descriptions
2
the connected PC running PiCPro.
connected PC running PiCPro.
sis to an external single point ground.
3
Connector
Shell
Table 4-7: PiCPro Port Pin Assignments
Pin Signal In/Out Connector Pinout
1NC N/A 9-pin male D-sub
2 RS232 Receive Data In
3 RS232 Transmit Data Out
4 Data Terminal Ready Out
5 Signal Ground In/Out
6NC N/A
7 Request-to-send Out
8NC N/A
9NC N/A
Connector
Shield
Drain In
6
9
Connector
Shell
1
5
38 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Table 4-8: PiCPr0 Port to PC Cable
Part Number: M.1302.8250
Length: 4 M (13 ft)
Cable type: 24 AWG, shielded, twisted pair, 4 conductor.
9-Pin female D-sub
(to PiCPro Port, face
view)
9-Pin female D-sub
(to PC COM Port,
face view)
9
6
Pin Signal Pin Signal Notes
2 Receive Data 3 Transmit Data Twisted
3 Transmit Data 2 Receive Data Pair
5 Signal Ground 5 Signal Ground
Shell Drain Shell Drain
5
1
4.6.2 Block I/O Port
The 9-pin female D-sub PiCPro Port connector (labeled “BLK IO”
on the front of the Control) provides serial communication between
1 to 77 Block I/O modules and the Control.
• Pin descriptions for are provided in Table 4-9.
9
6
5
1
• Pin assignments are provided in Table 4-10.
• The available Flying Lead cable is described in Table 4-11.
• Connections to the Block I/O Module are described in Table
4-12.
• Available Breakout Boxes and Cables are described in
Table 4-13.
• Breakout Box dimensions are shown in Figure 4-2
G & L Motion Control Inc. MMC Hardware Manual 39
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Standalone MMC Control
Function Notes Pin
Transmit Data + Transmits data to Block I/O Modules. 3
Transmit Data - Transmits data to Block I/O Modules. 4
Receive Data + Receives data from Block I/O Modules. 5
Receive Data - Receives data from Block I/O Modules. 6
Shield Ground Provides a path for shield current through the chas-
Pin Signal In/Out Connector Pinout
1NC N/A 9-pin female D-sub
2N/C N/A
3 Transmit Data + Out
4 Transmit Data - Out
5 Receive Data + In
6 Receive Data - In
7 Shield In
8NC N/A
9NC N/A
Connector
Shell
Drain In
Table 4-9: Block I/O Port Pin Descriptions
sis to an external single point ground.
Table 4-10: Block I/O Port Pin Assignment
9
6
Connector
Shell
7 & Shell
5
1
NOTE
Pin 7 of the Block I/O port connector is connected to the connector
shell within the MMC. Therefore, the shield may be connected to
either pin 7 or the connector shell.
40 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
.
Table 4-11: Block I/O Port to Flying Lead Cable
Part Number: M.1016.2568
Length: 3 M (10 ft)
Cable type: 24 AWG, twisted pair (individually shielded), 4 conductor.
9-Pin male D-sub (to Block I/O Port, face view)
5
1
Pin Signal Color Notes
3 Transmit Data + White Twisted
4 Transmit Data - Black Pair
7 Shield N/A with Shield
5 Receive Data + Red Twisted
6 Receive Data - Black Pair
7 Shield N/A with Shield
9
6
G & L Motion Control Inc. MMC Hardware Manual 41
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Standalone MMC Control
Table 4-12: Block I/O Port to Block I/O Module Wiring
Use this table to wire from the Block I/O Port to the first Block I/O
Module.
9-Pin male D-sub (to Block
I/O Port, face view)
5-Pin Pluggable Screw
Terminal (to Block I/O
Module, face view)
5
1
Pin Signal Pin Signal Notes
3 Transmit Data + 1 Receive Data + Twisted
4 Transmit Data - 2 Received Data 5 Receive Data + 4 Transmit Data + Twisted
6 Received Data - 5 Transmit Data 7 Shield Ground 3 Shield Ground
Shell Drain Shell Drain
9
6
1
2
3
4
5
Pair
Pair
Table 4-13: Block I/O Port Breakout Box and Cables
Description Length Part Number
MMC Block I/O Breakout Box N/A M.1016.2533
MMC Block I/O Connector to Breakout
Box Cable
MMC Block I/O Connector to Breakout
Box Cable
MMC Block I/O Connector to Breakout
Box Cable
.3 M (1 ft) M.1016.2543
.6 M (2 ft) M.1016.2544
.9 M (3 ft) M.1016.2545
a
a. The Breakout Box for the Block I/O connector can be attached to the “BLK I/
O” port on the MMC Control. The pinouts on the terminal strip interface provide a one-to-one transfer of the signals from the connector to the respective
pin(s) on the terminal block. The connector pins marked with the “ground”
symbol on the screw connector are connected to the “D” connector shell for
shield grounding purposes.
42 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Figure 4-2: Block I/O Breakout Box Dimensions
1.750”
3.000”
1
5
9
6
2.250”
1.750”
4.6.3 User Port
The 15-pin HD male D-sub User Port connector (labeled “USER
PORT” on the front of the Control) provides RS232 and RS485
serial communication between a serial device and the Control
• Pin descriptions are provided in Table 4-14
• Pin assignments are provided in Table 4-15
• The available Flying Lead cable is described in Table 4-16.
• The available RS-232 Exter HMI cable is described in Table
4-17.
• The available RS-485 Exter HMI cable is described in Table
4-18.
• Available Breakout Boxes and Cables are described in
Table 4-19.
• Breakout Box dimensions are shown in Figure 4-3
G & L Motion Control Inc. MMC Hardware Manual 43
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Standalone MMC Control
Function Notes Pin
RS232 Receive Data RS232-level signal that receives serial data from
RS232 Transmit Data RS232-level signal that sends serial data to the
RS232 Request-to-send RS232-level signal that indicates to the connected
RS232 Clear-to-send RS232-level signal that indicates to the Control
RS-232 Data-terminalready
RS-485 Receive Data + RS485-level signal that receives serial data from
RS-485 Receive Data - RS485-level signal that receives serial data from
RS-485 Transmit Data +RS485-level signal that transmits serial data to the
RS-485 Transmit Data - RS485-level signal that transmits serial data to the
Signal Ground Provides the return path for signals 8
Shield Ground Provides a path for shield current through the chas-
Table 4-14: User Port Pin Descriptions
the connected serial device.
connected serial device.
serial device that it can transmit data to the Control.
that it can transmit data to the connected serial device.
This output from the Control is always high
(12 Vdc).
the connected serial device(s).
the connected serial device(s).
connected serial device(s).
connected serial device(s).
sis to an external single point ground.
9
10
5
7
4
12
13
14
15
Shell
44 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Table 4-15: User Port Pin Assignments
Pin Signal In/Out Connector Pinout
1NC N/A
2N/C N/A
3N/C N/A
4 RS232 Data-terminal-ready
(12 Vdc)
5 RS232 Request-to-Send Out
6N/C N/A
7 RS232 Clear- to-Send In
8 Signal Ground In/Out
9 RS232 Receive Data In
10 RS232 Transmit Data Out
11 N/C N/A
12 RS485 Receive Data + In
13 RS485 Receive Data - In
14 RS485 Transmit Data + Out
15 RS485 Transmit Data - Out
Connector
Shell
Drain In
Out
15-pin HD male D-sub
6
11
15
Connector
Shell
1
5
10
G & L Motion Control Inc. MMC Hardware Manual 45
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Standalone MMC Control
Table 4-16: User Port to Flying Lead Cable
Part Number: M.1016.2565
Length: 3 M (10 ft)
Cable type: 28 AWG, shielded, twisted pair, 16 conductor.
