Intelligent Motion Systems MDI42 AC User Manual

Patent Pending

Excellence in Motion

TM

42

MOTION CONTROL

(with optional CANopen)

TM

FEATURES

• Highly Integrated Microstepping Driver/
Intelligent Motion Controller with Optional
Encoder/NEMA 42 High Torque 1.8°
Brushless Step Motor

• Advanced 2nd Generation Current
Control for Exceptional Performance
and Smoothness

• Single Supply: 120 or 240 VAC

• Cost Effective

• Extremely Compact

• High Positioning Accuracy

• No Tuning Required

• Stable at Low Speeds

• No Dithering at Zero Speed

• High Starting Torque

• Allows for Greater Inertia Mismatch

• Built-in Regeneration Circuitry

• Available Options:

- Integral Optical Encoder for Closed
Loop Control

- External/Remote Encoder (not supplied)
for Closed Loop Control

- Control Knob for Manual Positioning

- Integrated Planetary Gearbox

- IP65 Sealed Confi guration**

• Two Motor Lengths Available

• Auxiliary Logic Power Supply Input

• Up to 5 MHz Step Clock Rate

• 20 Microstep Resolutions up to
51,200 Steps Per Rev Including:
Degrees, Metric, Arc Minutes

• Open or Optional Closed Loop Control

• Programmable Motor Current

• Up to Eight +24 VDC Tolerant I/O Lines,
Sourcing or Sinking

• One 10 Bit Analog Input Selectable: 0 to +5
VDC, 0 to +10 VDC, 0-20 mA, 4-20 mA

• RS-422/485 or Optional CANopen
Communications

• 62 Software Addresses for Multi-Drop
Communications

• High Speed Position Capture Input or Trip
Output

• Electronic Gearing

**Consult Factory for Availability.

DESCRIPTION

The MDrive42AC Plus2 Motion Control
system of fers de sign ers a cost effec­tive, full featured programmable motion
con trol ler in te grat ed with a NEMA 42 high
torque 1.8° brushless step motor and a
microstepping driver operating at 120 or
240 VAC.

Unsurpassed smoothness and perfor­mance delivered by the MDrive42AC are
achieved through IMS's advanced 2nd
generation current control. By applying
innovative techniques to control current
fl ow through the motor, resonance is sig­nifi cantly dampened over the entire speed
range and audible noise is reduced.

The MDrive42AC accepts a broad input
voltage range from 95 to 264 VAC, deliv­ering enhanced performance and speed.
Oversized input capacitors are used to
minimize power line surges, reducing
problems that can occur with long cable
runs and multiple drive systems. An ex­tended operating range of –40° to +75°C
provides long life, trouble free service in
demanding environments.

The MDrive42AC Plus
system adds a versatile array of func tions
by com bin ing a full featured pro gram ­ma ble mo tion controller with our com pact
and cost ef fec tive MDrive42AC Micro­stepping products, adding little cost and
no increase in size. Stan dard of fer ings
include up to 8 general pur pose I/O lines
(sourcing or sinking) that operate to +24
VDC, one 10 bit analog in put, electronic
gearing, high speed position capture
input/trip output, microstep res o lu tions up
to 51,200 steps per rev o lu tion, 0 to 5 MHz
step clock rate, and a full fea tured easy­to-program in struc tion set.

The MDrive42AC Plus
system com mu ni cates over RS-422/485
which al lows for point-to-point or multiple
unit con fi g u ra tions utilizing one com mu -
ni ca tion port. Addressing and hard ware
support multiple uniquely addressed units
com mu ni cat ing over a single line.

2

Motion Control

2

Motion Control

Optional communication protocols
include CANopen. The CAN bus is 2.0B
active (11 and/or 29 bit) and is capable
of all standard frequencies from 10 kHz
to 1 MHz. CANopen features include
node guarding, heartbeat producer,
SDOs and PDOs. Highlights include
variable PDO mapping and extended
node identifi er.

The MDrive42AC Plus
is available with optional closed loop
control. This increases functionality by
adding stall detection, position mainte­nance and fi nd index mark.

