MAC050 - MAC141
&
MAC400 - MAC800
Integrated Servo Motors
User Manual
Including expansion modules
JVL Industri Elektronik A/S
LB0047-24GB Revised 17.9.2009
Important
User Information
!!
The MAC series of products are used to control electrical and
mechanical components of motion control systems.
You should test your motion system for safety under all potential
conditions. Failure to do so can result in damage to equipment
and/or serious injury to personnel.
Please contact your nearest JVL representative in case of technical assistance. Your nearest contact can be found on our web site www.jvl.dk
Copyright 1998-2009, JVL Industri Elektronik A/S. All rights reserved.
This user manual must not be reproduced in any form without prior written
permission of JVL Industri Elektronik A/S.
JVL Industri Elektronik A/S reserves the right to make changes to information contained in this manual without prior notice.
Similarly JVL Industri Elektronik A/S assumes no liability for printing errors
or other omissions or discrepancies in this user manual.
Warning
MacTalk and MotoWare are registered trademarks
JVL Industri Elektronik A/S
Blokken 42
DK-3460 Birkerød
Denmark
Tlf. +45 45 82 44 40
Fax. +45 45 82 55 50
e-mail: jvl@jvl.dk
Internet: http://www.jvl.dk
Contents
1 Introduction .................................................................................................................... 3
1.1 Features .............................................................................................................................................................. 4
1.2 Overall description ............................................................................................................................................. 5
1.3 Expansion modules overview ............................................................................................................................. 8
1.4 Setting up the MAC motor ............................................................................................................................... 12
2 Function description ..................................................................................................... 17
2.1 Using Position mode ......................................................................................................................................... 18
2.2 Gear Mode ........................................................................................................................................................ 19
2.3 Coil Mode ......................................................................................................................................................... 22
2.4 Analogue bi position mode ............................................................................................................................... 25
2.5 Mechanical zero search ..................................................................................................................................... 26
2.6 Error Handling .................................................................................................................................................. 31
2.7 Under Voltage Handling .................................................................................................................................... 42
2.8 Servo filter adjustment ...................................................................................................................................... 43
2.9 Using external SSI encoder ............................................................................................................................... 49
2.10 Power Save ....................................................................................................................................................... 55
2.11 Scope Function ................................................................................................................................................. 56
3 Hardware description ................................................................................................... 57
3.1 Connector overview......................................................................................................................................... 58
3.2 Power Supply.................................................................................................................................................... 59
3.3 Serial interface .................................................................................................................................................. 69
3.4 User I/O ............................................................................................................................................................ 70
4 Expansion Modules ....................................................................................................... 77
4.1 Expansion Modules MAC00-CS ........................................................................................................................ 78
4.2 Expansion Modules MAC00-B1/B2/B4 ............................................................................................................. 79
4.3 Expansion module MAC00-B41 ........................................................................................................................ 95
4.4 Expansion Modules MAC00-FC2/FC4 ............................................................................................................ 109
4.5 Expansion Module MAC00-FD4 ..................................................................................................................... 166
4.6 Expansion Module MAC00-FP2/FP4 .............................................................................................................. 180
4.7 Expansion Module MAC00-FS1/FS4 ............................................................................................................... 199
4.8 Expansion module MAC00-P5 ........................................................................................................................ 204
4.9 Expansion Module MAC00-R1/R3/R4 ............................................................................................................. 213
5 Appendix ..................................................................................................................... 251
5.1 Technical Data ................................................................................................................................................ 252
5.2 Torque Curves ................................................................................................................................................ 255
5.3 Efficiency curve ............................................................................................................................................... 257
5.4 Physical Dimensions ........................................................................................................................................ 258
5.5 Life time .......................................................................................................................................................... 261
5.6 Installation precautions ................................................................................................................................... 264
5.7 Emergency stop considerations ...................................................................................................................... 265
5.8 Trouble-shooting guide ................................................................................................................................... 271
5.9 Bus serial communication ............................................................................................................................... 273
5.10 Serial communication ...................................................................................................................................... 276
5.11 MacTalk communication ................................................................................................................................. 283
5.12 Connecting to other equipment ..................................................................................................................... 288
5.13 Accessories ..................................................................................................................................................... 291
5.14 CE Declaration of Conformity ........................................................................................................................ 293
5.15 UL Certificate of Compliance ......................................................................................................................... 295
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 1
2 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1 Introduction
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 3
1.1 Features
The MAC series of brushless servo motors with
integrated electronics represents a major step forward in motion control systems. All of the necessary electronics for a servo system are integrated
into the motor itself.
Traditional motor systems typically have the controller and drive electronics placed some distance
away from the motor. This increases machine
costs and has the negative effect that installation
time and costs are a major part of the total ex
pense of building machinery.
The basic idea of the MAC motor is to minimise
these costs, but also to make a component that is
much better protected against electrical noise
which can be a typical problem when using long
cables between a controller and motor.
All user inputs and outputs are filtered, which
means that the MAC motors will work properly
even in an environment with a high level of electri
cal noise.
The major advantages are:
• Lower installation costs
• Faster installation
• Quiet and maintenance-free operation
• Replacement for pneumatic solutions
• Replacement for step motors, offering much
faster response
• Great flexibility due to many I/O possibilities and
many functions.
• Less machine space required.
• Fewer possibilities for wiring errors.
-
Main Features:
• Low cost and high performance make the
MAC series ideal for high-volume applica
tions
• Pulse and direction inputs make it possible
to replace step motors.
• Quadrature input for gearing applications.
•
±10V input for controlling speed and
torque
• 2 ch. Quadrature output to master control-
ler when used as driver.
• Accepts position and velocity commands
sent via RS232/422 interface.
• Wide supply voltage range 12 to 48VDC
and 90 to 240VAC.
• Excellent efficiency compared to
-
step motors.
• High resolution (4096/8000 cpr) compared
to cost.
• Wide variety of expansion modules which
can be mounted internally:
- Profibus DP module
- CAN-Open® or DeviceNet module
- Ethernet module
- nano-PLC w/graphic programming
- Several module connector options
- Custom-designed modules on request
• Outputs for In position and Error
indication.
• High order digital filter which only needs a
single inertia adjustment.
• Standard NEMA23 flange.
• Built-in sensors make the motor stay stationary when powering up.
• Easy and simple Windows program - MacTalk available for installation/setup.
• High-efficiency power stage keeps temperature at a low level.
• CE approved. UL recognized (MAC800)
-
4 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1.2 Overall description
P
l
S
i
l i
t
f
Basic MAC motor block diagram including motor and feedback devices
y
supp
ower
connector(s)
+12-48VDC
(+24V and
90-240VAC)
Ground
Switchmode
Power
Supply
Power Dump
for absorbing
regenerative
energy
3-phase
driver
Current
Sensing
U
3-phase
V
brushless
W
motor
AIN
Analogue
input ±10V
A+
A
Analogue input
Level shifter
and filter
2 channel
differential
Tr a n s c e i v e r
B+
User I/O connector
+5VDC Out
ace
er
n
a
connector
er
B
Output 1
Output 2
Receive
Tr a n s m i t
Ground
2 Digital NPN
outputs showing
motor status
Asynchronous
serial interface
16 (32) Bit
Microprocessor
( ) = Valid for MAC400 and MAC800
All the internal building blocks of the MAC motor are shown in the illustration above.
The central microprocessor takes care of all the processes in the motor via the various
High speed
A/D converter
High speed
digital logic
array
Memory
and system
control
A
B
HU
HV
HW
Optical
incremental
encoder
Hall
elements
TT0934GB
I/O blocks such as the serial interface, differential transceiver (Multifunction I/O) and the
motor driver sections.
Please notice that the MAC400 and MAC800 have 2 supply voltages.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 5
1.2 Overall description
Basic
Motor Type
MAC050
MAC95
MAC140
MAC141
MAC400
MAC800
Continuous
Torque
0.11 Nm
(15.58 oz-in)
0.22 Nm
(31.15 oz-in)
0.32 Nm
(45,32 oz-in)
0.48 Nm
(168 oz-in)
1.27 Nm
(180 oz-in)
2.38 Nm
(337 oz-in)
Peak
Torque
0.32Nm
(45,3 oz-in)
0.62 Nm
(87.8 oz-in)
0.9 Nm
(127.45 oz-in)
1.59 Nm
(225,16 oz-in)
3.8 Nm
(538,1 oz-in)
7.2 Nm
(1019.6 oz-in)
Power
(cont.)
46 Watt 4000 RPM
92 Watt 4000 RPM
134 Watt 4000 RPM
134 Watt 2700 RPM
400 Watt 3000 RPM
750 Watt 3000 RPM
The MAC motor is available in 6 different sizes: MAC050, MAC95, MAC140, MAC141,
MAC400 and MAC800, with continuous power ratings from 46W to 750W. The basic
functions and I/O features are the same for all models.
1.2.1 Basic modes/functions in the MAC motor
The MAC motor offers the following functions.
- Passive mode.
The motor will be in a completely passive state but communication is active and internal registers can be set up.
Nom.
Speed
Flange Total
length
NEMA23
57x57mm
(2.3”x2.3”)
NEMA23
57x57mm
(2.3”x2.3”)
NEMA23
57x57mm
(2.3”x2.3”)
NEMA23
57x57mm
(2.3”x2.3”)
60x60mm
(2.86”x2.86”)
80x80mm
(3,14”x3,14”)
111.2 mm,
(4,38”)
130.5 mm
(5.13”)
152.5 mm
(6”)
172.0 mm
(6.77”)
192.0 mm
(7.56”)
175 mm
(6,89”)
-Velocity mode.
The motor velocity can be controlled using MacTalk software or by sending commands via the serial interface.
- Position mode
The motor position can be controlled using MacTalk or by sending position commands via the serial interface.
- Gear mode
The position of the motor is controlled by the multifunction I/O, which is configured
as input. Either a pulse and direction signal can be applied or a quadrature A and B
signal from, for example, an incremental encoder.
Th is mode is very powerful if the MAC motor is used to upgrade a step motor system
or if the motor is used in electronic gear applications such as a flying saw where an
external encoder tracks the position of a moving object.
- Gear Follow Mode
Same mode as gear mode, except that the input pulses are not buffered so that control strictly follows the input pulses.
-Analogue Velocity Mode
The motor velocity is controlled by a voltage applied at the ±10V analogue input.
This mode can be used in several applications but typical applications include main
taining variable but constant speed in feeding mechanisms or as a slave driver in multiaxis systems with a master position controller for several axes.
-
(continued next page)
6 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1.2 Overall description
- Analogue Velocity (with deadband) Mode.
Same function as Analogue Velocity Mode but a deadband around zero is inserted.
The deadband is +/-600mV. This feature is useful if a potentiometer or similar device
is used to control the speed of the motor, since the motor will be stationary if the
input voltage is almost at zero.
- Analogue Velocity/Gear Mode.
This mode is similar to Gear mode but it is possible to increase or decrease the position of the motor by adjusting the voltage applied to the ±10V input. A typical application is feeding mechanisms that require “on-the-fly” adjustment.
- Velocity/Analogue torque Mode.
The motor torque is fully controlled by a voltage applied at the ±10V analogue input.
This mode is useful if the motor is used for winding applications where a constant
torque is required in the process. Another typical application is as a slave driver in
multi-axis systems with a master position controller for several axes. The update fre
quency is 521 Hz. Use Analogue Torque (Direct) if a higher bandwidth is required.
- Analogue Torque (Direct) Mode.
Same function as Analogue Torque mode but the update frequency is much higher
(7812Hz). Please note that the top speed and acceleration are NOT controlled in this
mode. Use Analogue Torque Mode if this limitation is required.
-
-Analogue Gear Mode.
This mode is somewhat similar to Gear mode or Analogue Velocity/Gear mode. The po-
sition of the motor is controlled by the multifunction I/O, which is configured as input.
Either a pulse and direction signal can be applied or a quadrature A and B signal from,
for example, an incremental encoder.
The gear ratio specified will determine the basic gear ratio between the applied pulses and the motor movement. The special feature in this mode is that the basic gear
ratio can be changed +/-5% depending on the voltage applied to the analogue input.
+10V will adjust the gear ratio +5% higher and -10V will lower the gear ratio 5%.
A typical application is feeding mechanisms that require “on-the-fly” adjustment.
- Coil Mode.
Similar to gear mode but the position range can be limited in such a manner that the
motor changes direction every time the upper limit is reached and also if the lower
limit is reached. Both limits can be adjusted. The mode is intended to be used for con
trolling a wire/cable guider on a winding machine. The guide will follow the position
of the coil driven by a “main motor” and using this mode it is possible to feed the wire
in a very precise position regardless of the speed at which the “main motor” is run
ning.