15-Pin HD female D-sub (to User Port, face view)
1
5
Pin Signal Color Notes
3 N/C Blue Twisted
8 Signal Ground Blue/Black Pair
12 RS485 Receive Data + Brown Twisted
13 RS485 Receive Data - Brown/
14 RS485 Transmit Data + Violet Twisted
15 RS485 Transmit Data - Violet/Black Pair
4 RS232 Data-terminal Ready White
5 RS232 Request-to-send Red
7 RS232 Clear-to-send Green
9 RS232 Receive Data Yellow
10 RS232 Transmit Data Orange
Shell Drain N/A
11
15
Pair
Black
46 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Table 4-17: User Port to RS-232 Exter HMI Cable
Part Number: M.1302.8453
Length: 4 M (13 ft)
Cable type: 24 AWG, shielded, twisted pair, 4 conductor.
15-Pin HD female Dsub (to User Port, face
view)
9-Pin female D-sub
(to Exter HMI COM2
Port, face view)
1
5
Pin Signal Pin Signal Notes
9 Receive Data 3 Transmit Data Twisted
10 Transmit Data 2 Receive Data Pair
8 Signal Ground 5 Signal Ground
Shell Drain Shell Drain
15
11
9
6
5
1
G & L Motion Control Inc. MMC Hardware Manual 47
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Standalone MMC Control
Part Number: M.1302.8454
Length: 4 M (13 ft)
Cable type: 24 AWG, shielded, twisted pair, 6 conductor.
15-Pin HD female Dsub (to User Port, face
view)
Table 4-18: User Port to RS-485 Exter HMI Cable
25-Pin male D-sub (to
Exter HMI COM1
Port, face view)
1
5
Pin Signal Pin Signal Notes
12 Receive Data+ 2 Transmit Data+ Twisted
13 Receive Data- 15 Transmit Data- Pair
14 Transmit Data+ 3 Receive Data+ Twisted
15 Transmit Data- 16 Receive Data- Pair
8 Signal Ground 7 Signal Ground
Shell Drain Shell Drain
15
11
13
25
1
14
Table 4-19: User Port Breakout Box and Cables
Description Length Part Number
MMC User Port Breakout Box N/A M.1016.2530
MMC User Port to Breakout Box
Cable
MMC User Port to Breakout Box
Cable
MMC User Port to Breakout Box
Cable
.3 M (1 ft) M.1016.2715
.6 M (2 ft) M.1016.2716
.9 M (3 ft) M.1016.2717
a
a. The Breakout Box for the User Port connector can be attached to the “USER
PORT” connector on the MMC Control. The pinouts on the terminal strip
interface provide a one-to-one transfer of the signals from the connector to
the respective pin(s) on the terminal block. The connector pins marked with
the “ground” symbol on the screw connector are connected to the “D” connector shell for shield grounding purposes.
48 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Figure 4-3: User Port Breakout Box Dimensions
1.750”
3.000”
2.250”
4.6.4 General I/O Port
The 44-pin HD male D-sub General I/O Port connectors (labeled
“GEN I/O” on the front of the Control) provides connection
between user I/O devices and the Control. This port provides 16
source-only outputs (described in detail in Section 4.6.4.1 on page
53), and 16 sink or source inputs (described in detail in Section
4.6.4.2 on page 56).
1
9
2.250”
8
15
G & L Motion Control Inc. MMC Hardware Manual 49
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Standalone MMC Control
Function Notes Pin
DC Outputs 1-16 Nominal 24 Vdc Outputs capable of sourcing up to
DC Inputs 1-8 Nominal 24 Vdc Inputs (Sink or Source) Inputs
Sink/Source select pin
for DC Inputs 1-8
DC Inputs 9-16 24 Vdc (nominal) Inputs (Sink or Source) 9-16. 37-44
Sink/Source select pin
for DC Inputs 9-16
24 Vdc Out 24 Vdc power (nominal) is routed from the 3-pin
24 Vdc Common 24 Vdc Common is routed from the 3-pin Power
Shield Ground Provides a path for shield current through the chas-
• Pin descriptions are provided in Table 4-20
• Pin assignments are provided in Table 4-21
• The available Flying Lead cable is described in Table 4-22.
• Available Breakout Boxes and Cables are described in
Table 4-23.
• Breakout Box dimensions are shown in Figure 4-4
Table 4-20: General I/O Port Pin Descriptions
250 ma.
1-8
To make DC Inputs 1-8 “sourcing” inputs (24 Vdc
applied to the DC Input turns the input “on”), connect 24 Vdc Common to this pin. To make DC Inputs 1-8 “sinking” inputs (24 Vdc Common
applied to the DC Input turns the input “on”), connect 24 Vdc (nominal) to this pin.
To make DC Inputs 9-16 “sourcing” inputs (24
Vdc applied to the DC Input turns the input “on”),
connect 24 Vdc Common to this pin. To make DC
Inputs 9-16 “sinking” inputs (24 Vdc Common applied to the DC Input turns the input “on”), connect 24 Vdc (nominal) to this pin.
Power connector to these pins. Connect the Sink/
Source select pin (described above) to this pin to
configure the associated Inputs as “sinking” inputs.
connector to these pins. Connected the Sink/
Source select pin (described above) to this pin to
configure the associated Inputs as “sourcing” inputs.
sis to an external single point ground.
1-16
23-30
21
35
20, 34
22, 36
Shell
50 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Table 4-21: General I/O Port Pin Assignments
Pin Signal In/Out Connector Pinout
1DCOUT1Out 44-pin HD male D-sub
2DCOUT2Out
3DCOUT3Out
4DCOUT4Out
5DCOUT5Out
6DCOUT6Out
7DCOUT7Out
8DCOUT8Out
9DCOUT9Out
10 DCOUT10 Out
11 DCOUT11 Out
12 DCOUT12 Out
13 DCOUT13 Out
14 DCOUT14 Out
15 DCOUT15 Out
16 DCOUT16 Out
17-19 N/C N/A Pin Signal In/Out
20 IO24V Out 34 IO24V Out
21 DCSS1 In 35 DCSS2 In
22 IO24C Out 36 IO24C Out
23 DCIN1 In 37 DCIN9 In
24 DCIN2 In 38 DCIN10 In
25 DCIN3 In 39 DCIN11 In
26 DCIN4 In 40 DCIN12 In
27 DCIN5 In 41 DCIN13 In
28 DCIN6 In 42 DCIN14 In
29 DCIN7 In 43 DCIN15 In
30 DCIN8 In 44 DCIN16 In
31-33 N/C N/A Shell Drain In
16
31
44
Connector
Shell
1
15
30
G & L Motion Control Inc. MMC Hardware Manual 51
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Standalone MMC Control
Part Number: M.1016.2567
Length: 3 M (10 ft)
Cable type: 28 AWG, shielded, twisted pair, 44 conductor.