The closed loop confi guration is added
via a 512 line (2048 edge) optical
encoder with index mark, internal to the
MDrive42AC so there is no increase in
length. Or, for an expanded choice of
line counts and resolutions, closed loop
control is available with an interface
to a remotely mounted user-supplied
external encoder.

In addition to encoder options, the
MDrive42AC Plus
the capability of electronic gearing by
following a rotary or linear axis at an
electronically controlled ratio, or an
output clock can be generated fi xed to
the internal step clock.

A sealed version designed to meet
IP65 specifi cations is also available.
The sealed assembly allows the
MDrive42AC to be used in environ­ments where exposure to chemical,
dust and liquids may occur.

Two rotary motor lengths are available
as are linear actuators with long life
Acme screw**.

In ter face con nec tions are ac com plished
using standard industrial circular con­nectors. And connectivity has never
been easier with options ranging from

all-inclusive QuickStart Kits to indi­vidual interfacing cables.

2

Motion Control

2

Motion Control has

See pg 5.

new

www.imshome.com

MDrive

42AC Plus

2

MOTION CONTROL

GENERAL SPEC I FI CA TIONS

INPUT VOLTAGE

AUX. LOGIC INPUT VOLTAGE

ANALOG INPUT

GENERAL PURPOSE I/O

COMMUNICATION

MOTION

SOFTWARE

THERMAL

PROTECTION

†

Designed for line-neutral systems.

‡

Adjusting the microstep resolution can increase the range.

Range

Range

Resolution 10 Bit
Voltage Range 0 to +5 VDC,
Number/Type 8 Sourcing or Sinking (or 4 when Remote Encoder Option is Selected)

Logic Range

Output Sink/Source Current Up to 600 mA per Channel
Protection Over Temp, Short Circuit, Transient Over Voltage, Over Voltage, Inductive Clamp
Type (Standard) RS-422/485
Baud Rate 4800 to 115.2kbps
Type (Optional) CANopen DSP-402 (V2.0), DS-301 (V3.0), 2.0B Active
ID 11 and/or 29 Bit
Isolation Galvanic
Features Node Guarding, Heartbeat, SDOs, PDOs (Variable Mapping)

Open Loop
Confi guration

Closed Loop
Confi guration
(Optional)

Counters

Velocity

Accel/Decel

Electronic Gearing

High Speed I/O

Program Storage Type/Size Flash/6384 Bytes
User Registers (4) 32 Bit
User Program Labels and

Variables
Math Functions +, –, ×, ÷, >, <, =, <=, >=, AND, OR, XOR, NOT
Branch Functions Branch & Call

General Purpose I/O
Functions

Trip Functions Trip on Input, Trip on Position, Trip on Time, Trip Capture
Party Mode Addresses 62
Encoder Functions Stall Detection, Position Maintenance, Find Index

Operating Temperature

Type Thermal, Internal Fuse

Internal
Encoder

Remote
Encoder

120 V MDrive – 95 to 132 VAC @ 50/60 Hz
240 V MDrive – 95 to 264 VAC @ 50/60 Hz

+12 to +24 VDC

Maintains power to control and feedback circuits (only) when input voltage is removed.

0 to +10 VDC, 0-20 mA or 4–20 mA

+5 to +24 VDC – Inputs and Sinking Outputs; Inputs TTL Level Compatible
+12 to +24 VDC – Sourcing Outputs

Number of Settings

Steps Per Revolution

Type Internal,
Steps Per Revolution 51200
Resolution 512 Lines/2048 Edges Per Rev
Type User-Supplied Differential Encoder

Steps Per Revolution

Resolution

Type Position, En cod er/32 Bit
Edge Rate (Max) 5 MHz
Range +/- 5,000,000 Steps Per Second
Resolution 0.5961 Steps Per Second
Range 1.5 x 10
Resolution 90.9 Steps Per Second
Range‡/Resolution/Threshold

(External Clock In)
Input Filter Range 50 nS to 12.9 µS (10 MHz to 38.8 kHz)
Range‡ (Secondary Clock Out) 1 to 1

Position Capture

Trip Output – Speed/Resolution/
Threshold

192

Inputs

Outputs Moving, Fault, Stall,

Heat Sink –40° to +75°C (non-condensing)
Motor –40° to +90°C (non-condensing)