- Analogue bi position mode
The motor will move a certain distance or go to one of 2 positions depending on the
voltage at the analogue input. The voltage at the analogue input will be seen as a digital
signal, meaning either logic low or logic high.
The distance or positions can be set up in 2 internal registers and saved permanently
in the motor.
-
-
-Analogue to position
The position of the motor will change proportionally with the voltage at the analogue
input, between the zero position and a predefined position.
A typical apllication could be controlling a valve position using a voltage or a current
control signal.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 7
1.3 Expansion modules overview
JVL offers a wide variety of expansion modules to adapt the MAC motor to almost any
kind of application. The expansion module is easily mounted inside the motor. Only one
expansion module can be mounted.
The table below gives a brief overview of the features offered by the basic MAC motor
and the features that are available in each expansion module.
Basic modules
MAC00-B1, B2, B4
Connector module w/RS232
RS485 (non isolated) and LED’s
MAC00-B41
Connector module
with Optical isolated RS232, Rs485
6 General digital I/O
Support 2 multifunction I/O ports.
Wireless modules
MAC00-FB4
Wireless module
Bluetooth module
Fieldbus modules
MAC00-FC2, FC4
CANopen
Supports DS402
MAC00-FD4
DSUB Connectors
MAC00-B1
ed
n
n
ot pla
N
lanne
p
t
o
N
anned
pl
t
o
N
lanne
p
Not
Cable glands M12 Connectors
MAC00-B2
d
e
n
n
a
pl
ot
N
d
MAC00-FC2
d
o
N
Not p
anned
l
t p
anned
l
MAC00-B4
MAC00-B41
MAC00-FB4
MAC00-FC4
MAC00-FD4
MAC00-FP2, FP4
Profibus DP
12Mbit with 6(4) Inputs
and (2) outputs
Multiaxis modules
MAC00-FR4
High speed serial RS485
Multiaxis. Interf. to IEC61131-1
MAC00-FS1, FS4
High speed serial RS485
Multiaxis 460kbaud
MAC00-FS1
MAC00-FP2
d
nne
a
ot pl
N
d
anne
lanned
p
t
o
N
l
p
t
o
N
ed
plann
t
o
N
MAC00-FP4
MAC00-FR4
MAC00-FS4
8 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1.3 Expansion modules overview
Expansion module overview (continued).
Programmable modules
MAC00-R1, R3, R4
Nano PLC with graphic programming
interface 8 input and 4 outputs.
Process control modules
MAC00-P5
Process module 4-20mA input and output
galvanic isolated. Harting and M12 Connectors
Rear plates
MAC00-00/01/02 and MAC00-CS
Rearplates with or without
cable glandsConn.
No electronic features included
DSUB Connectors
MAC00-R1
anned
pl
t
No
MAC00-00
Cable glands M12 Connectors
MAC00-R3
d
e
ann
Not pl
MAC00-01 MAC00-02 MAC00-CSxx
MAC00-R4
MAC00-P5
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 9
1.3 Expansion modules overview
y
MAC Motors feature overview including expansion modules
Feature
Ty p e
Pulse inputs
Accepts pulse and direction or
quadrature encoder signal
Pulse outputs
90 degree phase shifted
RS422 (3)
4096 cpr
RS422 (3)
4096 cpr
RS422 (3)
8192 cpr
RS422 (3)
8192 cpr
RS422 (3)
8000 cpr
RS422 (3)
8000 cpr
RS422 (3)
8000 cpr
RS422 (3)
8000 cpr
RS422 (3)
RS422 (3)
RS422 (3)
RS422 (3)
RS422 (3)
RS422 (3)
RS422 (3)
outputs from internal encoder
Digital user inputs
For control of program flow
No
No
No
No
No
No
No
No
No
No
No
No
6 In/Out.
(selectable)
5-30V
No
No
or motor start/stop
Motor stat.
Motor stat.
Motor stat.
Motor stat.
Motor stat.
Motor stat.
Motor stat.
Motor stat.
Motor stat.
Motor stat.
PNP 10-32V
Motor stat.
PNP 10-32V
Motor stat.
PNP 10-32V
Motor stat.
PNP 10-32V
Motor stat.
PNP 10-32V
Digital user outputs
For indicating the motor status
2 x NPN
25mA
2 x NPN
25mA
2 x NPN
25mA
2 x NPN
25mA
2 x NPN
25mA
2 x NPN
25mA
2 x NPN
25mA
2 x NPN
25mA
2 x NPN
25mA
100mA
100mA
100mA
No
100mA
100mA
or as output from the program
AMP
Molex
AMP
Molex
AMP
Molex
AMP
Molex
AMP
Molex
AMP
Molex
AMP
Molex
AMP
Molex
Cable
Gland
DSUB
Plug-
able
Cable
Gland
M12
Conn.
M12
Conn.
M12
Conn.
M12
Conn.
Unbalanced async.
serial interface
For setup/sending commands
Balanced async.
serial interface
For setup/sending commands
±10V Analogue input
For controlling speed/torque
Also used for zero search
Basic MAC motors
MAC50,95,140,141-A1
Basic MAC motors IP42
MAC50,95,140,141-A3
Basic MAC motors IP67
MAC400-D2
Basic MAC motors IP55
MAC400-D5
Basic MAC motors IP55
MAC800-D2
Basic MAC motors IP55
MAC800-D3
Basic MAC motors IP66
MAC800-D5
Basic MAC motors IP55
MAC800-D6
Basic MAC motors IP55
5V TTL
19.2kbaud
Full Duplex
5V TTL
19.2kbaud
Full Duplex
5V TTL
19.2kbaud
Full Duplex
5V TTL
19.2kbaud
Full Duplex
5V TTL
19.2kbaud
Full Duplex
5V TTL
19.2kbaud
Full Duplex
5V TTL
19.2kbaud
Full Duplex
5V TTL
19.2kbaud
Full Duplex
RS422 (3)
19.2kbaud
Full Duplex
RS422 (3)
19.2kbaud
Full Duplex
RS422 (3)
19.2kbaud
Full Duplex
RS422 (3)
19.2kbaud
Full Duplex
RS422 (3)
19.2kbaud
Full Duplex
RS422 (3)
19.2kbaud
Full Duplex
RS422 (3)
19.2kbaud
Full Duplex
RS422 (3)
19.2kbaud
Full Duplex
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
Expansion modules
MAC00-CS
Conn. module w/cable glands
No electronic features added
MAC00-B1
Connector module w/DSUB
connectors
MAC00-B2
Connector module w/cable
glands (2)
MAC00-B4
Connector module
w/M12 connectors
MAC00-B41
Connector module
w/M12 connectors
MAC00-EW4
Wireless Ethernet module
w/M12 connectors
MAC00-FB4
Wireless bluetooth module
w/M12 connectors
1) All these modules offer IP67 protection class. Please notice that the final protection class is limited by the actual motor used.
2) Can be ordered without cable (eg. MAC00-CS) or with cable in lengths of 2, 10 or 20 metres (eg. MAC-CS-10).
3) Either pulse input, pulse output or serial must be chosen. Not all of them at the same time.
4) Onl
(2)
5V TTL
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
a total of 4 I/O terminals are available.
(3)
RS422
19.2kbaud
Full Duplex
RS422 (3)
RS485 19.2k
Full Duplex
(3)
RS422
RS485 19.2k
Full Duplex
(3)
RS422
S
R 485 19.2k
Full Duplex
(3)
RS422
S
R 485 19.2k
Full Duplex
(3)
RS422
S
R 485 19.2k
Full Duplex
RS422
(3)
R 485 19.2k
S
Full Duplex
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
No
No
JST
JST
JST
JST
JST
JST
JST
JST
Ext. connector type
IP42
IP67
(1)
IP55
IP55
IP55
IP66
IP55
IP66
IP67
(1)
IP42
IP67
(1)
IP67
(1)
IP67
(1)
IP67
(1)
IP67
(1)
TT0933GB
Protection class
Integrated brake
Continued next page.
10 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1.3 Expansion modules overview
)
y
MAC Motor expansion modules overview (continued from last page
Feature
Ty p e
Pulse inputs
Accepts pulse and direction or
quadrature encoder signal
Pulse outputs
90 degree phase shifted
No
No
No
No
No
No
RS422 (3)
RS422 (3)
RS422 (3)
No
No
No
outputs from internal encoder
Digital user inputs
For control of program flow
6 Inputs
Opto isol.
5-30V
4 Inputs
Opto isol.
5-30V (4)
4 Inputs
Opto isol.
5-30V (4)
6 Inputs
Opto isol.
5-30V
4 Inputs
Opto isol.
5-30V (4)
4 Inputs
Opto isol.
5-30V
4 Inputs
Opto isol.
5-30V
4 Inputs
Opto isol.
5-30V
No
8 Inputs
Opto isol.
5-30V
8 Inputs
Opto isol.
5-30V
8 Inputs
Opto isol.
5-30V
or motor start/stop
PNP 10-32V
PNP 10-32V
PNP 10-32V
PNP 10-32V
PNP 10-32V
PNP 10-32V
PNP 10-32V
PNP 10-32V
Motor stat.
PNP 10-32V
PNP 10-32V
PNP 10-32V
PNP 10-32V
Digital user outputs
For indicating the motor status
2 Outputs
25mA
2 Outputs
25mA (4)
2 Outputs
25mA (4)
2 Outputs
25mA
2 Outputs
25mA (4)
4 Outputs
300mA
2 Outputs
25mA
2 Outputs
25mA
100mA
4 Outputs
300mA
4 Outputs
300mA
4 Outputs
300mA
or as output from the program
Cable
Gland
M12
Conn.
M12
Conn.
Cable
Gland
M12
Conn.
M12
Conn.
DSUB
Plugable
M12
Conn.
M12
Conn.
DSUB
Plugable
Cable
Gland
M12
Conn.
Unbalanced async.
serial interface
For setup/sending commands
Balanced async.
serial interface
For setup/sending commands
±10V Analogue input
For controlling speed/torque
Also used for zero search
Expansion modules
MAC00-FC2
CAN-Open module
w/cable glands
MAC00-FC4
CAN-Open module
w/M12 connectors
MAC00-FD4
DeviceNet module
w/M12 connectors
MAC00-FP2
Profibus DP w/cable glands
MAC00-FP4
Profibus DP
w/M12 connectors
MAC00-FR4
High speed serial RS485
Multiaxis interf. to IEC61131-1
MAC00-FS1
RS485 High Speed. w/DSUB
connectors. Multiaxis control
MAC00-FS4
RS485 High Speed. w/M12
connectors. Multiaxis control
MAC00-P5
Process module 4-20mA
w/M12+Harting connectors
MAC00-R1
Nano PLC w/ DSUB connect.
MAC00-R3
Nano PLC w/cable glands (2)
MAC00-R4
Nano PLC w/M12 circular
connectors
1) All these modules offer IP67 protection class. Please notice that the final protection class is limited by the actual motor used.
2) Can be ordered without cable (eg. MAC00-CS) or with cable in lengths of 2, 10 or 20 metres (eg. MAC-CS-10).
3) Either pulse input, pulse output or serial must be chosen. Not all of them at the same time.
4) Onl
a total of 4 I/O terminals are available.
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
No
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
RS232
19.2kbaud
Full Duplex
No
No
No
No
No
RS485
230kBaud
Opto isol.
RS485
460kBaud
Opto isol.
RS485
460kBaud
Opto isol.
RS422
(3)
R 485 19.2k
S
Full Duplex
RS485
19.2kbaud
Half Duplex
RS485
19.2kbaud
HalflDuplex
RS485
19.2kbaud
HalflDuplex
(4)
(4)
(4)
No
No
No
No
No
No
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
RS422 (3)
2.5Mhz or
150kHz (LP)
No
No
No
TT1175GB
Ext. connector type
Protection class
Integrated brake
IP67
(1)
IP67
(1)
IP67
(1)
IP67
(1)
IP67
(1)
IP67
(1)
IP42
IP67
(1)
IP67
(1)
IP42
IP67
(1)
IP67
(1)
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 11
1.4 Setting up the MAC motor
Setup save/open
The complete setup
can be either saved
or reloaded from a
file using these
buttons
Startup mode
The basic functionality
of the MAC motor is
set up in this field.
Profile Data
All the main parameters for controling the motor behaviour
are set up in this field.
System control
Use these buttons to save data
permanently, reset the motor etc.
Zero Search
All the parameters regarding
the position zero search can
be specified here.
Error Handling
Use these fields to define error
limits for the position range etc.
Undervoltage handling
Determine what happens if the supply
voltage gets too low..
Input/Outputs
The functionality of the I/O's
is specified here.
Motor status
This field shows the
actual motor load,
position and speed etc.