Table 4-22: General I/O Port to Flying Lead Cable
44-Pin HD female D-sub (to Gen I/O Port, face view)
1
15
Pin Signal Color Notes Pin Signal Color Notes
1 DCOUT1 Black Twisted 22 IO24C Red Twisted
2 DCOUT2 Red Pair 23 DCIN1 Brown Pair
3 DCOUT3 Black Twisted 24 DCIN2 Red Twisted
4 DCOUT4 White Pair 27 DCIN5 Orange Pair
5 DCOUT5 Black Twisted 25 DCIN3 Green Twisted
6 DCOUT6 Green Pair 26 DCIN4 White Pair
7 DCOUT7 Black Twisted 28 DCIN6 Green Twisted
8 DCOUT8 Blue Pair 29 DCIN7 Blue Pair
9 DCOUT9 Black Twisted 31 None Green Twisted
10 DCOUT10 Yellow Pair 32 None Yellow Pair
11 DCOUT11 Black Twisted 33 None Green Twisted
12 DCOUT12 Brown Pair 34 IO24V Brown Pair
13 DCOUT13 Black Twisted 35 DCSS2 Green Twisted
14 DCOUT14 Orange Pair 36 IO24C Orange Pair
15 DCOUT15 Red Twisted 37 DCIN9 White Twisted
30 DCIN8 White Pair 38 DCIN10 Blue Pair
16 DCOUT16 Red Twisted 39 DCIN11 White Twisted
17 None Green Pair 40 DCIN12 Yellow Pair
18 None Red Twisted 41 DCIN13 White Twisted
21 DCSS1 Blue Pair 42 DCIN14 Brown Pair
19 None Red Twisted 43 DCIN15 White Twisted
20 IO24V Yellow Pair 44 DCIN16 Orange Pair
Shell Drain N/A
31
44
52 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Table 4-23: General I/O Port Breakout Box and Cables
Description Length Part Number
MMC Gen I/O Breakout Box N/A M.1016.2532
MMC Gen I/O & Aux I/O Connector to
Breakout Box Cable
MMC Gen I/O & Aux I/O Connector to
Breakout Box Cable
MMC Gen I/O & Aux I/O Connector to
Breakout Box Cable
a. The Breakout Box for the General I/O connector can be attached to the “GEN I/O”
port on the MMC Control, and on the “GEN I/O A” and “GEN I/O B” ports on the
MMC 32 In/32 Out Expansion module. The pinouts on the terminal strip interface
provide a one-to-one transfer of the signals from the connector to the respective
pin(s) on the terminal block. The connector pins marked with the “ground” symbol
on the screw connector are connected to the “D” connector shell for shield grounding
purposes.
.3 M (1 ft) M.1016.2539
.6 M (2 ft) M.1016.2540
.9 M (3 ft) M.1016.2541
a
Figure 4-4: General I/O Port Breakout Box Dimensions
1.875”
3.940”
1
23
2.625”
4.6.4.1 DC Output Operation
The General I/O Port provides 16 source-only 24 Vdc
outputs. Each of the 16 outputs on the general I/O
connector is a solid state switch rated at 250 ma. An
example of connecting the DC Outputs to loads is
shown in Figure 4-5.
There are two groups of eight outputs: group A = output
1 through output 8, group B = output 9 through output
16. Each group is capable of detecting a short circuit
condition. When a short circuit condition is sensed, all
22
44
5.312”
G & L Motion Control Inc. MMC Hardware Manual 53
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Standalone MMC Control
outputs in the group are turned off and remain off for
approximately 100 ms regardless of ladder activity.
After 100 ms, the ladder again controls the outputs. In
addition, each output is protected with internal clamping
diodes. Without clamping, high voltage transients
(kickback) from inductive loads might damage the
module.
For safety reasons, all outputs turn off (no current flow)
when a scan loss condition occurs.
For more information on DC output operation, refer to
Section A.3 on page 173 of Appendix A.
54 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Figure 4-5: General I/O Outputs Connected to Loads
MMC
GENERAL
CONNECTOR DC
LOAD
DCOUT1
DCOUT2
OUTPUT PINS
1
DCOUT3
DCOUT4
DCOUT5
DCOUT6
DCOUT7
DCOUT8
DCOUT9
DCOUT10
DCOUT11
DCOUT12
DCOUT13
DCOUT14
DCOUT15
3
5
7
9
11
13
15
DCOUT16
Power
Connector
_
+
DC Power Supply
Common
G & L Motion Control Inc. MMC Hardware Manual 55
To
SPG
Page 64
Standalone MMC Control
4.6.4.2 DC Input Operation
The General I/O Port provides sixteen 24 Vdc inputs.
There are two groups of eight inputs: group A = input 1
through output 8, group B = input 9 through output 16.
Each group can be configured as sourcing or sinking.
Connect the DCSS pin (DCSS1 for Group A, DCSS2
for Group B) to IO24C for a sourcing configuration.
Connect the DCSS pin (DCSS1 for Group A, DCSS2
for Group B) to +24 Vdc for a sinking configuration. An
example of connecting input devices in both a sink and
source configuration is shown in Figure 4-6.
In addition, the first input of each Group (Input 1 of
Group A, and input 9 of Group B), can be programmed
to provide a processor interrupt on either a low-to-high
or high-to-low transition.
For more information on DC input operation, refer to
Section A.2 on page 171 of Appendix A.
56 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Figure 4-6: General I/O Inputs Connected to Devices
SWITCHING
DEVICE
MMC
DCSS1
I/O 24V
DCIN1
DCIN2
DCIN3
DCIN4
DCIN5
DCIN6
DCIN7
DCIN8
DCSS2
I/O 24C
DCIN9
DCIN10
GENERAL
CONNECTOR DC
OUTPUT PINS
21
23
25
SINK
27
29
35
37
DCIN11
DCIN12
DCIN13
DCIN14
DCIN15
DCIN16
+24 Vdc
DC Power Supply
Common
4.6.5 Power Connection
The Power connector (labeled “PWR” on the front of the Control)
must be connected to a user-supplied +24 VDC power supply to
provide power to the Control. The power supply screw terminal
connection (3 pin) is at the bottom of the CPU section of the MMC.
Power
Connector
_
+
39
41
43
To
SPG
SOURCE
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Standalone MMC Control
This +24 Vdc appears as an output at several points on the MMC
connectors. Figure 4-7 illustrates the pin-out.
The MMC converts +24 Vdc power from this connector to DC
power at voltages of +5 Vdc, + 15 Vdc, and -15 Vdc and supplies
them to the logic side of the system. The same supply that powers
the Control can be used for the field side of the system. Optionally ,
an external power supply (or supplies) can be used for the field side
of the system. Such supplies are not routed through the MMC, but
they should all have the same power cut-off switch as the Control.
The 24 VDC applied at the MMC input power connector is also
available:
• To power the DC outputs
• To power the sink/source inputs
• To power the axes interface
• To power any attached MMC Option Modules
CAUTION
Always shut off power at the main disconnect switch before you
begin to work on the MMC.
Figure 4-7: Pin Out for the 3-pin Power Supply Screw Terminal Connection
Power Source
24V DC
+24V
COM
24 Vdc
24 Vdc Common
GROUND
SPG
58 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
4.7 Analog Motion Control Connections & Operation
This section provides theory-of-operation and connection information on the
Analog Motion Control board, which is located on the left side of an MMC
Control.
4.7.1 Axis I/O Ports
The 15-pin HD female D-sub Axis I/O Port connectors (labeled
“A1”, “A2”, “A3”, and “A4” on the front of the Control) provide
connection between analog drives and the Control by providing the
following:
• Two 24 Vdc outputs, described in detail in Section 4.7.1.1
on page 64.
• One DC input, described in detail in Section 4.7.1.2 on page
66.
• One 16-bit resolution analog output, described in detail in
Section 4.7.1.3 on page 67.
• One quadrature, incremental encoder input, described in
detail in Section 4.7.1.4 on page 67.
Additional information is provided in this section as follows:
• Pin descriptions provided in Table 4-24
• Pin assignments are provided in Table 4-25
• Available MMC Smart Drive cables are described in Table
4-26.
• The available Flying Lead cable is described in Table 4-27.
• Available Breakout Boxes and Cables are described in
Table 4-28.
• Breakout Box dimensions are shown in Figure 4-8
G & L Motion Control Inc. MMC Hardware Manual 59
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Standalone MMC Control
Function Notes Pin
Encoder Input (A, A/,
B, B/, I, I/)
D/A Output (DA+, DA-)+/- 10V D/A output for controlling an analog
DC Input (DCIN+,
DCIN-)
DC Outputs (DCOUT1,
DCOUT2)
DCOSS Connect this pin to +24 Vdc to configure the
24 Vdc out 24 Vdc output to be used to power connected
COM 24 Vdc Common used to provide the 24 Vdc
Shield Ground Provides a path for shield current through the
Table 4-24: Axis I/O Port Pin Descriptions
Provides connections to an incremental encoder
having differential ou tputs.
drive having a differential input.