Input Filter Range 50 nS to 12.9 µS (10 MHz to 38.8 kHz)
Resolution 32 Bit

†

20

200,

400, 800, 1000, 1600, 2000, 3200, 5000,
6400, 10000, 12800,
40000, 50000, 51200, 36000 (0.01 deg/µstep),
21600 (1 arc minute/µstep), 25400 (0.001mm/µstep)

Optical

200,

400, 800, 1000, 1600, 2000, 3200, 5000,
6400, 10000, 12800,
40000, 50000, 51200, 36000 (0.01 deg/µstep),
21600 (1 arc minute/µstep), 25400 (0.001mm/µstep)

User-Defi ned
Note: µstep/rev 2X the encoder count/rev minimum

9

Steps Per Second

0.001 to 2.000/32 Bit/TTL

150 nS/32 Bit/TTL

Home, Limit Plus, Limit Minus, Go, Stop, Pause, Jog
Plus, Jog Minus, Analog In, General Purpose

20000, 25000, 25600,

20000, 25000, 25600,

2

2

Velocity Change, General Purpose

MOTOR SPECIFICATIONS

Holding Torque Detent Torque Rotor Inertia Weight (Motor+Driver)

SINGLE LENGTH

DOUBLE LENGTH

2 MDrive42AC Plus2 Motion Control REV060208

1147 oz-in / 810 N-cm 35 oz-in / 25 N-cm

2294 oz-in / 1620 N-cm 84 oz-in / 59 N-cm

0.0917

0.1833

oz-in-sec2 / 6.5

oz-in-sec2 / 13.0

kg-cm

kg-cm

2

14.07 lb / 6.38 kg

2

21.25 lb / 9.64 kg

SPEED-TORQUE

T

i
N

PIN ASSIGNMENTS

MDrive42AC – 120VAC

1800

1600

1400

1200

1000

800

600

Torque in Oz-In

400

200

0

0 2000

(600)

4000

(1200)

Speed – Full Steps/Second (RPM)

MDrive42AC – 240VAC

1800

1600

1400

1200

1000

800

600

Torque in Oz-In

400

200

0

0 2000

(600)

Speed in full steps per second (RPM)

4000

(1200)

Double Motor Length
Single Motor Length

6000

(1800)

Double Motor Length
Single Motor Length

6000

(1800)

8000

(2400)

8000

(2400)

10000
(3000)

10000
(3000)

1271

1130

989

847

706

565

424

282

141

1271

1130

989

847

706

565

424

282

141

Torque in N-cm

orque

n

-cm

P1: I/O CONNECTOR

M23 Circular

(Male)

Expanded I/O Remote Encoder Closed Loop Control

Function

Pin 1 I/O 9 Channel A +
Pin 2 I/O 11 Channel B +
Pin 3 Step/Clock I/O Index +
Pin 4 I/O 1 I/O 1
Pin 5 Direction/Clock I/O Index –
Pin 6

No Connect No Connect
Pin 7 Aux-Logic (+12 to +24 VDC) Aux-Logic (+12 to +24 VDC)
Pin 8 Aux-Ground Aux-Ground
Pin 9 I/O 3 I/O 3

Pin 10 I/O Ground I/O Ground
Pin 11 I/O Power I/O Power
Pin 12 Shell Connect Shell Connect
Pin 13 I/O 12 Channel B –
Pin 14 Capture/Trip I/O Capture/Trip I/O
Pin 15 Analog In Analog In
Pin 16 I/O 2 I/O 2
Pin 17 I/O 4 I/O 4
Pin 18 I/O 10 Channel A –
Pin 19

P2: COMM CONNECTOR

RS-422/485 CANopen

M12

Circular

Function

(Female)

Pin 1 TX – Pin 1 Shield

No Connect No Connect

P3: POWER CONNECTOR

Euro AC

M12

Circular

(Male)

Function

(Male)

Pin 1

Chassis Ground
Pin 2 AC Power Line
Pin 3 AC Power Neutral

Function

Pin 2 TX + Pin 2 CAN +V
Pin 3 RX + Pin 3 CAN –V
Pin 4 RX – Pin 4 CAN High
Pin 5 Comm Ground Pin 5 CAN Low