Inputs
This field shows the
actual supply voltage,
the speed at the pulse
input and the voltage
at the analogue input.
Errors
If a fatal error occurs,
information will be
displayed here.
MAC motor connection
information Always shows
if the motor is on line or not.
TT0914GB
1.4.1 MacTalk introduction
The MacTalk software is the main interface for setting up the MAC motor for a specific
application.
The program offers the following features:
- Choice of the operating mode of the MAC motor.
- Changing main parameters such as speed, motor torque, zero search type, etc.
- Monitoring the actual motor parameters in real time, such as motor load, supply voltage, voltage at the analogue input, etc.
- Changing protection limits such as position limits, maximum position error.
- Determine what should happen if the supply voltage gets too low.
- Saving all current parameters to disc.
- Restoring all parameters from disc.
- Saving all parameters permanently in the motor.
- Updating the motor firmware or MacTalk software from the internet or a file.
The main window of the program changes according to the selected mode, thus only
showing the relevant parameters for operation in the selected mode.
The following pages describe the actual window for each mode and how the parameters
affect the MAC motor operation.
12 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1.4 Setting up the MAC motor
1.4.2 Toolbar description
The toolbar at the top of the MacTalk window contains the most commonly used features.
Open
Opens a setup file from disc and downloads the setup to the motor. If no motor is connected, the setup is shown in MacTalk and can be edited and saved to disc again.
Save
Saves the actual setup from the motor to a file. If no motor is connected, the actual offline settings (including module setups and program) will be saved.
Save in flash
The complete current setup of the basic motor will be saved permanently in the flash
memory. If the motor is powered down or reset, the saved setup will be used.
Reset position
Resets the position counter to 0. The content of the position counter can be monitored
in the right side of the main screen as “Actual position”.
Clear errors
Clears all the errors (if any). Please note that if an error is still present, the motor will
remain in the actual error state.
Reset motor
Reset the motor. Same as doing a power off / on operation.
Filter setup
Short-cut to the servo filter setup screen.
Stop motor
Stops the motor immediately using a controlled deceleration ramp and puts the motor
into passive mode. If a program is present this is stopped as well.
This button shall be considered as a functional stop button and is available also by using
the keyboard shortcut CTRL+F8.
Pressing the “STOP” button will immediately stop the motor by changing the currently
running mode to “passive” using a fast controlled deceleration curve.
Using a MAC motor or a module that enables the user to execute RxP programs this
execution is also halted to prevent the motor from starting up if a startup-mode is setup
from a program.
Warning! Do not consider this button as an appropriate Emergency stop. Always fit an Emergency stop circuitry to your motor setup.
MacTalk Address
Only if more than one motor is connected to the same interface. The address specified
in this field determines with which motor line communication is made.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 13
1.4 Setting up the MAC motor
r
1.4.3 Saving or opening a setup file to/from disc
The complete motor setup can be saved to disc or retrieved from disc and transferred
to the motor. The setup files can be saved anywhere on the hard disc or to a floppy disc.
Saving and opening a file over a network is also possible.
The setup files use the extension .MAC. By default, the setup files are saved in the same
directory where MacTalk itself is also installed. Other directories can be selected.
From file to motor.
Use Open to select a file containing the desired motor setup.
When opening the file the setup will simultaneously be sent
to the motor.
Remember to use the Save in flash button if the setup must
be permanently saved in the motor.
From motor to file.
Use Save or Save as to save the actual setup in a motor as a
setup file. Make sure that the motor is on-line with MacTalk,
otherwise only the MacTalk default setup is saved.
In case where a motor is present and a disc file is opened the user is prompted for keeping the connection or going offline and displaying the file content. The following message
box appears.
Transfers data to the moto
and display the data in
MacTalk afterwards.
Going off/line and displays
the data in MacTalk.
If the user decides to go offline the following textbox is presented.
TT1151GB
TT1153GB
14 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
1.4 Setting up the MAC motor
Pressing “OK” disconnects the motor from the PC application and all data can be edited
without any interruption in the motor. The following MacTalk view is presented.
TT1152GB
As seen in the bottom info line, the motor is disconnected and the filedata is currently
present in MacTalk. To re-establish communication with the motor, simply press the
“Go Online” button and if any data has been changed a warning box appears enabling the
user to save current data before re-establishing communication with the motor as this
will overwrite existing data in MacTalk.
If data is changed in MacTalk the user is warned that current data in MacTalk may be
overwritten and needs to be saved. The following warning message box appears.
TT1154GB
Choosing “No” will immediately upload all motor data, presing “Yes” will save all data in
the open file.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 15
16 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2 Function description
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 17
2.1 Using Position mode
.
A
2.1.1 Position mode
Follow the description below to set up the MAC motor in Position mode.
The MacTalk program is used to set up the motor initially. During normal operation, positioning commands can either be given through MacTalk or via one of the serial interfaces. The main window in MacTalk is as follows when position mode is selected.
Startup mode
Choose Position mode
Profile Data
ll the main parameters for the
motion profile
are setup in this
field.
Motion Parameters
The desired position
and the "in position"
window can be
specified here.
Reset Position
Use this button to reset the
actual position counter
Zero Search
All the parameters regarding
the position zero search can
be specified here. See the
Mechanical zero search
Error Handling
Use these fields to define error
limits for the position range etc.
MAC motor connection information
Always shows if the motor is on line or not.
chapter.
Input/Outputs
The functionality of the I/O's is specified
here. In position mode, only Pulse Output
or Serial Interface is relevant.
Motor status
This field shows the
actual motor load,
position and speed etc.
Inputs
This field shows the
actual supply voltage
Errors
If a fatal error occurs,
information will be
displayed here.
Run Status
The motor status
can be monitored here
TT0926GB
.
Startup Mode Select position mode in this field.
Reset Position The counter which keeps track of the actual position can be reset us-
ing this button.
Error Handling Worst case limits for the position range can be set up here. Please
consult the Error Handling chapter for details.
Input/Outputs The multifunction I/O terminals can be defined here. In Position
mode these terminals can either work as a quadrature output from
the internal encoder or as a serial RS422 interface for commands sent
from a master controller. See also the
Multifunction I/O general de-
scription, page 72.
Motor Status The actual mode, speed, position, position error, load torque, load
current, regenerative energy (returned energy from the motor) can
be monitored here.
Inputs The supply voltage can be measured here.
18 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.2 Gear Mode
.
Main parameters used in gear mode
Startup mode
Choose “Gear mode”
or Gear (Follow)
Profile Data
All these parameters
can be used to limit the
motion. For example
the maximum torque
or velocity.
Gear factor
The ratio between
the incomming pulses
and the actual motor
movement is specified
here.
Error Handling
Use these fields to define error
limits for the maximum follow error etc.
Zero Search
Zero search can also be used. During zero search
the gear mode will be set inactive. See also the
chapter.
Search
Zero
Input/Outputs
The must be setup as pulse input.
I/O Type
The must also be setup for the
input type
actual pulse type (quadrature or pulse/dir.).
Motor status
This field shows the
actual motor load,
position and speed etc.
Inputs
This field shows the
actual supply voltage
and velocity at pulse
input
Errors
If a fatal error occurs,
information will be
displayed here.
Run Status
The motor status
can be monitored here
TT0968GB
2.2.1 Gear Mode - overall description
In gear mode, the motor follows a pulse signal applied to the Multifunction I/O terminals.
The ratio between the incoming pulses and the motor movement can be adjusted to a
desired value. A ratio from 1024:1 down to 1:1024 can be selected. Typically this mode
is used if the MAC motor is incorporated into an application where movement needs to
be synchronized with an external movement. Another typical application is the replace
ment of step motors, since the MAC motor in Gear Mode can work like a step motor
using pulse and direction.
The following setup must be done to operate in gear mode (listed according to importance).
Startup Mode Select Gear Mode in this field.
Gear Factor This field defines the ratio between incoming pulses and the motor
movement. If the preferred motor direction needs to be reversed, the
sign in the “output” field must be inverted.
Example: 1024 must be -1024 to reverse the direction of movement.
Input/Outputs The multifunction I/O terminals must be set to “pulse input” since gear
mode uses the incoming pulses at this input to control the motor movement. Also the “Input type” must be selected. Choose “Quadrature” if
an incremental encoder is connected or “pulse-direction” if it is a step
motor signal. See also
(Continued next page)
-
Hardware description, page 57.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 19
2.2 Gear Mode
Profile data In gear mode, motor movement is fundamentally controlled from the
external signal source, but via the 4 parameters specified in “Profile
data” field it is possible to add limitations to speed, etc.
“Velocity”
The velocity field can be used to limit the maximum speed of the motor. Example - if an external encoder is producing a frequency which
theoretically should give a MAC motor speed of 10000 RPM, the
speed can be limited to 4000 RPM (max. allowed speed for the
MAC). The motor will be unstable and go in error within some time
since it is not able to run at 10000 RPM. Note that no pulses are lost
if the velocity is limited. They are simply remembered and used when
the input frequency falls to a level at which the motor is able to fol
low.
“Acceleration”
The acceleration parameter can be useful in systems in which the signal source instantaneously applies a high frequency without any acceleration. Under this condition, the MAC motor will take care of
making a controlled acceleration and deceleration. Note that no puls
es are lost if the acceleration is limited. They are simply remembered
and used when motor velocity reaches a level corresponding to the
input frequency.
-
-
“Torque”
The maximum torque can be limited in the range 0-300%. 300%
corresponds to the rated peak torque of the MAC motor used.
“Load”
The Load parameter is the overall gain in the position/velocity filter
and ensures that the motor is stable with the actual mechanical inertia
used in the application. See also the filter setup chapter for further
details.
Error Handling Worst case limits for the position range and follow error (maximum
position error) can be set up here. Please consult the Error Handling
chapter for details.
Motor Status The actual mode, speed, position, position error, load torque, load
current, regenerative energy (energy returned from the motor) can
be monitored here.
Inputs The supply voltage can be measured here.
Zero search In typical gear mode applications the motor is moving relatively with-
out any absolute zero point, but for applications that require a specific mechanical zero position, the general zero search in the MAC
motor can be used. Please consult the chapter
search, page 26.
Mechanical zero
20 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.2 Gear Mode
Example 1: Encoder (quadrature) input.
An external encoder feeds the MAC motor. The I/O type is set to
“Pulse input“ and “Input type” is set to “Quadrature” in order to de
code the encoder signal. The encoder is connected to the A and B
terminals (Multifunction I/O’s). See also
The resolution of the external encoder is 500 ppr. The MAC motor
itself has 1024ppr (MAC50-141) or 2000 ppr (MAC800). If this appli
cation requires that the MAC motor rotates 1 rev. each time the external encoder has rotated 1 rev., the Input parameter is set to 500
(external encoder) and the Output parameter is set to 1024 or 2000.
Now the ratio between the external encoder and the MAC motor
will be 1:1. Ensure the “Profile data” is set to proper values in order
not to limit motor operation unintentionally.
Example 2: Pulse and direction input.
A step motor system is replaced by a MAC motor, meaning that the
MAC motor receives a pulse and direction signal which is a very com
mon signal format in step motor applications.
The I/O type is set to “Pulse input“ and “Input type” is set to “Pulsedirection” in order to decode the input signal. The pulse signal is con
nected to the A terminals (Multifunction I/O) and the direction signal
is connected to the B terminals (Multifunction I/O’s).
See also User I/O, page 70.
The MAC motor is replacing a step motor system with 400 steps per
revolution, which means that when the pulse source produce 400
pulses, it expects the MAC motor to rotate one revolution.
The MAC motor itself has 1024ppr (MAC50-141) or 2000ppr
(MAC800). If this application requires that the MAC motor rotates 1
revolution each time 400 pulses are received, the Input parameter is
set to 800 since the MAC motor detects on both the rising and falling
edge of the input signal.
The Output parameter is set to 4096 or 8000 since the number of
counts (edges) on the internal encoder is 4096 or 8000. Now the
MAC motor will move 1 revolution if 400 pulses is applied to the
pulse input. Ensure the “Profile data” is set to proper values in order
not to limit motor operation unintentionally.
The following table can be used as guide for setting up typical gear ra
tios:
-
User I/O, page 70.
-
-
-
Pulse and direction gear ratio setup - “Commonly used ratios”
Applied number of pulses
per MAC motor revolution.