Provides connection to an input device (sink or
source).
Provides connection to an output device (sink or
source).
outputs (DCOUT1 & DCOUT2) as sinking-type,
and to +24 Vdc Common to configure the DC
Outputs (DCOUT1 & DCOUT2) as sourcingtype.
input and/or output devices.
return path for sinking-type outputs.
chassis to an external single point ground.
1-5, 10
8, 9
6, 7
13, 14
15
11
12
Shell
Table 4-25: Axis I/O Port Pin Assignments
Pin Signal In/Out Connect or Pinout
1A In 15-pin HD female D-sub
2A/ In
3B In
4B/ In
5I In
6DCIN+In
7 DCIN- Out
8D/A+Out
9 DA- Out
10 I/ In
11 +24 Vdc Out
12 COM In
13 DCOUT1 In/Out
14 DCOUT2 In/Out
15 DCOSS In/Out
Connector
Shell
Drain In
10
15
11
Connector
Shell
5
1
6
60 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Table 4-26: Axis I/O Port to MMC Smart Drive Cable
Part Numbers:
.5 M (1.6 ft): M.1302.5990 2.5 M (8.2 ft): M.1302.7714
1 M (3.3 ft): M.1302.5991 3.5 M (11.5 ft): M.1302.7715
1.5 M (4.9 ft): M.1301.5992 5 M (16.4 ft): M.1302.7537
2 M (6.6 ft): M.1302.5993
Cable type: 28 AWG, shielded, twisted pair, 18 conductor.
15-Pin HD male D-sub (to
Axis I/O Port, face view)
26-Pin HD male D-sub (to
MMC Smart Drive I/O
Port, face view)
5
1
Pin Signal Pin Signal Notes
1 A 1 A Twisted
2A/ 2A/ Pair
3 B 3 B Twisted
4B/ 4B/ Pair
5 I 5 I Twisted
10 I/ 6 I/ Pair
11 +24 Vdc 10 IO24V Twisted Pair
12 COM 16 IOCOM (20 AWG)
13 DCOUT1 17 IN1 Twisted
14 DCOUT2 18 IN2 Pair
6 DCIN+ 26 OUT4
7 DCIN - Jumpered
12 COM
15 DCOSS Jumpered
11 +24 Vdc
Shell Drain Shell Drain
15
11
9
1
26
19
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Standalone MMC Control
Table 4-27: Axis I/O Port to Flying Lead Cable
Part Number: M.1016.2519
Length: 3 M (10 ft)
Cable type: 28 AWG, shielded, twisted pair, 16 conductor.
15-Pin HD male D-sub (to Axis I/O Port, face view)
5
1
Pin Signal Color Notes
1 A Blue Twisted
2 A/ White/Blue Pair
3 B Black Twisted
4 B/ White/Black Pair
5I Red Twisted
10 I/ White/Red Pair
8 D/A+ Green Twisted
9 D/A - White/Green Pair
6 DCIN+ Yellow Twisted
7 DCIN- White/Yellow Pair
11 +24 Vdc Orange Twisted
11 +24 Vdc White/Orange Pair
12 COM Brown Twisted
13 DCOUT1 White/Brown Pair
14 DCOUT2 Violet Twisted
15 DCOSS White/Violet Pair
Shell Drain N/A
15
11
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Table 4-28: Axis I/O Port Breakout Box and Cables
a
Description Length Part Number
Axis Connector Breakout Box N/A M.1016.2529
MMC Axis A”n” to Breakout Box Cable .3 M (1 ft) M.1016.2535
MMC Axis A”n” to Breakout Box Cable .6 M (2 ft) M.1016.2536
MMC Axis A”n” to Breakout Box Cable .9 M (3 ft) M.1016.2537
a. The Breakout Box for the Axis Connector can be attached to the A1, A2, A3, and A4
ports on the Standalone MMC Control or the MMC Axis I/O Option Module. The
pinouts on the terminal strip interface provide a one-to-one transfer of the signals from
the connector to the respective pin(s) on the terminal block. The ground pin on the terminal strip provides a connection to the metal D-shell.
Figure 4-8: Axis I/O Port Breakout Box Dimensions
1.750”
2.250”
3.000”
1
9
2.250”
8
15
G & L Motion Control Inc. MMC Hardware Manual 63
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Standalone MMC Control
4.7.1.1 Axis I/O Port DC Outputs
Each Axis I/O Port provides 2 sink or source 24 Vdc
outputs. Each of the 2 outputs on is a solid state switch
rated at 100 ma. When the DCOSS pin is tied to the
+24V, the outputs will be in a source configuration as
shown in Figure 4-9. When the DCOSS pin is tied to
COMMON, the outputs will be in a sink configuration
as shown in Figure 4-10.
For safety reasons, all outputs turn off (no current flow)
when a scan loss condition occurs.
For more information on DC output operation, refer to
Section A.3 on page 173 of Appendix A.
Figure 4-9: Axis I/O DC Output Source Configuration
MMC Axis I/O Connector Drive
DC OUT 1
DCOSS
DC OUT 2
+24V
COM
13
15
14
11
12
Sourcing Outputs Sinking Inputs
Drive
Enable
Drive
Reset
64 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
Figure 4-10: Axis I/O DC Output Sink Configuration
MMC Axis I/O Connector
DC OUT 1
DCOSS
DC OUT 2
+24V
COM
13
15
14
11
12
Drive
Sinking Outputs Sourcing Inputs
+24V
Drive
Enable
+24V
Drive
Reset
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Standalone MMC Control
4.7.1.2 Axis I/O Port DC Input
Each Axis I/O Port provides one 24 Vdc input. Each
input is an optically isolated solid state switch. It turns
on or off according to the logic state sent to it by the
CPU. When the switch turns on, current flows through
the switch. When the switch turns off, current flow
stops.
These outputs are intended to interface with the drive
enable and drive reset inputs. When an output is turned
on current can flow through the switch in either
direction. This allows the outputs to be connected in a
sink or source configuration. One of the input pins
should be connected to either +24 Vdc or COM. The
remaining input pin should be tied to the input signal
that will be switching. Refer to Figure 4-11.
For safety reasons, all outputs turn off (no current flow)
when a scan loss condition occurs.
For more information on DC input operation, refer to
Section A.2 on page 171 of Appendix A.
Figure 4-1 1: Axis I/O Port DC Input
MMC Axis I/O Connector Drive
DC IN+
DC IN -
6
7
COM
+24V
Drive Ready
66 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
4.7.1.3 Axis I/O Port Analog Output
The Axis I/O Port provides a +/-10 V differential
Analog Output. The Analog Output is typically
connected to the drive Command Input. Only shielded
twisted pair wire should be used to make the connection
between the analog output and the drive as shown in
Figure 4-12.
The CPU sends the analog output section a 16-bit digital
word to each analog output channel. Each digital word
is converted to a corresponding voltage within the range
of ±10 Vdc. The voltage is buffered and brought out to
a pair of I/O connections as a differential type voltage
output. This output is less subject to interference from
electrical noise than a single-ended output would be.
You can adjust each analog output channel in software
for offset adjustments, gain scaling, and unipolar
outputs.
For safety reasons, all outputs are automatically reset to
0 Vdc when a scan loss condition occurs.
Figure 4-12: Axis Port D/A Output
MMC Axis Connector Drive
DA+
DA-
8
9
Shielded
Twisted
Pair
4.7.1.4 Axis I/O Port Encoder Input
The Axis I/O Port provides an input for a differential
incremental encoder. The encoder output signals from
the drive should be connected to the Axis I/O Port
G & L Motion Control Inc. MMC Hardware Manual 67
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Standalone MMC Control
The power supply that powers the encoder must be referenced to
the power supply that powers the MMC. This is done by connecting
the “common” terminal of each supply back to Single Point
Ground. Failure to observe this precaution may result in sporadic
encoder operation and/or damage to the MMC.
encoder input for each axis. The Axis I/O Port encoder
input accepts RS422 differential inputs. The encoder
signals should be quadrature type. All encoder wiring
between the MMC and the drive should be shielded
twisted pair as shown in Figure 4-13.