MECHANICAL SPECIFICATIONS

Dimensions in Inches (mm)

MDrive42AC Plus

MDrive Lengths Inches (mm)

Motor
Length

ENCODER VERSION

Single 7.4 (187.96) 9.4 (238.76)
Double 9.4 (238.76) 11.4 (289.56)

2

L

MAX2

L

MAX

L

MAX

SINGLE SHAFT or

0.49

(12.5)

L

MAX2

VERSION

CONTROL KNOB

L

MAX2

0.059
(1.5)

Option

Ø 1.90

(Ø 48.3)

2.17

(55.0)

1.375
(34.9)

0.75

(19.05)

(Ø 22.1)

0.335

(8.51)

Ø 2.185

(Ø 55.5)

Ø 0.75

(Ø 19.05)

Connectors

Ø 0.87

3.0

(76.2)

P1

P2

P3

0.1875

0.83

(21.08)

4.50

(114.3)

I/O Comm Power

Ø 0.53

(Ø 13.5)

Ø 0.87

(Ø 22.1)

0.65

(16.51)

3.50 SQ.

(88.88 SQ.)

4.331 SQ.

(110.0 SQ.)

(4.76)

*CANopen option increases
overall height by 0.09"/2.0mm

7.4

(187.96)

6.75

(171.45)

Connectivity details:
www.imshome.com/cables_cordsets.html

Control Knob

P1: 19-Pin M23

(Male)

P2: 5-Pin M12 (Female)

(or CANopen – Male)

P3: 3-Pin Euro AC

(Male)

MDrive42AC Plus2 Motion Control REV060208 3

(

)

(

)

MDRIVE42AC PLUS WITH PLANETARY GEARBOX

The MDrive42AC Plus is available with a Planetary Gearbox option developed to increase torque at lower speeds, enable better
inertia matching and produce fi ner positional resolutions. These effi cient, low maintenance Planetary Gearbox come fully assembled
with the MDrive and are offered in a large number of reduction ratios in 1-, 2- and 3-stage confi gurations. An optional NEMA Output
Flange allows mounting the Planetary Gearbox to the load using a standard NEMA bolt circle. Planetary Gearbox may be combined
with other MDrive42AC Plus options, however are unavailable with Linear Actuators.

Planetary Gearbox Parameters

1-STAGE

2-STAGE

PM105

3-STAGE

1-STAGE

2-STAGE

PM120

3-STAGE

Permitted

Output Torque

(oz-in/Nm)

4956/35.0 0.80 1.0° 135/600 27/120 9.7/4.4 10.0/4.5

14869/105.0 0.75 1.5° 202/900 40/180 13.2/6.0 13.6/6.2

27614/195.0 0.70 2.0°

7080/50.0 0.80 0.55° 135/600 27/120 12.3/5.6 12.7/5.8

21242/150.0 0.75 0.60° 202/900 40/180 17.6/8.0 18.1/8.2

42484/300.0 0.70 0.65°

Gearbox

Effi ciency

Maximum

Backlash

Planetary Gearbox for MDrive42Plus

Dimensions in Inches (mm)

PM105 Model

*Gearbox without Flange

†Gearbox with Flange

M8 x 0.630 (16.0) Deep*

4x 0.33 (Ø 8.5) Hole

4.20 SQ.
(106.7 SQ.)

†

3.35 ±0.004 SQ.*

(85.0 ±0.1 SQ.)

3.50

88.9

†

†

Ø 0.98

Ø 2.187

(Ø 55.54)

(Ø 25.0)

Ø 2.76*

(Ø 70.0)

or

Ctrg. DIN 332-D M10

Key DIN 6885-A-8x7x40mm

PM120 Model

*Gearbox without Flange
†Gearbox with Flange

M10 x 0.866 (22.0) Deep*

4x 0.35 (Ø 9.0) Hole

†

Ø 3.15*

(Ø 80.0)

or

†

Ø 2.187

(Ø 55.54)

Ø 1.26

(Ø 32.0)

Output Side with Ball Bearing

Maximum Load

(lb-force/N)

Weight

(lb/kg)