200 400 4096 8000
400 800 4096 8000
500 1000 4096 8000
800 1600 4096 8000
1000 2000 4096 8000
2000 4000 4096 8000
4096 (Same as motor resolution) 8192 4096 8000
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 21
Input
register
Output
register
MAC50-141 MAC800
2.3 Coil Mode
p
B
2.3.1 Coil Mode - overall description
The Coil Mode is similar to gear mode but the position range can be limited in such a
manner that the motor changes direction every time 2 predefined limits (upper and low
er) are reached. Both limits are fully adjustable. The mode is intended to be used for controlling a wire/cable guider on a winding machine. The guide will follow the position of
the coil driven by a “main motor” like it was mechanically connected by a transmission,
and by using this mode it is possible to steer the wire to the desired position at the coil,
also when the “main motor” changes speed. Since Coil Mode is very similar to Gear
mode, it is recommended that the gear mode setup instructions are followed before us
ing the additional features described in this section. See Gear Mode, page 19.
-
-
MAC motor
Position
P4
P3
P2
P1
P6
Start direction
Notes:
P1, P2, P3 and P4 can be changed at any time. It is allowed to set P1=P2 and P3 = P4
The
osition of the motor is always locked to the external encoder like it was a mechanical gear (pulse by pulse).
MAC motor position versus position of master encoder
P5
Start position
Coil mode
Master encoder
position
TT0993G
When coiling a thick thread compared to the coil, and the number of windings per layer
are few, it is preferable to stop the traverse motion while one winding is coiled at the top
of the previous winding at the edges. Therefore the edges can be cut off at the positions
given by registers P2 and P3, as shown in the illustration above.
When starting a new coil, you must specify the starting position, and the starting direction
of the MAC motor to achieve repeatability. The starting position, related to the basic
function shown in the illustration above, is given by the value of register P5. The starting
direction is given by the value of register P6, which value must be +1 or -1 for either a
positive or negative direction.
A typical setup could be:
P1 = 10000 Left position limit of basic function
P2 = 12000 Left cut off position
P3 = 58000 Right cut off position
P4 = 60000 Right position limit of basic function
P5 = 12000 Starting position ( at left edge )
P6 = 1 Start traversing right (positive direction)
Positioning at the start position is initiated by setting the analogue input, (AIN), high.
When setting this input low, the MacMotor will resume normal coiling function.
22 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.3 Coil Mode
The rules for setting up P1 ... P6 are:
P1 <= P2 <= P3 <= P4
P1 <= P5 <= P4
P6 = +1 or -1
2.3.2 The gear ratio in coil mode
The gearing ratio must be specified in the exact same manner as GEAR mode, using the
Input and Output registers. See
2.3.3 Initiating zero search in coil mode
The MAC motor can be set up to make an initiating zero search at power up. When using
the sensor zero search modes, the zero search function uses the analogue input as zero
sensor input and the coiling function uses the signal to sense the ’go to start position com
mand’. Still the two signals can be coupled in parallel if the zero search sensor is activated
away from normal working area (Normally open).
In conjunction with the above setup for registers P1 ... P6, the setup for the zero search
could therefore be:
Zero search type: “Sensor 1”
Zero search velocity: -100
Zero search position: -2000
Start mode: Coil Mode
Gear Mode - overall description, page 19.
-
Having ended the power-up zero search, you must give the MAC motor an initial startposition command before starting the first coil process.
2.3.4 Filter setup in coil mode
Recommended filter setting for this application (using the filter selector).
Please note that the filter setting can also depend on other factors such as the inertia, friction etc. in the actual system.
Current filter: Medium or high.
Position filter: x-y coordinate = 3, 3 ( fast, almost hard )
Follow error type: Static, degree = 75%
Remember load factor to finely adjust the LOAD factor (MacTalk main tab).
Other settings, ( recommended ):
- Max velocity: Set limit higher than the normal speed used
- Acceleration: Set high value (example 300000 RPM/sec)
- Torque: 300%
- Gear factor: Set value
- Follow error: 0
- Function error: 0
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 23
2.3 Coil Mode
d
2.3.5 Register overview in MacTalk
The following screen is shown in MacTalk when selecting Coil Mode.
Main parameters used in coil mode
Startup mode
Choose “Coil mode”
Profile Data
All these parameters
can be used to limit the
motion. For example
the maximum torque
or velocity.
Coil mode parameters
Set P1 to P6 in this
field according to
the description in
this chapter.
Gear factor
The ratio between
the incomming pulses
and the actual motor
movement is specifie
here.
TT1127GB
The general setup, such as selecting maximum velocity, gear ratio and input type setup,
is similar to Gear Mode. Only the Coil Mode parameters differ from Gear Mode.
For details of the overall setup, please See Gear Mode, page 19.
24 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.4 Analogue bi position mode
2.4.1 Analogue bi position Mode - overall description
For primitive positioning purposes, the basic MAC motor offers the Analogue bi position
mode. The Analogue bi position mode offers:
The motor will move a certain distance or go to one of 2 positions depending on the volt-
age at the analogue input. The voltage at the analogue input will be seen as a digital signal
meaning either logic low or logic high.
The distance or positions can be setup in 2 internal registers and saved permanently in
the motor.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 25
2.5 Mechanical zero search
2.5.1 Mechanical zero search modes
In all positioning systems, there is a requirement to be able to find a mechanical zero position after the system is powered up or at specific times during operation. For this purpose the MAC motor offers 3 different Zero search modes which can be selected in the
MacTalk main window or by sending a command at one of the serial interfaces.
Select the Zero search mode
using this field. The selected format will
be used as follows :
- Immediately after ther motor is powered up
(only the “Power up ....” Formats)
- If a search is initiated via the serial
interface or
- From an expansion module (MAC00-R1,
R3 or FP2).
Please note that the 3 formats for
“Power up” Zero search must not be
selected if an expansion module is used
(MAC00-R1, R3 or FP2). If an automatic
zero search after “Power up” is required
when using one of these modules, the
function must be enabled on the product tab
for the actual module. (See also the chapters
describing the expansion modules)
TT0919GB
The menu offers 7 choices:
Disabled (default) The Zero search is disabled.
Power up: Torque Similar to “Torque” but the Zero search will automatically
be started after power up.
Power up: Sensor type 1 Similar to “Sensor type 1” but the Zero search will auto-
matically be started after power up.
Power up: Sensor type 2 Similar to “Sensor type 2” but the Zero search will auto-
matically be started after power up.
Torque The Zero search will start searching for Zero until a me-
chanical “collision” occurs. The point at which the motor
torque is equal to the specified value of the Zero search
torque is defined as the zero position.
Sensor type 1 The Zero search function will start seeking for Zero until
an external sensor is activated. The point at which the sen
sor is activated is defined as zero. The active sensor level
can be changed by changing the sign at the value specified
in the Zero search torque field.
Sensor type 2 Like above (Sensor type 1) but after the sensor is activated
the direction of movement is reversed and the point at
which the sensor is disabled is defined as zero.
The following sections explain in detail the functionality of the 3 fundamental Zero search
modes.
-
2.5.2 Starting a Zero search
If the Zero search mode is set to Disabled, no Zero search is done at any time.
If one of the 3 modes Power up: Torque, Sensor type 1 or Sensor type 2 is selected, the respective Zero search mode will be executed every time the MAC motor is powered up.
The Zero search can also be initiated by sending a specific command via one of the serial
interfaces — please consult the technical manual (LB0048-xx) for more details.
26 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.5 Mechanical zero search
S
W
2.5.3 “Torque” Zero search
Torque Zero search is carried out according to the following illustration.
Zero search position
offset. This position is preset to the positioncounter after the zero point is found.
Zero search defines the velocity
used during Zero search. The sign of the
specified velocity defines the zero search
direction.
Zero search is used as the
trip level when the zero position is reached
Ve lo ci ty
To r q u e
Home
To r q u e
is an optional
velocity
torque
Acceleration
is specified by
the general acceleration parameter
under “Profile data”
in MAC-Talk
Zero search
started
hen the torque rises
higher than the value
specified in the field
search Torque
drop to zero. And the actual
position is set to the value
specified in
Zero
the speed will
Zero search position.
elect the mechanical zero
search mode in this field.
The speed and acceleration
is set to the general setting
in MacTalk under “Profile data”
Time
Time
Zero search
active
Move away from
collision point
The move is done
in 500mS with the “zero
search velocity”
Move to position 0
(only if “Zero search
position” was <>0)
TT0921GB
The Zero search method using a torque as a reference is a cheap, simple way to find the
mechanical zero position, but please be aware of following critical points.
- Make sure that the Zero search torque is set to a proper value higher than the mechanical friction in the system in order to avoid a faulty zero point being found. It is a
good idea to let the motor run in velocity mode with the same velocity and observe
what the actual motor torque is. This value can be observed in the status area in the
right side of the main window. Set the Zero search torque to a value 10-20% higher
than the actual torque observed during this procedure.
- To improve the repeatability precision of the zero point, make sure that the mechanical “collision” point is as stiff and well-defined as possible.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 27
2.5 Mechanical zero search
B
W
2.5.4 “Sensor type 1” Zero search
Sensor type 1 zero search is carried out according to the following illustration.
Select the mechanical zero
search mode using this field.
The position is sampled in the exact
position where the sensor was
activated. The motor the decelerates
and moves the reverse distance back
to the position where the sensor was
activated.
Zero search position
offset. See description in
other chapter.
Zero search velocity
velocity used during Zero search.
The sign of the specified velocity
defines the zero search direction.
Zero search torque
trip level when the zero position
is reached.
1=active high -1=active low.
is an optional
defines the
Sensor status
is used as the
The Zero sensor must be connected to the analogue input (AIN), which during Zero
search functions as a digital input. For connection information, see
70.
2.5.5 “Sensor type 2” Zero search
Sensor type 2 zero search is carried out according to the following illustration.
Velo ci ty
Zero search position
offset. See description in
other chapter.
ero search velocity
Z defines the
velocity used during Zero search.
The sign of the specified velocity
defines the zero search direction.
Zero search torque
trip level when the zero position is
reached.
+1=active high 1=active low.
is an optional
Sensor
status
is used as the
-
Zero search
started
Analogue input, page
Select the mechanical Zero
search format in this menu.
hen the zero search sensor is activated, the
motor decelerates and starts to move in
the reverse direction with 1/64 of Zero search
Velocity. When the edge of the Zero search
sensor is passed the motor stops and the
zero position is found.
Acceleration specified by
the general acceleration
parameter under the “Profile
data” in MAC-Talk
Time
Zero search
started
In this example the
active sensor level
is set to high
(Home Torque=1)
Time
TT0922G
TT0924GB
The Zero sensor must be connected to the analogue input (AIN), which during Zero
search functions as a digital input.
For connection information, see Analogue input, page 70.
28 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.5 Mechanical zero search
”
2.5.6 Making a Zero point offset
Common for all the zero search modes, it can optionally be chosen to define the zeropoint as a value other than zero (position 0).
When is it useful to use the zero point offset?
- If it is desired that the position interval under normal operation is always “nice” positive values from 0 to x instead of a mixture of negative and positive values. This can
occur if the zero point sensor is placed a long distance away from the normal posi
tioning interval or inside the normal positioning interval.
- If an automatic move to an initial position is desired after a power-up zero search.
The offset value must be specified in the “Zero search position” field.
The total zero search will be performed in following order.
1. The zero search is started either automatically (power up) or initiated by command
from the interface or via an expansion module.
2. The basic zero search is completed and the position counter is set to the value specified in the “Zero search position” field.
3. If the zero search position value is different from position, the motor will now move
to position 0.
4. The zero search is now completed and the motor will switch to normal operation
which means the mode selected in the “Startup mode” field in the main window.
-
The illustration below shows the complete cycle.
The motor will always go to position 0
after a complete zero search is done this
causes the motor to move the difference
between 0 and the value specified in the
Ve lo ci t y
Zero search in progress
velocity etc. depends on
the actual zero search mode.
Zero search
started
TT0951GB
“Zero search position” field.
After the basic zero search has
been done, the actual position counter
is set to the value specified in the
“Zero search position” register
The speed and acceleration
is set to the general setting
in MacTalk under “Profile data
Time
Actual position counter
is now zero (position 0).
Zero search complete.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 29
2.5 Mechanical zero search
2.5.7 Find index position after zero search
The motor offers 2 unique points per revolution called the index points. These points are
found by the internal hall sensors and are always the same.
By enabling the ’Find index after zero search’ feature, an extra precise zero point can be
defined.
This feature is intended to be used if the external sensor does not offer the desired precision. The feature can be used after each of the basic zero search modes including the
torque zero search mode.
Enable the index search feature in the Main window.
Select “Find index after homing”
using this field.
TT0974GB
When the feature is selected, it is very important that the external zero search sensor is
adjusted to the correct position range with a certain margin to the index points to ensure
that the same index is always found during every zero search. If the external sensor is
activated too close to the index points, it can cause the motor to finalize the zero search
with reference to the wrong index point, which in practice will constitute an error of 0.5
motor revolution. Adjustment of the zero search point must be done regardless of which
of the 6 (3) zero search formats is selected.