For more information on the Encoder input operation,
refer to Section A.4 on page 175 of Appendix A.
NOTE
Figure 4-13: Axis Port MMC Encoder Input
MMC Axis I/O Connector
1
A
A/
2
3
B
4
B/
I
5
10
I/
Shielded
Twisted
Pairs
Drive
A
A/
B
B/
I
I/
4.7.2 Aux I/O Port
The 44-pin HD female D-sub Auxiliary I/O Port connector (labeled
“AUX I/O” on the front of the Control) provides connection to an
68 MMC Hardware Manual G & L Motion Control Inc.
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Standalone MMC Control
incremental encoder and various I/O devices by providing the
following inputs to the Control:
• Five fast DC inputs, described in detail in Section 4.7.2.2 on
page 76.
• 12 optically isolated DC inputs, described in detail in Sec-
tion 4.7.2.3 on page 77.
• One quadrature, incremental encoder channel, described in
detail in Section 4.7.2.4 on page 79.
• One 12-bit resolution analog input channel, described in
detail in Section 4.7.2.5 on page 80.
Additional information is provided in this section as follows:
• Pin descriptions fare provided in Table 4-29
• Pin assignments are provided in Table 4-30
• The available Flying Lead cable is described in Table 4-31.
• Available Breakout Boxes and Cables are described in
Table 4-32.
• Breakout Box dimensions are shown in Figure 4-14
G & L Motion Control Inc. MMC Hardware Manual 69
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Standalone MMC Control
Function Notes Pin
Encoder Input (A, A/, B,
B/, I, I/)
DC Input 1-6 (DCIN1DCIN12)
DC Input 7-12 (DCIN1DCIN12)
DC Sink/Source A
(DCSSA)
DC Sink/Source B
(DCSSB)
Analog Input
(ANLGIN+, ANLGIN-)
Fast Inputs 1-5
(FASTIN1-5+,
FASTIN1-5-)
24 Vdc out 24 Vdc output to be used to power connected
COM 24 Vdc Common used to provide the 24 Vdc
+5 Vdc Out +5 Vdc output to be used to power connected
Shield Ground Provides a path for shield current through the
Table 4-29: Aux I/O Port Pin Descriptions
Provides connections to an incremental encoder
having differential ou tputs.
Provides connection to an input device (sink or
source).
Provides connection to an input device (sink or
source).
If this pin is connected to +24 Vdc, inputs 1-6 are
“sinking”. If this pin is connected to +24
Common, inputs 1-6 are “sourcing”.
If this pin is connected to +24 Vdc, inputs
DCIN1-DCIN6 are “sinking”. If this pin is
connected to +24 Common, inputs DCIN7DCIN12 are “sourcing”.
+/- 10V 16-bit A/D input 13,14
Differential Fast Inputs for latching Encoder
position.
input and/or output devices.
return path for sinking-type outputs.
encoder (150 ma maximum).
chassis to an external single point ground.
1-6
32-37
39-44
31
38
16, 17, 19,
20, 22, 23,
25, 26, 28,
29
8, 9
10, 11
12
7, 15, 18,
21, 24, 27,
30, Shell
70 MMC Hardware Manual G & L Motion Control Inc.
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Table 4-30: Aux I/O Port Pin Assignment
Standalone MMC Control
Pin Signal
In/
Out
Pin Signal
1A In 25
2A/ In 26
FASTIN4+
FASTIN4-
In/
Out
a
In 44-pin HD female D-
a
In
3 B In 27 Shield In
4B/ In 28FASTIN5+In
5 I In 29 FASTIN5- In
6I/ In 30Shield In
7 Shield- In 31 DCSSA In/Out
8, 9 +24 Vdc Out Out 32 DCIN1 In
10, 11 COM In 33 DCIN2 In
12 +5 Vdc Out Out 34 DCIN3 In
13 ANLGIN+ In 35 DCIN4 In
14 ANLGIN- In 36 DCIN5 In
15 Shield In 37 DCIN6 In
16 FASTIN1+ In 38
17 FASTIN1- In 39
18 Shield In 40
19 FASTIN2+ In 41
20 FASTIN2- 42
21 Shield 43
22
23
FASTIN3+
FASTIN3-
a
a
44
Shell Drain In
DCSSB
DCIN7
DCIN8
DCIN9
DCIN10
DCIN11
DCIN12
a
a
a
a
a
a
a
In/Out
In
In
In
In
In
In
24 Shield
Connector Pinout
sub
30
15
44
31
Connector
Shell
16
1
a. Signal not available on MMC-A2
G & L Motion Control Inc. MMC Hardware Manual 71
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Standalone MMC Control
Part Number: M.1016.2566
Length: 3 M (10 ft)
Cable type: 28 AWG, shielded, twisted pair, 44 conductor.
Table 4-31: Aux I/O Port to Flying Lead Cable
44-Pin HD male D-sub (to Aux I/O Port, face view)
15
1
44
31
Pin Signal Color Notes Pin Signal Color Notes
1 A Black Twisted 22
2A/ RedPair23
FASTIN3+
FASTIN3-
a
Red Twisted
a
Brown Pair
3 B Black Twisted 24 Shield Red Twisted
4 B/ White Pair 27 Shield Orange Pair
5 I Black Twisted 25
6 I/ Green Pair 26
FASTIN4+
FASTIN4-
a
Green Twisted
a
White Pair
7 Shield Black Twisted 28 FASTIN5+ Green Twisted
8 + 24 Vdc Out Blue Pair 29 F ASTIN5- Blue Pair
9 + 24 Vdc Out Black Twisted 31 DCSSA Green Twisted
10 COM Yellow Pair 32 DCIN1 Yellow Pair
11 COM Black Twisted 33 DCIN2 Green Twisted
12 +5 Vdc Out Brown Pair 34 DCIN3 Brown Pair
13 ANLGIN+ Black Twisted 35 DCIN4 Green Twisted
14 ANLGIN- Orange Pair 36 DCIN5 Orange Pair
15 Shield Red Twisted 37 DCIN6 White Twisted
30 Shield White Pair 38
16 FASTIN1+ Red Twisted 39
17 FASTIN1- Green Pair 40
18 Shield Red Twisted 41
21 Shield Blue Pair 42
19 Fastin2+ Red Twisted 43
20 Fastin2- Yel low Pair 44
DCSSB
DCIN7
DCIN8
DCIN9
DCIN10
DCIN11
DCIN12
a
a
a
a
Blue Pair
White Twisted
Yellow Pair
White Twisted
a
Brown Pair
a
White Twisted
a
Orange Pair
Shell Drain N/A
a. Signal not available on MMC-A2
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Table 4-32: Aux I/O Port Breakout Box and Cables
a
Description Length Part Number
MMC Aux I/O Breakout Box
b
MMC Aux I/O Breakout Box with Encoder
Isolation
c
MMC Gen I/O & Aux I/O Connector to
N/A M.1016.2531
N/A M.1017.4236
.3 M (1 ft) M.1016.2539
Breakout Box Cable
MMC Gen I/O & Aux I/O Connector to
.6 M (2 ft) M.1016.2540
Breakout Box Cable
MMC Gen I/O & Aux I/O Connector to
.9 M (3 ft) M.1016.2541
Breakout Box Cable
a. The Breakout Box for the Auxiliary I/O Connector can be attached to the AUX I/O
port on the Standalone MMC Control or the MMC Axis I/O Option Module. Both a
standard Breakout Box as well as a Breakout Box that provides encoder isolation
are available. The pinouts on the terminal strip interface provide a one-to-one transfer of the signals from the connector to the respective pin(s) on the terminal block.