Radial Axial Gearbox w/Flange

337/1500

337/1500

2.33 ±0.02*
(59.1 ±0.5)

or

2.04 ±0.02
(51.7 ±0.5)

†

67/300

67/300

*

0.20
(5.0)

0.35*

(9.0)

0.50

(12.7)

16.8/7.6 17.3/7.8

22.9/10.4 23.5/10.7

k1 ±0.02 (±0.5)

†

0.079

or

(2.0)

Ø 4.13

(Ø 105.0)

†

Gearbox Lengths Inches (mm)

0.079
(2.0)

0.24

(6.2)

k1

†

†

2.86 ±0.02*
(72.7 ±0.5)

or

2.53 ±0.02
(64.2 ±0.5)

1-Stage
2-Stage
3-Stage

†

GEARBOX* with FLANGE

5.73 (145.5) 5.9 (149.9)

7.07 (179.6) 7.13 (181.0)

8.41 (213.7) 8.35 (212.0)

k1 ±0.02 (±0.5)

0.20*

or

(5.0)

0.59*

or

(15.0)

Ratios and Part Numbers

Planetary

Gearbox

1-Stage
1-Stage
1-Stage

2-Stage
2-Stage
2-Stage
2-Stage
2-Stage
2-Stage
2-Stage
2-Stage
2-Stage
2-Stage

3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage

MDrive42AC Plus

3-Stage
3-Stage
3-Stage
3-Stage
3-Stage
3-Stage

**Indicates limited ratios available for PM120 gearbox.

†

‡ Include optional planetary gearbox by adding –G plus
3 characters to the end of an MDrive part number.

Ratio

(Rounded)

3.71:1 ** G1A1 G2A1

5.18:1 G1A2 —

6.75:1** G1A3 G2A3

13.73:1** G1A4 G2A4

15.88:1 G1A5 —

18.37:1 G1A6 —

19.20:1 G1A7 —

22.21:1 G1A8 —

25.01:1** G1A9 G2A9

26.85:1 G1B1 —

28.93:1 G1B2 —

34.98:1 G1B3 —

45.56:1** G1B4 G2B4

50.89:1** G1B5 G2B5

58.86:1 G1B6 —

68.07:1 G1B7 —

71.16:1 G1B8 —

78.72:1 G1B9 —

92.70:1** G1C1 G2C1

95.18:1 G1C2 —

99.51:1 G1C3 —

107.21:1 G1C4 —

115.08:1 G1C5 —

123.98:1 G1C6 —

129.62:1 G1C7 —

139.14:1 G1C8 —

149.90:1 G1C9 —

168.85:1** G1D1 G2D1

181.25:1 G1D2 —

195.27:1 G1D3 —

236.10:1 G1D4 —

307.55:1** G1D5 G2D5

Part Number

PM105

PM120

Model

‡

Model

4.33 SQ.
(110.0 SQ.)

3.50 SQ.

(88.9 SQ.)

3.94 SQ.*

100.0 SQ.

†

Ctrg. DIN 332-D M12

Key DIN 6885-A-10x8x50mm

4 MDrive42AC Plus2 Motion Control REV060208

Ø 4.72

(Ø 120.0)

†

0.59

(15.0)

Gearbox Lengths Inches (mm)

GEARBOX* with FLANGE

1-Stage
2-Stage
3-Stage

6.23 (158.2) 6.58 (167.2)

7.57 (192.4) 7.93 (201.4)

8.92 (226.6) 9.28 (235.6)

MDrive42AC Plus

k1

†

ORDER INFORMATION — MDrive42AC Plus2 Motion Control

CONNECTIVITY

CONNECTING

QuickStart Kit

new

For rapid design verifi cation, all-inclusive QuickStart Kits have com­munication converter, prototype development cable(s), instructions
and CD for MDrivePlus initial functional setup and system testing.

Communication Converter

new

Electrically isolated, in-line con ver t er pre-wired with mating connec­tor to conveniently set/program communication parameters for a
single MDrivePlus via a PC's USB port. Length 12.0' (3.6m).
Mates to connector:

5-Pin M12 ............................................MD-CC401-001

5-Pin M12 CANopen ..............................MD-CC500-000*

*Requires mating connector adapter and power supply, not supplied.