The illustration below shows the MacTalk Tests tab which must be used for adjusting the
zero search point.
Press this botton to see
where the zero search
sensor (sensor search mode) or
mechanical stop (torque search
mode) is located.
The actual position will be
displayed by the little white dot
in the left side of the window.
Ensure that the zero point test is made several times to ensure that the white dot is located in the acceptable interval each time.
30 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
TT0975GB
2.6 Error Handling
Error Handling
Use these fields to define error
limits for the maximum follow error etc.
2.6.1 Error handling
The MAC motor incorporates 5 fundamental parameters used for protection-related
purposes. They all have effect regardless of the operation mode the motor is set up to
use.
TT0969GB
Follow error
It is possible to define the maximum allowable difference between the actual position of
the motor and the desired position. Depending on the setting of the servo filter etc., this
position difference will change. For protection it can be useful to define that the differ
ence is not allowed to exceed for example 500 counts (the motor has 4096 counts per
rev. fixed). If a mechanical collision occurs, the position difference will typically be ex
ceeded and cause a follow error making the motor passive with no further movement.
The default is 0, meaning that the feature is disabled.
Function error
Similar to Follow Error but the number of difference counts is only measured from the
point where the peak torque is reached, making it impossible for the motor to follow the
commanded movement. Default is 0, meaning that the feature is disabled.
Position limit min. and max.
Same as the physical limit switches but performed by software. Default is 0, meaning that
the feature is disabled.
Error acceleration
If an unrecoverable error occurs, it can be expedient to use a controlled deceleration instead of a sudden stop. If the inertia in the system is high and the mechanical parts are
weak, a sudden stop can cause damage and unintended behaviour. Use this parameter
to define the deceleration during an unrecoverable error. Default is 0, meaning that the
feature is disabled.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 31
2.6 Error Handling
2.6.2 Monitoring errors and warnings
When using the MacTalk PC-program any error or warning is shown in ’Status’’ field at
the main tab.
General error and warning monitoring area
In this area actual values for the motor operation is
monitored continously. Most of these monitored
values will trip a corresponding error message.
Example : The error message ‘Overload’ will be
tripped if the the monitored value ‘Motor load (mean)’
gets above 99%. Therefore make sure that the value
during normal operation have a proper margin to 100%.
Actual error(s) are shown here if any
Warnings and status information are presented here
2.6.3 Error message ’Ohmis losses too high’
The following list show the possible error messages, the cause of the error and possible
actions to prevent the error from happening.
Each error can also be monitored by reading the error status register (register 35) by
using software packages like the OCX driver or MacRegIO.
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The calculated accumulated loos in the motor and electronics
Possible cause of this error The motor has been loaded above maximum continuous torque
Solutions to avoid error - Reduce average motor load.
How to return to normal
operation
Error bit / Firmware name Bit 0 / ’I2T_ERR’
1 / ’Overload’
above limit. The actual level of losses can be observed in the
’Motor load (mean)’ field (see the screen dump above).
rating for too long time, causing a critical internal temperature.
- Reduce the speed and/or acceleration.
- Adjust servo filter to a stable behaviour during any event.
- Make sure that the supply voltage is at the specified level.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
TT1170GB
32 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.6 Error Handling
2.6.4 Error message ’Follow error’
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The actual difference between the actual motor position and the
Possible cause of this error The motor has been applied too high a load or the ’maximum fol-
Solutions to avoid error - Increase the ’’Maximum follow error’ value.
How to return to normal
operation
Error bit / Firmware name Bit 1 / ’FLW_ERR’
2 / ’Follow error’
intended position is higher than the value specified in the ’Max
imum follow error’ field in MacTalk.
low error’ value have been set at an unrealistic low value in regards to the actual hardness of the servo filter.
- Adjust the servo filter hardness to a more aggressive value.
- Make sure that the torque setting is not limiting the motor
movement.
- Set the ’Maximum follow error’ to 0 (default) which will disable the detection of this error type.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
2.6.5 Error message ’Function error’
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition If the actual load torque of the motor gets higher than the spec-
Possible cause of this error The motor has been applied too high a load or the ’maximum
Solutions to avoid error
How to return to normal
operation
Error bit / Firmware name Bit 2 / ’FNC_ERR’
3 / ’Function error’
ified torque setting permits it will cause the motor to slip away
from where it is supposed to be. If the number of motor counts
missing in this situation gets higher than the value specified in
the ’Maximum function error’ field in MacTalk it will trigger the
’function error’. If the actual motor torque never reaches the val
ue specified in the ’torque’ field this error will never be triggered.
The above condition is valid when the motor is operated in Position mode, Biposition mode, or Analogue to position mode.
function error’ value have been set at an unrealistic low value in
regards to the ’torque’ setting.
- Increase the ’Maximum follow error’ value.
- Adjust the servo filter hardness to a more aggressive value.
- Make sure that the torque setting is not limiting the motor
movement.
- Set the ’Maximum function error’ to 0 (default) which will disable the detection of this error type.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
-
-
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 33
2.6 Error Handling
2.6.6 Error message ’Regenerative overload’
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The amount of power dissipated in the motors built-in power
Possible cause of this error The returned amount of energy from the motor has been too
Solutions to avoid error - Decrease the load inertia.
How to return to normal
operation
Error bit / Firmware name Bit 3 / ’UIT_ERR’
4 / ’Regenerative overload’
dump (breaking) resistor is above safe limit.
This error is tripped if the ’Regenerative load’ is >99%.
The regenerative load value can be monitored in the ’Motor status field’.
high. This can typically happen if:
- The motor decelerate a large load inertia too fast.
- The motor is forced backwards.
- The servo filter or ’Load’ parameter is not adjusted to a stable
motor operation and the motor tends to oscillate causing en
ergy to flow forward and backward from/to the motor.
In all situations the motor will start to work as a generator that
generate energy backward into the drive electronics.
- Decrease the top speed and/or the acceleration value.
- Make sure that the supply voltage is within nominal range in
order to leave extra capacity at the internal capacitors.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
-
Error message 5, 6 and 7 do not exist since bits are used for other status purposes.
2.6.7 Error message ’Position Limit Exceeded’
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The actual position of the motor is outside the value(s) specified
Possible cause of this error The motor has been commanded outside the value(s) specified in
Solutions to avoid error - Set the position limits descriped above to more realistic values.
How to return to normal
operation
Error bit / Firmware name Bit 7 / ’PLIM_ERR’
8 / ’Position Limit Exceeded’
in the ’position limit min.’ or ’position limit max.’ specified in the
’error handling’ area of the main tab in MacTalk.
the ’position limit min.’ or ’position limit max.’ registers.
Be aware that the error can happen even if the motor is in passive mode and the motor is forced outside this range.
- Make sure that the position limits also cover worst case situations such as position overshot (if using a soft filter).
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
34 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.6 Error Handling
2.6.8 Error message ’Temperature too high’ (only MAC400 and 800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The temperature has been higher than 73°C (163F) which is not
Possible cause of this error - Ambient temperature is higher than allowed.
Solutions to avoid error - Make precautions to decrease the surounding ambient tem-
How to return to normal
operation
Error bit / Firmware name Bit 8 / ’DEGC_ERR’
9 / ’Temperature too high’
allowed.
Please note that this error is only available in MAC400 and
MAC800 since MAC050-141 do not include a temperature
measurement circuit.
- The motor is build into an environment where it can not dissipate enough heat.
- The motor is not mounted on a proper mechanical structure
where heat can be dissipated.
perature.
- Lower the speed and or load on the motor.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
2.6.9 Error message ’Low AC-voltage’ (only MAC400 and 800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The mains supply is not connected or the mains voltage is too
Possible cause of this error - The mains supply is not connected correctly.
Solutions to avoid error - Make sure that the external fuse is OK and that the mains sup-
How to return to normal
operation
Error bit / Firmware name Bit 9 / ’UV_ERR’
10 / ’Low AC-voltage’
low.
Please note that this message is only available in MAC400 and
MAC800 since MAC050-141 do not include AC supply.
- The external fuse has blown.
ply is connected correctly according to the chapter Power Sup-
ply, page 59.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
See also the chapter Under Voltage Handling, page 42.
Error message 11 do not exist since bits are used for other status purposes.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 35
2.6 Error Handling
2.6.10 Error message ’Phase error’ (only MAC050 to 141)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The motor phase current has been measured to be Out of Range
Possible cause of this error - The servofilter (control loop) is unstable.
Solutions to avoid error - Make sure that the servo filter is not set to an extreme unre-
How to return to normal
operation
Error bit / Firmware name Bit 11 / ’IX_ERR’
12 / ’Phase error’
and the motor driver is shut down to prevent permanent failure.
Please note that this message is only available in MAC050 to
MAC141.
- The motor has been physically blocked.
- The motor has been running into a sudden mechanical collision.
alistic setting compared to the nature of the actual load. See
also
Servo filter adjustment, page 43.
- Avoid that the motor during normal operation is meeting a mechanical collision or an extreme overload situation.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
2.6.11 Error message ’Overvoltage on bus’ (only MAC400 / 800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The internal busvoltage has been higher than 450VDC which is
Possible cause of this error - The internal brake resistor is not sufficient to handle the
Solutions to avoid error - Make sure that the mains voltage is within specified voltage
How to return to normal
operation
Error bit / Firmware name Bit 11 / ’OV_ERR’
12 / ’Overvoltage on bus’
not allowed in order to prevent damages of the motor.
Please note that this message is only available in MAC400 and
MAC800.
amount of returned energy from the motor. Use an external resistor or if already present lower the value of the resistor.
- The mains supply voltage is too high.
range.
- If this error only happens during a motor movement the error
can probably be avoided by connecting an external power
dump resistor or decrease the ohmic value if a resistor is al
ready present. See also Connecting an external power dump re-
sistor, page 68.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
-
36 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.6 Error Handling
2.6.12 Error message ’UnderVoltage on Bus’ (only MAC050 to 141)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The voltage of the DC powersupply has been measured to be
Possible cause of this error - The current rating of the external power supply is too small.
Solutions to avoid error - Use a power supply with a higher current rating.
How to return to normal
operation
Error bit / Firmware name Bit 12 / ’UV_ERR’
13 / ’UnderVoltage on Bus’
lower than the limit selected in the register ’Min voltage’. This
has resulted in an error as configured in the setup of ’Undervolt
age handling’. See also Under Voltage Handling, page 42.
Please note that this message is only available in MAC050 to
MAC141.
- The power supply is not able to deliever the required peak currents that the motor need. This is a typical problem when using
switch mode power supply.
- The power cable is under dimensioned.
- The under voltage min. setting must be decreased.
- Use a power cable with at least 0,75mm² wires (up to cable
lengths of 10m. If the power cable is longer, use 1,5mm² or use
multiple wires in parallel.
- Connect a capacitor across the supply line close to the motor.
Especially if using a switch mode power supply this will help.
See also Power supply (only MAC050 to 141), page 59.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
-
2.6.13 Error message ’Peak error, motor overcurrent’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The motor phase current has been measured to be Out of Range
Possible cause of this error - The servofilter (control loop) is unstable.
Solutions to avoid error - Make sure that the servo filter is not set at an extreme unre-
How to return to normal
operation
Error bit / Firmware name Bit 12 / ’IPEAK_ERR’
13 / ’Peak error, motor overcurrent’
and the motor driver is shut down to prevent permanent failure.
Please note that this message is only available in MAC400 and
MAC800.
- The motor has been physically blocked.
- The motor has been running into a sudden mechanical collision.
- The actual AC supply voltage is too low to run the motor at the
actual speed.
alistic setting compared to the nature of the actual load. See
also
Servo filter adjustment, page 43.
- Avoid that the motor during normal operation is meeting a me-
chanical collision or an extreme overload situation.
- This error type is not software resetable. Cycle the control voltage (24VDC).
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 37
2.6 Error Handling
2.6.14 Error message ’Overspeed’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The actual velocity (speed) has been higher than allowed.
Possible cause of this error - Velocity too high.
Solutions to avoid error - Make sure that the velocity setting is within specified range
How to return to normal
operation
Error bit / Firmware name Bit 13 / ’SPEED_ERR’
14 / ’Overspeed’
Please note that this message is only available in MAC400 and
MAC800.
- Servofilter is not stiff enough and speed may overshoot during
start and/or stop or when sudden load changes happens.
This error is triggered at 4300 RPM (MAC400) and 3600 RPM
(MAC800).
(0-3000 RPM nominal).
- Make sure that the servo filter is set to stable setting in order
to avoid overshoots during acceleration or similar. See also
Servo filter adjustment, page 43.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
Error message 15 do not exist since bits are used for other status purposes.