The connector pins marked with the “ground” symbol on the screw connector are
connected to the “D” connector shell for shield grounding purposes.
b. Aux I/O Breakout Box dimensions are shown in Figure 4-14.
c. See Section 4.7.2.1 on page 74 for details on the Breakout Box with Encoder Isola-
tion.
Figure 4-14: Aux I/O Port Breakout Box Dimensions
1.875”
3.940”
1
23
2.625”
5.312”
22
44
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Standalone MMC Control
4.7.2.1 Isolated Breakout Box Details
The Isolated Breakout Box is different then the Standard
Breakout Box in three ways:
• The Isolated Breakout Box provides optical isola-
tion between the encoder (A, A/, B, B/, I, I/) signals
and the Control. This boosts the encoder common
mode voltages allowed from approximately 10 volts
to hundreds of volts. This allows reliable encoder
operation in the presence of large amounts of electrical noise and ground disturbances relative to the
Control.
• Since the Isolated Breakout Box uses +5 Vdc from
pin 12 of the Control to power it’s internal circuitry,
there is no +5 Vdc current to power the encoder.
Therefore, the pin 12 screw terminal on the Isolated
Breakout Box does not carry +5 Vdc, and the
encoder must be powered by an external supply.
• When using the Isolated Breakout Box, the “index”
inputs (I, I/) must be connected. If the connected
encoder does not provide the index function, connect I on the Breakout Box to +5 Vdc, and I/ to +5
Vdc Common. Failure to connect I and I/ will result
in a “loss-of-feedback” by the Control.
Figure 4-15: Connections from Encoder to Encoder Isolated AUX I/O
Breakout Box
Screw Terminals
(I & I/ must be
connected)
A+
A-
B+
B-
1
2
3
4
I+
5
I-
6
Optical
Isolator
Optical
Isolator
Optical
Isolator
+5V
1
A+
2
A-
3
B+
B-
4
5
I+
6
I-
12 +5V
MMC Connector
Pins
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Standalone MMC Control
Figure 4-16: Encoder and Power Connections for Encoder Isolator
Encoder
+5V
Power Supply
GND
A
AB
B-
I
I-
Single Point
Ground (SPG)
Isolated Breakout Box
1
2
3
4
5
6
AUX I/O
J1
J2
Control
AUX I/O
Table 4-33: Encoder Specifications
Item Specification
Encoder Driver Required RS-422 differential
Recommended Encoder Drivers 7272 , 75183, 8830, 75114, 9614,
26LS31 (or equivalent)
Differential Input Voltage Range 2.5 volts to 7.0 volts
Differential Input Current Range 2.5 ma (Input Voltage = 2.5 volts)
to 30ma (Input Voltage = 7.0
volts)
Input pulse width (minimum) 600 nanoseconds
Input frequency (maximum) on A or B
inputs from Quadrature output encoder
Input frequency (maximum) on A or B
inputs from Pulse output encoder
250KHz (1.0 MHz count rate,
using quadrature edges)
500KHz (500KHz count rate)
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Standalone MMC Control
IMPORTANT
When using the Isolated Breakout Box, the “index” inputs (I, I/) must be connected. If the connected encoder
does not provide the index function, connect I on the
Breakout Box to +5 Vdc, and I/ to +5 Vdc Common.
Failure to connect I and I/ will result in a “loss-of-feedback” by the Control.
4.7.2.2 Aux I/O Port Fast Inputs
The Aux I/O Port provides one fast 24 Vdc input for
each encoder input, as follows:
Fast Input Association - Aux I/O Port
Fast Input Encoder
FASTIN1 Axis 1
FASTIN2 Axis 2
FASTIN3 Axis 3
FASTIN4 Axis 4
FASTIN5 Aux I/O
The fast input can be used to latch the encoder position
under various conditions. Shielded twisted pair wiring
should be used for all fast input connections. The fast
inputs can be connected in either a source or sink
configuration. The source configuration is illustrated in
Figure 4-17, and the sink configuration is illustrated in
Figure 4-18.
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Figure 4-17: Fast Inputs Connected Using Shielded Twisted Pair (Source)
MMC AUX I/O Connector
FI 1-
FI 1+
16
17
Source
Switch
+24V
Shielded
Twisted
Shield
CHS
18
Pair
Figure 4-18: Fast Inputs Connected Using Shielded Twisted Pair (Sink)
MMC AUX I/O Connector
FI 1+
16
FI 1-
17
Shielded
Twisted
Shield
CHS
18
Pair
4.7.2.3 Aux I/O Port DC Inputs
The Aux I/O Port provides 12 general purpose 24 Vdc
inputs. The inputs are configured as two groups of six.
Each group can be configured as sourcing or sinking.
Connect the DCSS pin to COM for a sourcing
+24V
Sink
Switch
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Standalone MMC Control
configuration by connecting the DCSS pin to either the
COM pin on the Aux I/O Port or to the Common of an
external supply . Connect the DCSS pin to +24 Vdc for a
sinking configuration by connecting the DCSS pin to
either the +24 Vdc pin on the Aux I/O Port or to the +24
Vdc of an external supply. Both sinking and sourcing
configurations, using the Aux I/O +24V and COM pins,
are shown in Figure 4-19.
All 12 inputs are available on the four axis MMC-A4,
and 6 inputs are available on the two axis MMM-A2.
For more information on DC input operation, refer to
Section A.2 on page 171 of Appendix A.
78 MMC Hardware Manual G & L Motion Control Inc.
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MMC AUX I/O Connector
Standalone MMC Control
Figure 4-19: Aux I/O Port Inputs
+24V
DCSSA
DC IN 1
DC IN 2
DC IN 3
DC IN 4
DC IN 5
DC IN 6
COM
COM
DCSSB
DC IN 7
DC IN 8
DC IN 9
DC IN 10
DC IN 11
DC IN 12
+24V
8
31
32
33
34
35
36
37
11
10
38
39
40
41
42
43
44
9
SINKING
INPUTS
SOURCING
INPUTS
4.7.2.4 Aux I/O Port Encoder Input
The Aux I/O Port provides an input for a differential
incremental encoder. This encoder is typically used as a
digitizing (read only) axis. This axis then acts as a
“master” axis, and the other servo axis are “slaved” to
its position. The Aux I/O Port encoder input accepts
RS422 differential inputs. The encoder signals should
be quadrature type. All encoder wiring between the
MMC and the drive should be shielded twisted pair as
shown in Figure 4-20.
G & L Motion Control Inc. MMC Hardware Manual 79
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Standalone MMC Control
The power supply that powers the encoder must be referenced to
the power supply that powers the MMC. This is done by connecting
the “common” terminal of each supply back to Single Point
Ground. Failure to observe this precaution may result in sporadic
encoder operation and/or damage to the MMC.
Figure 4-20: Aux Port MMC Encoder Input
For more information on the Encoder input operation,
refer to Section A.4 on page 175 of Appendix A.
NOTE
MMC Aux I/O Connector
1
A
A/
2
3
B
4
B/
I
5
6
I/
4.7.2.5 Aux I/O Port Analog Input
Shielded
Twisted
Pairs
Drive
A
A/
B
B/
I
I/
The Aux I/O Port provides one differential analog input
channel. The input range is ±10 VDC. The analog input
voltage is sampled every 100 µsec by a 12-bit A/D
converter. The most recent conve rsion result is stored in
an on-board register. This register can be read at any
time by the application.
The analog input signal passes through a common mode
and differential mode filter prior to being applied to the
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Standalone MMC Control
A/D converter. These filters improve the noise
immunity of the module.
4.8 SERCOS Motion Control Connections & Operation
This section provides information on connecting to the SERCOS Motion
Control board, which is located on the left side of a SERCOS MMC Control.