Prototype Development Cables

Speed test/development with pre-wired mating connectors that
have fl ying leads other end. Single-ended cordsets are PVC jack­eted with foil shield and unconnected drain wire. Length 13.0'
(4.0m).
Mates to connector:
19-Pin M23

Straight Termination ..........................MD-CC100-000

Right Angle Termination .....................MD-CC101-000

3-Pin Euro AC

Straight Termination ..........................MD-CC200-000

Right Angle Termination .....................MD-CC201-000

PART NUMBERING

K

**

QuickStart Kit
details above

2

Plus

expanded features

Plus2-65

IP65 sealed

**Consult Factory for Availability.

MDI M Q4 2 –

MDrive Version

2

3 = Plus
4 = Plus2-65 (sealed)**

P1: I/O, 19-Pin M23 Circular Connector
P3: Power, 3-Pin Euro AC Connector

P2: Communications, 5-Pin M12
Circular Connector

Example #1: Part Number MDI3MRQ42B2
MDrive42AC Plus
circular I/O interface, RS-422/485 communications
with 5-pin M12 circular connector, NEMA 42 double
length motor and 240 input voltage.

Communications

R = RS-422/485
C = CANopen

2

Motion

Motor

A = Single Length
B = Double Length

Control with 19-pin M23

OPTION

Input Voltage

1 = 120 Volt
2 = 240 Volt

is an

OPTIONS

OPTIONS

Internal Encoder

An internal 512-line (2048 count) differential optical

encoder with index mark is available factory-mounted.

Remote Encoder

This MDrivePlus Motion Control is offered with differential en-

coder inputs for use with a remote encoder (not supplied).

Control Knob

For manual shaft positioning, a factory-mounted rear control

knob is available.

Planetary Gearbox

Effi cient, low maintenance planetary gearboxes are

offered factory-mounted. Refer to details and part num­bers on the back cover.

** Consult Factory for Availability.
‡ Not Available with Sealed –65 Versions.

Connectivity details: www.imshome.com/cables_cordsets.html

‡

OPTIONS

Internal
Encoder

Example: MDI3MRQ42B2–EQ adds a 512-line internal
optical encoder with index mark to example #1.

Remote
Encoder

Example: MDI3MRQ42B2–EE adds differential encoder inputs for
use with remote encoder (not supplied).

May not be combined with internal encoder option.

Control
Knob

Example: MDI3MRQ42B2–N adds a rear control knob to
example #1.

Planetary
Gearbox

Refer to gearbox page for complete
table of ratios and part numbers.

Example: MDI3MRQ42B2–G1A2 adds a PM105 1-stage
planetary gearbox with 5.18:1 ratio to example #1.
Add –F for optional NEMA flange.

–EQ

–

EE

–N

Not available with sealed –65 versions.

–G

– F

Optional NEMA Flange

U.S.A. SALES OFFICES
Eastern Region

Tel. [phone] - Fax [phone]
e-mail: [e-mail]

Central Region

Tel. [phone] - Fax [phone]
e-mail: [e-mail]

Western Region

Tel. [phone]

[e-mail]

e-mail:

IMS ASIA PACIFIC OFFICE

30 Raffl es Pl., 23-00 Caltex House
Tel. [phone] - Fax [phone]
e-mail: [e-mail]

, Singapore 048622

IMS EUROPEAN SALES MANAGEMENT

4 Quai Des Etroits
69005 Lyon, France
Tel. [phone] - Fax [phone]
e-mail: [e-mail]

IMS UK Ltd.

Sanderson Centre, 15 Lees Lane
Gosport, Hampshire PO12 3UL
Tel. [phone] - Fax [phone]
e-mail: [e-mail]

TECHNICAL SUPPORT

Tel. [phone] - Fax [phone]
e-mail: [e-mail]

Intelligent Motion Systems, Inc.

370 North Main Street, P.O. Box 457

Marlborough, CT 06447 - U.S.A.

Tel. [phone] - Fax [phone]

e-mail: [e-mail]

http: //www.imshome.com

© Intelligent Motion Systems, Inc. All Rights Reserved. REV060208

IMS Product Disclaimer and most recent product information at www.imshome.com.