2.6.15 Error message ’SSI Read error’ (only MAC050 to 141)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition
Possible cause of this error - The encoder is not connected correctly.
Solutions to avoid error - Use proper cabling between the motor and the external SSI en-
How to return to normal
operation
Error bit / Firmware name Bit 15 / ’SSI_ERR’
16 / ’SSI Read error’
An external SSI encoder has been enabled but communication
with the encoder has failed.
- The format chosen is not compatible with the actual encoder.
- Improper cabling have been used.
coder. A screened cable with twisted pair wires is recommended.
- Make sure that the right SSI format is selected.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
power.
38 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.6 Error Handling
2.6.16 Error message ’Internal Encoder error’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition A malfunction in the internal encoder has been detected.
Possible cause of this error - The encoder disc is broken because the motor have been ex-
Solutions to avoid error - Do not expose the shaft or the motor for mechanical shocks.
How to return to normal
operation
Error bit / Firmware name Bit 15 / ’INDEX_ERR’
16 / ’Internal Encoder error’
posed to mechanical shock. Typical the shaft have been hit very
hard during mounting of the motor.
Return the motor for service.
2.6.17 Error message ’Invalid Filter settings’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The servo filter settings are not within valid ranges.
Possible cause of this error - The setup file used has been corrupted.
Solutions to avoid error - Select a new filter or contact your JVL.
How to return to normal
operation
Error bit / Firmware name Bit 16 / ’OLD_FILTER’
17 / ’Invalid Filter settings’
- The setup file used is an old type not compatible with the actual motor version.
- Correct the servo filter setting.
See also Servo filter adjustment, page 43.
- Cycle the 24VDC power.
2.6.18 Error message ’Control voltage unstable’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition The control voltage (24VDC at the P+ and P- terminals) has been
Possible cause of this error - The control voltage has been detected outside the nominal
Solutions to avoid error - Make sure that the voltage is stable in the specified voltage in-
How to return to normal
operation
Error bit / Firmware name Bit 17 / ’U24V ’
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 39
18 / ’Control voltage unstable’
unstable and detected outside the specified voltage range for a
too long time.
voltage range.
- The voltage has been applied too slowly with variations.
terval.
- Make sure that the voltage is applied in less than 500mS.
- Cycle the 24VDC power. A reset will not clear the error.
2.6 Error Handling
2.6.19 Error message ’PWM locked’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition An uUnrecoverable errornrecoverable error has occured and the
Possible cause of this error This error is typically followed by other error messages. See in-
Solutions to avoid error - See other error messages that follows this error.
How to return to normal
operation
Error bit / Firmware name Bit 20 / ’PWM_LOCKED’
21 / ’PWM Locked’
motor output driver is shut down in order to prevent any further
damages. The error could be one of following.
- The motor current has been significantly higher than allowed
during normal operation.
- The internal encoder has a fault.
dividual description of these errors.
- This error type is not software resetable. Cycle the control voltage (24VDC).
2.6.20 Error message ’Modbus Com. Error’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition Modbus communication has not been possible due to a commu-
Possible cause of this error - The motor is setup as master but it has not been possible to
Solutions to avoid error - If the actual system is a master/slave configuration, make sure
How to return to normal
operation
Error bit / Firmware name Bit 21 / ’COM_ERR’
22 / ’Modbus Com. Error’
nication error.
reach a slave motor.
- The motor is setup as a slave but do not receive any position
information
that a slave motor is present.
- Make sure that the cabling is made in a proper manner with
twisted pair wires and screened cable.
- Make sure that the opposite unit in the communication system
uses same parameters such as baudrate etc.
- Adjust the time out register.
- The error is cleared if error free communication is re-established but the motor need to be re-entered in the desired operation mode.
- Try to save actual settings and restart the motor by a reset or
cycle the power (24VDC).
40 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.6 Error Handling
2.6.21 Error message ’Current loop error’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition Error only relevant when using the MAC00-P5 module.
Possible cause of this error
Solutions to avoid error - Check the cable feeding the 4-20mA input.
How to return to normal
operation
Error bit / Firmware name Bit 22 / ’CURLOOP_ERR’
23 / ’Current loop error’
The 4-20mA input at the MAC00-P5 module has been detected
lower than 2,0mA which is outside normal range.
- Cable fault.
- Fault in the external 4-20mA source that feed the MAC00-P5
current input.
- Make sure that the 4-20mA signal stay at a level higher than
2,0mA.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
24VDC power.
2.6.22 Error message ’Slave error’ (only MAC400/800)
Message no. / Message
Type / Motor action Unrecoverable error / Motor is set in passive mode.
Error condition - Modbus communication with a slave motor has not been pos-
Possible cause of this error - The motor is setup as master but it has not been possible to
Solutions to avoid error - If the actual system is a master/slave configuration make sure
How to return to normal
operation
Error bit / Firmware name Bit 23 / ’SLAVE_ERR’
24 / ’Slave Error’
sible due to a communication error.
- A connected slave motor has discovered an error. See the slave
error register.
reach a slave motor.
- A connected slave motor has discovered an error. See the slave
error register.
that a slave motor is present.
- Make sure that the cabling is made in a proper manner with
twisted pair wires and screened cable.
- Make sure that the opposite unit in the communication system
uses same parameters such as baudrate etc.
- Reset the motor, clear the error bit(s) in register 35 or cycle the
24VDC power.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 41
2.7 Under Voltage Handling
Undervoltage Handling
Use these fields to define the behaviour of the
motor when mains power disappear.
2.7.1 Undervoltage handling
The MAC motor offers the possibility to define the behaviour during and after the mainsvoltage disappear. This situation could for example be during an emergency stop which
causes the mains supply to be cut while the control voltage is still applied to the motor.
3 options exist:
TT1130GB
2.7.2 Undervoltage -> Set error bit
Default = Off.
If this option is selected an under voltage will be handled like an error situation and the
corresponding error bit will be set. The motor is stopped using the “error deceleration’
before the motor is switched to passive mode, like any other error situation.
When the main power is re-applied the motor will stay in passive mode and report and
under voltage error. To get the motor back in normal operation the error must be
cleared and a operation mode must be selected.
2.7.3 Undervoltage -> Stop controlled and go to passive
Default = Off
This option makes the motor decelerating according to the normal acceleration parameter and go to passive mode when the mains power is removed. When main power is
re-applied the motor stay in passive mode. To get the motor back in normal operation
an operation mode must be selected.
2.7.4 Undervoltage -> Set velocity to 0
Default = Off.
This option simply just set the velocity to 0 causing the motor to decelerate and stay stationary (except in “torque direct mode”) when mains power is removed. The velocity
setting will stay at 0 also after the main power is re-applied. A velocity value (>0RPM)
must be written into the velocity register to get the motor moving again.
42 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.8 Servo filter adjustment
2.8.1 Servo filter adjustment
The MAC motor contains a higher-order digital filter regulation core. The purpose of the
filter is to ensure that the desired speed, torque and/or position are achieved and sec
ondly that stability is obtained.
The motor’s default setting (when delivered) is normally appropriate for most applications. The only necessary adjustment is the LOAD parameter which is available via the
Main setup in the MacTalk software. For more demanding applications, the Filter selector
can be used.
2.8.2 Adjusting the LOAD parameter
The LOAD parameter must be increased proportional to the inertia of the payload in the
system. The default value of the LOAD parameter is 1.0000.
The proper LOAD value must be determined as follows.
LOAD=(Motor inertia+Load inertia)/Motor inertia.
-
Adjust Load according to the attached inertia.
Example:
A system uses a MAC800. The MAC800 has a motor inertia
of 0.92kg/cm² (according to technical data in appendix).
If the load inertia is 9.2kg/cm² (motor intertia x 10) the Load
needs to be adjusted to
LOAD=(Motor inertia+Load inertia)/Motor inertia
LOAD=(0.92 + 9.2) / 0.92 =
If the load inertia is not fully known, it is highly recommended to slowly increase the
LOAD parameter until the motor starts to be unstable and noisy. Then decrease the val
ue 20-30% to obtain a certain safety margin.
Remember to save the adjustment permanently in the motor by pressing the “Save in
flash” button.
2.8.3 Exceptions when adjusting LOAD
Precautions must be taken if the transmission from the motor to the load is elastic or involves a certain amount of backlash. A typical situation where precautions must be taken
is when using a belt drive actuator, since the motor’s forces may have to be transmitted
past a gear, for example, and then the belt until the payload is finally met. This “transmis
sion chain” is typically very elastic and the gear will contain a certain amount of backlash.
The main problem is that the motor does not directly “see“ the final payload.
When the motor starts to rotate, it will not “sense” the payload before the backlash distance is passed and the belt is tightened. It is therefore not a linear system and the LOAD
cannot be increased as much as in theory.
11
TT1022GB
-
-
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 43
2.8 Servo filter adjustment
2.8.4 Filter selector basics
If the desired motor response cannot be achieved using only the LOAD parameter, the
filter selector can be used.
The filter selector can be found in the MacTalk upper toolbar.
Using the Filter selector, the “personality” of the motor response can be optimised to
specific applications. The following overall behaviours can be adjusted:
- Follow error during movement and/or when the motor is stationary.
- Stability with a high load inertia.
- Stability if the load inertia changes during operation.
- Motor noise
The filter selector is in principle the same for the complete MAC motor range except that
the MAC50 to MAC141 also include the possibility to adjust the current filter.
MAC050, 95, 140 and 141
Filter selector:
MAC400 and 800
Filter selector:
TT1024GB
44 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.8 Servo filter adjustment
T
2.8.5 Adjusting the current filter (only MAC050 to 141)
The current filter is adjustable in the MAC050 to MAC141 models. This feature is useful
if the audible noise from the motor needs to be decreased. Please note that the band
width of the current filter will also be lowered which can cause efficiency at higher speeds
also to be lowered. As shown in the selector box below, it is not recommended to select
the “Low noise” filter if the motor is operated above 3000 RPM (MAC141: 2000 RPM).
A general recommendation is to select the high noise filter since it has the best dynamic
performance.
MAC050, 95, 140 and 141
Current filter selector:
TT1025GB
2.8.6 Adjusting the Position/Velocity filter
The Position/Velocity filter is the main filter which sets up the main response performance of the motor.
-
Velocity/position
filter selector:
12345
Follow error
/ Torque
Applied torque
Follow error
Hardness
Hardness:
The follow error is decreased by choosing
a harder filter but the stability is also
decreased.
The 5 levels of hardness will affect the
motor torque in the following manner.
In case of certain follow error the torque
is integrated up to 300% (full torque).
Fastness
Velocity
Time
300% motor torque is produced when
these follow errors are present:
Column 1 : Follow error of 8000 counts
Column 2 : Follow error of 2000 counts
Column 3 : Follow error of 500 counts
Column 4 : Follow error of 125 counts
Column 5 : Follow error of 1 count (no error is accepted)
Commanded velocity
Actual velocity
Time
Fastness:
he relationship between a slow and
a fast filter is seen as the ability to
track the commanded velocity within
time. By choosing a faster filter the
velocity reaches the required velocity
faster.
TT1026GB
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 45
2.8 Servo filter adjustment
2.8.7 Damping
In almost any application it can be useful to damp (suppress) certain oscillations.
The damping selector can be used for this purpose.
The following damping types are available:
-None
Damping feature is disabled.
-Low frequency
When selecting Low frequency, oscillations caused by a poor mechanical transmission
can be reduced. Poor mechanical transmission means backlash in the coupling or
elastic toothbelts, etc. The filter becomes more tolerant to variations in the inertia
which normally can cause the motor to become unstable.
- High frequency
When selecting High frequency, oscillations at higher frequencies will be reduced. This
can typically occur if the filter starts to oscillate at a frequency related to the sample
frequency. Often this can be heard as an audible noise.
- High+Low frequency (only available on MAC400-800)
This is a combination of High and Low frequency settings.
-Low+Low frequency (only available on MAC400-800)
This setting is similar to Low frequency but adds extra tolerance to variations in the
inertia.
Damping selector:
TT1027GB
46 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.8 Servo filter adjustment
V
e
2.8.8 Follow error compensation
This feature makes it possible to achieve a minimum position error during movement
(dynamically). The 2 main types are:
- Static
Will reduce follow error at constant speed, which can be useful for electronic gear applications since the motor will follow exactly what is demanded without any position
error.
- Dynamic
Will reduce follow error during acceleration or deceleration (speed changes). This feature is intended to be used for applications which require that a commanded speed or
target position is reached as fast as possible but without any overshoots etc.
The Dynamic compensation provides 3 levels (Dyn 1 to 3). Using a higher Dyn
number, the filter order is increased and better performance may be possible, but will
depend on the actual application.