The MMC SERCOS board is an alternate type of motion control used as part
of an MMC base unit. It provides an interface between the MMC and a fiber
optic ring. A ring can have from one to eight SERCOS slaves. The module
contains an on board processor. There is one SERCOS ring port located at
the center of the module. This ring port has a receive and a transmit fiber
optic connector. There is also an RS232 port used for loading FLASH
memory updates.
The SERCOS board is controlled by an application created in PiCPro. An
on-board processor interprets the functions and performs appropriate
operations according to the SERCOS communications protocol.
The data transfer rate is 4M Baud with user-defined update rate.
If a scan loss occurs, SERCOS communications are reset. There is no
communication with the SERCOS slaves until they are re-initialized.
4.8.1 SERCOS Receive and Transmit Ports
The SERCOS Receive Port and Transmit Port connectors (labeled
“RECV” and “XMIT” on the front of the Module) located in the
center of the board can connect to one SERCOS ring. The
connection to this ring is made through a pair of female fiber optic
SMA connectors. The module’s transm itter is connected to the first
receiver in the loop and the module’s receiver is connected to the
last transmitter in the loop.
Available SERCOS cables are shown in Table 4-34.
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Standalone MMC Control
Table 4-34: SERCOS Cables
Description Model Number Length Part Number
Heavy Duty
SERCOS
Cable
a. SERCOS Cables can be used to make the connection between a Standalone MMC SERCOS
Control and a SERCOS Drive, and between SERCOS drives.
SERCOS-0.50m-6mm-AA .5 M (1.6 ft) M.1302.6379
SERCOS-1.00m-6mm-AA 1 M (3.3 ft) M.1302.6400
SERCOS-2.00m-6mm-AA 2 M (6.6 ft) M.1302.6401
SERCOS-3.00m-6mm-AA 3 M (9.8 ft) M.1302.6402
SERCOS-5.00m-6mm-AA 5 M (16.4 ft) M.13 02.6403
SERCOS-10.00m-6mm-AA 10 M (32.8 ft) M.1302.6404
SERCOS-15.00m-6mm-AA 15 M (49.2 ft) M.1302.6405
SERCOS-30.00m-6mm-AA 30 M (98.4 ft) M.1302.6406
a
82 MMC Hardware Manual G & L Motion Control Inc.
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Figure 4-21: SERCOS Connections - One Ring
PC connected to RS232 port
for Field Updates of
G&L Motion Control system
software
Position, Velocity, or Torque Commands
Standalone MMC Control
MMC/SERCOS Module
MMC
SPD
Pic
Pro
R
RECV
XMIT
T
LOADER
BLK
I/O
USER
PORT
GEN
I/O
+24V
COM
PWR
Feedback and Diagnostics
R
T
SERCOS Slave 1
4.8.2 Loader Port
The 9-pin male D-sub Loader Port connector (labeled “LOADER”
on the front of the Module) provides a serial connection to a PC to
enable the user to update the FLASH memory on the Module.
Fiber Optic Ring
RT RT
(Up to eight SERCOS slaves)
SERCOS Slave 2
SERCOS Slave n
• Pin descriptions for are provided in Table 4-35
• Pin assignments are provided in Table 4-36
• The available SERCOS Loader Port to PC cable is
described in Table 4-37
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Function Notes Pin
Receive Data RS232-level signal that receives serial data from
Transmit Data RS232-level signal that transmits serial data to the
Signal Ground Provides the return path for signals 5
Shield Ground Provides a path for shield current throu gh the
Table 4-36: SERCOS Loader Port Pin Assignments
Pin Signal In/Out Connector Pinout
1NC N/A 9-pin male D-sub
2 RS232 Receive Data In
3 RS232 Transmit Data Out
4NC N/A
5 Signal Ground In/Out
6NC N/A
7NC N/A
8NC N/A
9NC N/A
Connector
Shield
Shield In
Table 4-35: SERCOS Loader Port Pin Descriptions
2
the connected PC running PiCPro.
3
connected PC running PiCPro.
Connector
chassis to an external single point ground.
Shell
6
9
Connector
Shell
1
5
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Table 4-37: SERCOS Loader Port to PC Cable
Part Number: M.1302.8250
Length: 4 M (13 ft)
Cable type: 24 AWG, shielded, twisted pair, 4 conductor.
9-Pin female D-sub
(to SERCOS Loader
Port, face view)
9-Pin female D-sub
(to PC COM Port,
face view)
9
6
Pin Signal Pin Signal Notes
2 Receive Data 3 Transmit Data Twisted
3 Transmit Data 2 Receive Data Pair
5 Signal Ground 5 Signal Ground
Shell Drain Shell Drain
5
1
9
6
5
1
4.9 Replacing the MMC Battery
Follow the procedure below to replace the MMC battery when the “P” light is
flashing.
1. After DC power has been applied to the MMC for at least five minutes, turn off
power. This ensures that the contents of memory will not be lost while the
battery is removed. Disconnect the input power connector from the MMC.
2. Remove the MMC (including any optional modules) from the cabinet.
3. Use a static-free work surface if possible. Ground yourself using a properly
grounded wrist strap before you open the case. These are standard precautions
before handling any electronics component.
4. Lay the MMC system on the work surface. If there are no optional modules
attached, remove the cover by removing the five screws, two on top, two on the
bottom, and one on the right side of the MMC.
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If there are one or more optional modules attached, remove the four screws that
attach the first optional module and remove the MMC from the optional modules.
DO NOT touch any of the capacitors. Do not touch the pins on any
of the ICs. Even with precautions against static you may destroy the
circuitry.
5. Refer to Figure 4-22 for the location of the battery. Note how the polarity markers are oriented.
WARNING
Figure 4-22: Battery Location in MMC
Connectors
Battery
Clip
Not all components shown
6. Use a screwdriver to gently pry up the battery clip. Slide the battery out.
Replace it with a 3V coin cell, BR2032 battery, + side up.
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7. Screw the cover or optional modules back on. Return the MMC to the cabinet.
Connect the power cable. Turn on power and check the lights.
4.10 Specifications
Table 4-38: Part Numbers
Characteristic MMC Specifications
Model Part Number Speed
MMC-A2 M.1017.3772 Std. 256K 128K 64K 2 2 2 2 2 1
MMC-A2
Plus
MMC-A4 M.1017.3774 Std. 256K 128K 64K 4 4 4 4 2 1
MMC-A4
Plus
MMC-S8 M.1017.3770 Std. 256K 128K 64k 8 8 8 4
* Using features such as servo tasks, S-curve, RATIO_RL, M_LINCIR, M_SCRVLC, PLS, and CAM_OUT
places a heavier burden on available CPU time. Consult G&L Motion Control for assistance if you want to
exceed the number of axes in this chart.
M.1302.7095 X3 256K 128K 64K 18 18 16 8 3 1
M.1302.7096 X3 256K 128K 64K 20 20 16 8 3 1
App
Mem
RAM
Mem
User
Mem
Number of servo axes available
at six update rates*
8
ms4ms2ms1ms.5ms
.25
ms
Table 4-39: General Specifications
CPU 32 bit RISC processor with numeric coprocessor
Battery 3V Coin Cell, BR2032 lithium battery
CAUTION for Lithium Batteries
Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type
recommended by the manufacturer. Dispose of used batteries according to the manufacturer’s instructions.
Flash Disk 2 Megabytes
Memory See Table 4-38 above.
PiCPro Port (to workstation) RS232 serial port, secured protocol.