Follow error compensation:
The best result is normally obtained in the
range 90-110%.
TT1028GB
Dynamic follow error compensation Static follow error compensation
elocity
Follow error
None
DYN1
DYN2
DYN3
DYN3
DYN2
DYN1
None
Commanded velocity Commanded velocity
Actual velocity
Time
Time
Velocity
Actual velocity
Tim
Follow error
Static
Time
Please note that the dynamic compensation level Dyn 3 is only available on the MAC400800 but for all motor sizes the available dynamic compensation is limited to Dyn 1 or 2 if
a slow main filter is selected.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 47
2.8 Servo filter adjustment
2.8.9 Transferring and saving the filter
After setting the filter choices, the filter can be transferred to the motor.
The complete setup including the filter configuration can also be saved to and later recalled from disc by using the Open and Save buttons in the toolbar.
2.8.10 Additional adjustment
Now the desired filter is set up in the motor and the performance can be tested. Further
improvement may be required and typically it may be necessary to experiment in order
to obtain an optimum result.
Please note that the LOAD parameter must still be used to adjust the inertia ratio between the motor and load. See also Adjusting the LOAD parameter, page 43.
48 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.9 Using external SSI encoder
55G
SSI Control
section
Only MAC050 to 141
The FastMac
commands field
Input/Output
setup
2.9.1 SSI Encoder
SSI support is added to the MAC50-141 series of servomotors, this feature is very useful
to determine the absolute position of the motor shaft if an encoder is connected directly
to this or another encoder position.
The SSI interface
When the differential lines are used for SSI, the A1+/- lines work as a Clock signal from
the motor to the encoder, while the B1+/- signals work as a Data signal from the encod
er to the motor.
CLOCK
Power
management
TT11
B
-
n*T
t
1
a
121
T
3
n+1
t
3
DATA
n
MSB
t
2
n-1
1
0
LSB
TT1158GB
The figure above shows the SSI protocol principle. The Clock line is normally high. When
a reading is requested, the Clock goes low for t
micro seconds to allow the encoder to
1
sample and prepare a value. On the first rising edge of the Clock (1), no sampling is done,
but on the second rising edge of the Clock (2) the first data bit is read from the Data line.
Shortly after reading the bit value, the motor will set the Clock high and execute another
cycle, where the data bit is sampled just before each rising Clock. After the last data bit
has been sampled, the Clock stays high.
In the MAC-motor several registers are available for storing values for different purposes.
Position registers P1-P8 (available from MacTalk etc.) are used to hold SSI positions.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 49
2.9 Using external SSI encoder
When the motor starts up during power on or a software reset the SSI encoder is read
4x and the value is decoded from Gray-code to an absolute position with an 25bit accu
racy (25-bit signed).
This position is scaled to fit motor resolution and then saved in position register P7 (register 61) as a 32-bit signed value.
The SSI encoder feature is based on an external encoder resolution of 1024 cnt/rev. (256
pulses/rev.) this value is scaled to fit the motor resolution which is 4096 cnt/rev.
SSI is a serial protocol without any error detection or correcting features so in order to
determine if the correct value is read, the value is read 4 times and the same value need
to be read all 4 times.
If this value has changed during the read cycle, the error register 35 bit 15 is set and also
bit 15 in the SSI control register 178.
If this error condition has happened be sure to clear the error in register 178 before doing a save in flash operation.
2.9.2 Encoder positioning and usage
A new position is calculated based on the encoder position stored in P7 and a previously
saved value (a position sample) in register P6.
This value stores in P6 is a position reference stored when a position reset is done.
The calculation is as follows:
P8 = (P7 - P6) + P5
Only MAC050 to 141
-
The P5 value is used when an offset is to be added to the position. So the desired ’0’ position is saved into P6 and the actual position (from the encoder) is saved into P7 and then
again P5 is used to offset this position.
Example 1:
The encoder shaft is connected to the motor shaft, meaning that 1 revolution at the external encoder is equal 4096 motor counts.
Motor start up, encoder reading = 12288 (random position)
Motor P_IST = P_SOLL = 12288
This position we want to define as position 0 so we run the position reset procedure
(see Reset position procedure) and store 12288 into P6.
The motor is reset (software reset or power cycle) and the new position is calculated by:
P4 is by default 0, so
P8 = (12288 - 12288)
P8 = 0
This value is transferred to P_IST and P_SOLL, so
P_IST = P_SOLL = P8 = 0.
Now the encoder position 12288 is defined as position 0 in the system.
Example 2:
Let's say that we need to define a fixed position as position = 100 because
we want our motor to be 100 counts from the actual 0-position at exactly this physical
position.
50 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.9 Using external SSI encoder
We set P5 = 100 and save this position into flash (set register 211 = 2).
In the previous example we set the 0-position to 12288 counts. So by setting P5 = 100
will result in the same position being :
P8 = (P7 - P6) + P5
P8 = (12288-12288) + 100
P8 = 100
Which again will be transferred to P_IST and P_SOLL if synchronization bit is set in the
SSI-setup register at startup.
2.9.3 Registers used by SSI
Register 178, SSI_SETUP_BITS1 where:
Bit: 0 1 2 3 4 - 14 15
Function: SSI Enable/
Disable
SSI enable will setup the motor to read the SSI at startup. The Synchronize bit transfers
the position calculated in P8 into P_IST and P_SOLL.
SSI Reset position is used to preset a position to the value stored in P5. Default P5=0.
Bit15=1 indicates a read failure, that is different values are read within the 4 times the
values is read.
Not used Synchronize
P_IST=P8,
P_SOLL=P8
SSI reset
position
(P6=current
position)
Only MAC050 to 141
Future
options
SSI
Read Error
Register 57 P5 32-bit signed Holds the preset value that is used when a reset position is done
Register 59 P6 32-bit signed Holds the encoder value when the last Reset position was done. This
Register 61 P7 32-bit signed Holds the newly read encoder value, scaled into motor counts.
Register 63 P8 32-bit signed Holds the calculated position, that is transferred to P_IST and P_SOLL
value is used as a refence at startup to calculate the actual position.
if the synchronization bit is set up in the setup register 178.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 51
2.9 Using external SSI encoder
2.9.4 Encoder connections:
Using the LIKA rotary encoder MMC60 connected to the MAC00-B4 module the PIN
configuration is as follows:
The encoder is connected to the IO-plug using the 8-pin female M12 -plug.
M12-Pin Signal Colour (LIKA Encoder cable) Description
1 A+ White Clock +
2 A- Brown Clock -
3 B+ Green Data +
4 B- Yellow Data -
5 N.C - O1 from motor
6 O+ Red 24V supply to encoder
7 Gnd Black + Shield Gnd and shielding
8 N.C -
See Mac-manual for further details regarding the IO connection in the module.
Because the plug doesn't support a 24V power outlet, O1 or O2 can be used to supply
the power to the encoder unit. To be able to do this register 161 needs to be setup.
Bit 3 and bit 4 in register 161 indicates whether IO1 and IO2 are user controlled or setup
as previously as IO1 indicating ’In position’ and IO2 indicating errors.
Only MAC050 to 141
Example:
IO2 is used as 24V power supply to the encoder so we need IO2 as user controlled output and set the output to source the O+ voltage.
Register 161 bit 4 needs to be on
Register 161 = 16 (0x10)
Register 179, bit0 and bit1 holds the output value, but they are inverted so for IO2 to be
high (O+) bit1 needs to be 0.
So we hold the register to the default value 179 = 0 and IO2 will source power to the
encoder.
When IO2 is on (O+), the red LED inside the motor is lit. This is normally used for error
indication when the IO2 isn't setup for user control.
52 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.9 Using external SSI encoder
g
2.9.5 Setup SSI using MacTalk
To setup the MAC-motor for reading the SSI encoder value at startup, first set the I/O
setup for using SSI input. This means that the A and B input -channels are setup for input
on both. Because the plugs doesn't support any 24V supply output for supplying the en
coder, both IO1 and IO2 can be used for this purpose.
Only MAC050 to 141
-
TT1159GB
Output 2 is selected for driving
the power supply to the encoder.
This will setup the Multiturn I/O for using
both A and B channel in communicating
with the encoder usin
SSI
SSI setup on the advanced tab.
This section gains access to the registers 178, for setting up the SSI functionality previously described.
The SSI position is stored in register P8, which is displayed under this section too. The
value is also accessible from the register-tab.
Reset position procedure
To reset the motor to a specific position, first read the SSI encoder value by setting register 211 = 1
This will reset the motor and read the SSI value. Next set the Reset-bit in the SSI_SETUP
register (register 178 bit 3). Now the encoder value has been transferred to P6 and
needs to saved in flash. The Flash saving procedure is done by writing 211 = 2.
This will also reset the motor and calculate the new position based on the saved value.
If a preset value is to be used instead of 0, this value is entered in P4 and will automatically
be used when the motor starts up (previously explained).
If this preset value is to be used, simply write the position to position register P4 (register
55) and save the value to flash memory by writing 211 = 2.
Read SSI procedure.
Every time the motor is power cycled or a software is commanded the SSI encoder is
read at startup.
To do a software reset simply write register 211 = 1 and let the motor startup. The
reading and the startup will take approximately 1-2 seconds.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 53
2.9 Using external SSI encoder
I/O Setup
Because of the strict timing in the motor it is not possible to read the encoder value when
motor has started. This is due to strict timing control in the motor.
As a new feature the MAC40-141 firmware now supports setting up IO1 and IO2 as user
controllable. IO1 and IO2 is settable from these controls.
When all values has been setup, remember to save in flash and/or into a .mac file before
removing power from the motor.
If an encoder is available on the motor, the actual position value is read as soon as the
motor start-up after a reset.
Only MAC050 to 141
54 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
2.10 Power Save
2.10.1 Power Save
The MAC50-141 firmware supports a function to save power in Position mode and Analogue bi-position mode that can automatically set the motor into Passive mode during
pauses in movements, and restore the original mode when a new movement is required.
This can be useful for battery powered applications as well as general power and cost
savings and to reduce audible and electrical noise.
The power save function is enabled when bit 0 in register 180, SETUP_BITS, is set to
one.
When Power Save is enabled, the motor is set into Passive mode after the actual position
has been within the In Position Window for one second. This position, where Passive
mode was entered, is then remembered, and as soon as the actual position gets farther
from the remembered position than the value in the In Position Window register, the
motor is set back into the original Position or Analogue bi-position mode.
Cautions.
When Power Save is enabled, some functions may work differently from what is expected. For instance, in Analogue bi-position mode, changing the Low or High Position values
will not have effect until the motor is set back into active mode by turning the axis or reselecting the active mode.
Only MAC050 to 141
Also with under-voltage conditions, where the motor is set to enter Passive mode and
restore the original mode when the voltage gets back to normal, can leave the motor in
Passive mode, so in this case under-voltage handling should rather set an error bit that
should be monitored.
In some tricky cases, when the motor is Power Saved and the axis turns very slowly away
from the saved position, the motor will stay in Passive mode until the actual position has
moved twice the distance that is stored in the In Position window register. This happens
because the motor initially wakes up at the correct distance, but will re-enter Passive
mode immediately because it was not outside the In Position window long enough to
resume the original active mode. This issue can be reduced by selecting a better value
for the In Position window register.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 55
2.11 Scope Function
2.11.1 Scope Function
Preliminary - this function is still under development.
The Scope function is a 4 channel oscilloscope that is, a very good and necessary function
for testing a new application or finding errors in an existing system.
The Setup has to be selected to set up the Scope function correctly before use. Most registers in the MAC motors can be chosen for viewing, different trigger functions can be
selected, saving and loading scope pictures are possible etc.
TT1106GB
TT1110GB
56 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3Hardware description
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 57
3.1 Connector overview
g
Connector overview for the basic MAC motors
Basic MAC050-141 motor
Rear end
2
3
M2.5 mounting threads for
expansion module.
1
RS232 Interface
Signal levels 5V
4 - Ground
3 - Transmit Tx (5V)
2 - Receive Rx (5V)
1 - +5VDC out (max. 30mA)
Connector cable part:
Manufacturer : JST
Type : ZHR-4 (1.5mm pitch)
Crimp contacts : SZH-002T-P0.5
Error LED (red)
1
Power LED (green)
Basic MAC-400 motor
3
M2.5 mounting threads for
expansion module.
2
2
User I/O
1 - GND
2 - AIN
3 - O1
4 - O2
5 - A+
6 - A7 - B+
8 - B-
Connector cable part:
Manufacturer: AMP
: 770602-8 (2.54mm pitch), Crimp contacts: 770601-1
Housin
Main signal ground
Analogue input +/- 10V
Status outputs
Multifunction I/O
see text
- .