Software selectable baud rate to 57.6K
User Port (to serial interface device) RS232/RS485 serial port
Supports RTS/CTS hardware handshaking
Software selectable baud rate to 19.2K
Input voltage 20 VDC to 30 VDC
Input power MMC: 250 mA plus I/O power
MMC Plus: 450mA plus I/O power
Time-of-day clock
Clock tolerance
Operating temperature range 5°C to 55°C (41°F to 131°F)
Storage temperature range -40°C to 85°C (-40°F to 185°F)
Humidity 5 to 95%, non-condensing
Access via PiCPro 10.2 and above or your application program
At 25°C (77°F),±1 second per day
Over temperature, voltage and aging variation,
+2/-12 seconds per day
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CE Marked Conforms to Directives 73/23/EEC, 89/336/EEC, 92/31/EEC, 93/
68/EEC by conforming to the following standards:
EN 50081-2:1993EMC Generic Industrial Emissions
EN 50082-2:1995EMC Generic Industrial Immunity
EN 61131-2:1994/A11:1996 Low voltage directive requirements for
programmable controllers
Operates with emissions below EN55011/ CISPR 11
Class A limits
Immune to:
•Electrostatic discharge (4K V contact mode, 8K V air discharge)
per EN61000-4-2
•RF electromagnetic fields per EN61000-4-3, ENV 50141, and
ENV50204
•Electrical fast transients per EN61000-4-4
•Magnetic fields per EN61000-4-8
Refer to the EMC Guidelines for more information.
UL and C/UL Listed E126417
Physical size 2.25" wide x 9.6" high x 5.3" deep
57.15 mm x 243.84 mm x 134.62 mm
Vibration (per IEC 68-2-6) 10-57 Hz (constant amplitude = .15 mm)
57 - 2000 Hz (acceleration = 2 g)
Shock (per IEC 68-2-27) Four shocks per axis (15g/11 msec)
Axis Port Analog Output
Output channels 2 or 4
Resolution 16 bits
Output voltage range ±10 VDC
Maximum output current (1K Ω load) ±10 mA
Power on output voltage 0 V ±100 mV
Scan loss output voltage 0V ±100 mV
Accuracy ±0.375% of FSR Drift ± 50ppm/°C
Update rate 68 µsec
Aux Port Analog Input
Input channel 1
Resolution 12 bits
Input voltage range ±10 V
Accuracy ±0.2% of FSR
Sample rate 100 µsec
Common mode filter 3 dB @ 10 K Hz
Differential mode filter 3 dB @ 475 Hz
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Axis Port & Aux Port Encoder Input
Input channels 3 or 5
Input receiver 26C32 differential RS422 receiver
Recommended Encoder Drivers 7272, 75183, 8830, 75114, 9614, 26LS31 (or equivalent)
Encoder signals Differential quadrature
Input threshold ±750 mV
Input termination 120 ohm, provided on board
Maximum input voltage 5 V
Maximum A or B input frequency 250 K Hz (1 M feedback unit count rate)
Fast input voltage Nominal 24 VDC, maximum 30 VDC
Guaranteed on voltage 15 VDC
Guaranteed off voltage 5 VDC
Turn on/off time 1 ms
Axis Port, Aux Port, and Gen I/O Port DC Inputs
Configuration The general inputs are divided into two groups of eight. Each group
can be configured for sourcing or sinking. The auxiliary inputs are
divided into two groups of six inputs. Each group can be configured
for sourcing or sinking. The axis inputs have one input per axis.
Each input can be configured for sourcing or sinking.
Operates with IEC Type 1 inputs (per IEC 1131=2).
Input voltage Nominal 24 VDC, maximum 30 VDC
Guaranteed on voltage 15 VDC
Guaranteed off voltage 5 VDC
Turn on/off time 1 ms
Fast inputs 50 μsec
Gen I/O Port DC Outputs
Number of outputs 16 outputs
Input voltage Nominal 24 VDC, 30 VDC maximum
Configuration Two groups of eight solid-state switches.
Protection of logic circuits Optical isolation between the logic and field side, transient
suppression on the 24V external supply
Maximum current .25 A per output
Voltage range 24 VDC nominal, 5 to 30 VDC
Switch characteristics Solid-state switches
Time delay on for resistive loads 50 µsec max
Time delay off for resistive loads 50 µsec max
Leakage current in off state 0.5 mA max
Switch voltage, maximum ON 1 VDC max
Short circuit protection for each group 15 A (max) pulses for about 130 µsec every 100 msec until short is
removed
Scan loss response Outp uts turn off
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Axis Port DC Outputs
Number of outputs 2 outputs per axis
Configuration Each set of axis outputs can be configured as sourcing or sinking.
Maximum current 100 mA per output
Voltage range 24 VDC nominal, 5 to 30 VDC range
Scan loss response Outputs turn off
Aux Port +5 Vdc Output
+5 VDC 150 mA maximum current available. Connections to this point
should be over short distances and away from electric noise signals.
SERCOS Motion Board
SERCOS Interface Interfaces with one ring with from one to eight digital drives
SERCOS port SMA female connectors for interfacing to 1000 µ meter plastic fiber
optic cable with SMA male connectors.
Fiber optic receiver specifications:
Peak input power (optical level low) -31.2dBm max
Peak input power (optical level high) -20.0 dBm min,
0.0dBm max
Fiber optic transmitter specifications:
Peak output power (optical level high) is -10.5 dBm min,
-5.5 dBm max
Update loader port RS232 interface
Type Plastic with step index profile (POF)
Core diameter
Fiber diameter
Operating temperature 0° C to 55° C (32° F to 131° F)
Minimum bend radius One time: 30 mm
T ensile strength One time: 250 N
Connectors SMA sty le male
980 µm ±60 µm
1000 µm ±60 µm
Continuous: 80 mm
Continuous: 100 N
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5 Standalone Digital MMC Control
5.1 Introduction
This section contains information for the Standalone Digital MMC Control
only. Information on the Standalone MMC Control is contained in Section 4
on page 29. Block I/O information can be found in the Block I/O Hardware
Manual. Software information can be found in the PiCPro online help, the
Function/Function Block Reference Guide, ASFB Manuals or on-line.
5.2 Features
• 400 Mhz Celeron Processor with 256 Kbytes of level 2 cache
• 3 Mbytes of Application Memory
• 960 Kbytes of RAMDISK Memory
• 192 Kbytes of Data Memory
• 100Base-T Ethernet port
• PicPro RS232 port, baud rates up to 115.2 Kbaud
• User RS232/RS485 port, R TS/CTS handshaking, baud rates up to
115.2 Kbaud
• Battery-backed time-of-day clock
• Application stored in battery-back RAM
• Block I/O port for I/O expansion
• Up to 4 MMC Option Modules can be user-installed
• 32 and 64 axis versions available
• PicPro USB high speed peripheral port (future)
• User USB high speed peripheral port (future)
• Compact Flash memory socket (future)
• UL Listed and CE Marked.
5.3 Overview
The Standalone Digital MMC-D64 Control can control up to 64 Digital
MMC Smart Drives (32 drives on the -D32), providing 64 (32) axis of servo
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control. I/O can be added using G&L Motion Control’s serially distributed
Block I/O.
Additionally, a maximum of four field-installable Option Modules can be
added directly to the Control, as follows:
• Up to two MMC Communications Option Modules (Profibus or
DeviceNet).
• Up to four MMC 32 In/32 Out Option Modules.
5.4 Power Supply Requirements
The Standalone Digital MMC Control is powered by user-supplied 24 Vdc
(nominal). The maximum power consumption is 1A (24 W). Also, MMC
Option Modules attached to the Standalone Digital MMC Control draw
power from the Control’s 24 Vdc connector. When determining the size of
the 24 Vdc power supply, use the worksheet found in Table 5-1.
Table 5-1: Power Supply Worksheet
MMC Module
64 Axis Standalone Digital MMC
Control (-D64)
32 Axis Standalone Digital MMC
Control (-D32)
Axis I/O Option Module 100
MMC Ethernet Option Module 200
MMC DeviceNet Option Module 100
MMC Profibus Option Module 100
MMC 32 In/32 Out Option
Module
Required power supply current (Add Column A)
Current
(mA)
1,000
900
100
# of
Units
Col A
Subtotal
(mA)
Col B
Current
(mA)
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