(Maximum 5V)
Basic MAC-800 motor
1
3
Rear end
1
2
3
M2.5 mounting threads
for expansion module.
Power Supply
12
+12-48VDC
GND
Connector :
Manufacturer : Molex
Housing: 09-91-0200 (3.96 pitch)
Crimp contacts: 08-50-106
TT1161GB
3.1.1 Connector description
The basic MAC motor is equipped with 3 connectors.
-RS232 Interface
The motor setup and monitoring is done via this interface. The windows-based
MacTalk software must be installed on a computer and used for this purpose. It is
also possible to send position, velocity and other commands from, for example, a
PLC if MacTalk is not used.
-User I/O
This connector includes all the main I/O necessary to run the motor in gear mode,
velocity mode, etc. An analogue input (±10V) can be used for velocity or torque
control or it can be used for a Zero search sensor. 2 Status outputs are also available
to show the actual status of the motor. Terminals 5 to 8 are multifunction terminals,
where the specific function of the terminals depends on the motor setup.
The functions can be only one of following:
1. Pulse outputs. The internal encoder-pulses are output as a quadrature signal.
2. Pulse inputs. e.g. an external encoder can be connected for gearing applications.
3. RS422 communication. This interface is intended for permanent connection.
-Power Supply
Connect the main supply to this connector. The voltage must be within the range
12 to 48VDC nominal. Please note that the MAC400 and 800 only accepts +18 to
30 VDC. For further information about the MAC400 and 800 main supply,
See How to connect power supply (only MAC400), page 62 and How to connect the pow-
er supply (only MAC800), page 66.
A connector kit is available “MAC00-CONKIT1”. See Accessories, page 291.
58 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.2 Power Supply
S
p
Basic MAC motor
Rear end
Power Supply
12
Connector :
Manufacturer : Molex
Type : 09-91-0200 (3.96 pitch)
+12-48VDC
Fuse T10A
(See text)
Only MAC050 to 141
Error LED (red)
Power LED (green)
= < 3metres
The distance between the
MAC motor and the
capacitor must be less
than 3 metres otherwise
the peak performance of
the motor is reduced.
+
A 4700µF/50V capacitor
in the power supply output is recommended.
3.2.1 Power supply (only MAC050 to 141)
The power supply must be connected to the terminals marked +48V and GND.
The supply voltage can be in the range 12VDC up to 48VDC; however the maximum
speed of the motor (4000 RPM) is based on 48VDC. A lower voltage will decrease speed
performance.
This curve below shows the relationship between voltage and recommended speed.
peed in RPM
4000
3000
2000
1000
Restricted area
motor losses will
be too high
Safe operation area
0
0 12243648
O
eration below 12V is not recommended
+
Power Supp ly
12-48VDC
Earth
TT0910GB
MAC50, 95, 140
MAC141
Max 2800 RPM@48VDC)
Supply
Volt a ge ( V DC)
TT0925GB
If a supply voltage lower than 48VDC is used, it will not influence the motor torque unless
the corresponding speed at this voltage is overridden. The MAC motor continuously
measures the actual supply voltage and optimises the current control filter. This feature
ensures that the motor always produces full torque within the safe area of operation.
3.2.2 Power supply grounding (only MAC050 to 141)
No additional grounding/earthing of the motor is necessary since the complete motor
housing is connected directly to pin 2 of the Power Supply connector.
The overall earthing of the system must be done at a central point close to the power
supply.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 59
3.2 Power Supply
Only MAC050 to 141
3.2.3 Dimensioning power supply and fuse (Only MAC050 to 141)
The power supply must be dimensioned according to the actual motor size (MAC050,
95, or 140/141).
The size of the pre-fuse also depends on the actual model of the MAC motor.
Use the following table to select the power supply and fuse ratings.
Desired
voltage
-
12VDC 20W T4A 40W T6.3A 60W T10A
24VDC 40W T4A 80W T6.3A 160W T10A
48VDC 80W T4A 160W T6.3A 320W T10A
Supply
rating
See also Power Supplies, page 292 in the appendix which shows the standard power supplies that JVL can offer.
3.2.4 Emergency stop
Please consult the chapter: Emergency stop considerations, page 265
MAC050 MAC095 MAC140 or 141
Fuse size Supply
rating
Fuse size Supply
rating
Fuse size
60 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.2 Power Supply
T
3.2.5 Power supply circuitry (only MAC400)
The MAC400 supply is split into 2 individual circuits with full galvanic isolation between
the circuits. The control circuitry requires a voltage in the range 18 to 30VDC and the
power circuity must be supplied with 90 to 240VAC. Having 2 independent supply cir
cuits offers the feature that the supply voltage for the power circuitry (90-240VAC) can
be removed for safety reasons, while the control circuitry can continue operating and
thus keep the position counter updated and keep other vital functions such as communi
cation active.
Only MAC400
-
-
P+/- must be permanently connected
if control circuitry
must be keept active
while main power is
disconnected.
Power
Supply
18-30VDC
+
Optional
230VAC
115VAC
MAC400 Supply diagram
P+
P-
Isolation barrier
Power dump ou tput
PD
Bus output (320VDC Nom.)
BO
Bus common
CM
PE
L2
N
L1
PE
Overvolt.
Protection
Mains
Filter
EMERGENCY
STOP and RELAY
See section 5.6.2 for
further information
Control Core
Inrush
limiter
+
-
115VAC
230VAC
Opto
Isolators
Power dump
Dump
resistor
Driver
L1
L2
N
PE
Single phase
90 - 240VAC
+ Earth
E
M
T1171GB
The circuit above is shown with an emergency relay (box) which can be omitted if the
application does not require this safety feature. There are shown examples of Emergency
stop and relay in section 5.6.2
The internal power dump is intended to cover 90% of all applications but if the error
message “overvoltage” is monitored, an external power dump resistor must be connect
-
ed between the terminals PD and BO.
3.2.6 Emergency stop
Please consult the chapter: Emergency stop considerations, page 265
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 61
3.2 Power Supply
)
)
)
)
3.2.7 How to connect power supply (only MAC400)
The power supply for the control circuitry is connected through the expansion module
at the terminals called P+ and P- or directly at the internal power supply connector.
The power circuitry must be applied according to the illustration below.
Only MAC400
TT1172GB
MAC400 supply connection
PDO connector
Main power connector
Main power, internal bus voltage and power
dump are accessible through these connectors.
Mains power must be 115 or 230VAC.
Main power connector
N
(Neutral)
A
PE (Earth
B
C
L1
L2
(230VAC
(115VAC)
Polar izatio n
(Female)
(male)
Control power (+18-30VDC) must
be connected to the P+ and P- terminal
at the expansion module.
See the actual module used, for details
of connection.
PDO connector
CM
(Common)
C
guides
PE(Earth
PD
B
A
BO (Bus out 325VDC
(Power dump output)
Terminal descriptions:
L1 115VAC input (phase).
L2 230VAC input (phase).
N 115/230VAC input (neutral).
PE Earth must be used with the DC-bus and the PD terminals.
PD Power dump output - see also Connecting an external power dump resistor, page 68.
BO Bus output (nom. 325VDC).
CM Common. Ground for the internal DC-bus.
CAUTION
shock. Disconnect all power and
wait 5 m in. before servicin g
3.2.8 MAC400 Grounding
Make sure that the machine part on which the MAC400 is mounted is properly grounded
to the main part (body) of the machine in order to avoid major ground/earth current to
flow through the motor and cause interference to other signal groups such as interface
cables.
- Risk of electric
62 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.2 Power Supply
t
3.2.9 Sizing the external fuse (Prefuse).
When using 115V supply voltage:
To met UL requirements, the prefuse must be a class RK5 such as the type FRN-R-10
(10Amp.) from manufacturer: Cooper Bussmann INC.
When using 230V supply voltage:
Prefuse T6.3A@230VAC type gG, Do or Dz in the phase line Rated for600V/150kA.
3.2.10 Connecting an external power dump resistor
MAC400 with external power dump connection.
BO-PD (V)
Note ! : Its only necessary to
connect screen to signal source.
Vol ta ge ( V)
Vel oci ty
PE
TT1173GB
PDCM
BO
Screen
Shielding/housing must
be connected to earth
Terminal description for the “Dump” connector.
CM =
BO =
PD =
R
Use a value of 33
to 68 Ohm/50W
Wirewound
Common. Is internally connected to the ground of the DC bus.
Is only intended to be used if multiple motors share DC-bus.
Bus output. The internal DC bus is connected to this terminal.
Power Dump output. Behind this terminal is placed a switch
(IGBT transistor) which connect the terminal to the internal
bus ground if the voltage become higher than 400VDC.
Only MAC400
PD activated
when voltage
exceeds 400V
Energy fed back from
he motor to the DC bus
Nom. 325VDC
Time
400V
Time
Time
The internal power dump can absorb up to 6W continuously and 1.4kW peak, which is
considered as appropriate for most applications.
However should a situation occur in which the connected load inertia is too large or the
deceleration too fast, the internal power dump will not be able to absorb all the returned
energy and will report the error message “regenerative overload”.
In this situation the only possible solutions are as follows:
1. Decrease the acceleration/deceleration parameter.
2. Lower the attached load inertia.
3. Connect an external power resistor.
The drawing above shows how to connect an external power resistor. A wirewound
type is recommended since it will be able to absorb higher peak power than other types
of resistors.
Warnings: Ensure that the resistor value is between 33 to 68 Ohm/50W since the out-
put otherwise can be damaged. Also avoid short-circuit of the output.
CAUTION
shock. Disconnect all power and
wait 5 m in. before servicin g
- Risk of electric
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 63
3.2 Power Supply
3.2.11 Power cable acessories for MAC400
The following standard cables can be supplied by JVL
JVL no: Type: Description
WP0002 MAC400 115/230VAC power cable 2 m. Straight M16 conn and free end. Female
WP0005 MAC400 115/230VAC power cable 5 m. Straight M16 conn and free end. Female
WP0020 MAC400 115/230VAC power cable 20 m. Straight M16 conn and free end. Female
WP0102 MAC400 Brake cable 2 m. Straight M16 conn and free end. Male
WP0105 MAC400 Brake cable 5 m. Straight M16 conn and free end. Male
WP0120 MAC400 Brake cable 20 m. Straight M16 conn and free end. Male
WP0402 MAC400 230V power cable with earth 2m. Straight M16 conn and free end. Female
WP0405 MAC400 230V power cable with earth 5m. Straight M16 conn and free end. Female
WP0420 MAC400 230V power cable with earth 20m. Straight M16 conn and free end. Female
Only MAC400
64 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.2 Power Supply
T
B
3.2.12 Power supply circuitry (only MAC800)
The MAC800 supply is split into 2 individual circuits with full galvanic isolation between
the circuits. The control circuitry requires a voltage in the range 18 to 30VDC and the
power circuity must be supplied with 90 to 240VAC (Set by solder jumper
supply voltage (only MAC800), page 67). Having 2 independent supply circuits offers the
feature that the supply voltage for the power circuitry (90-240VAC) can be removed for
safety reasons, while the control circuitry can continue operating and thus keep the po
sition counter updated and keep other vital functions such as communication active.
Only MAC800
Using 115V
-
P+/- must be permanently connected
if control circuitry
must be keept active
while main power is
disconnected.
Power
Supply
18-30VDC
+
Optional
90-240VAC
MAC800 Supply diagram
P+
P-
Isolation barrier
Power dump out put
PD
Bus output (320VDC Nom.)
BO
Bus common
CM
Overvolt.
Safety
Protection
Fuse
L1
N
PE
Mains
Filter
EMERGENCY
STOP and RELAY
See section 5.6.2 for
further information
Control Core
Inrush
limiter
115VAC setup
+
-
Opto
Isolators
Powe r dum p
Dump
resistor
Driver
L1
Single phase
N
90 - 240VAC
+ Earth
PE
E
M
T1162G
The circuit above is shown with an emergency relay (box) which can be omitted if the
application does not require this safety feature. There are shown examples of Emergency
stop and relay in section 5.6.2. The internal power dump is intended to cover 90% of all
applications but if the error message “overvoltage” is monitored, an external power
dump resistor must be connected between the terminals PD and BO.
3.2.13 Emergency stop
Please consult the chapter: Emergency stop considerations, page 265.
3.2.14 Sizing the external fuse (Prefuse).
When using 115V supply voltage:
To met UL requirements, the prefuse must be a class RK5 such as the type FRN-R-15
(15Amp.) from manufacturer: Cooper Bussmann INC.
When using 230V supply voltage:
Prefuse T10A@230VAC type gG, Do or Dz in the phase line Rated for600V/150kA.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 65
3.2 Power Supply
of connection.
3.2.15 How to connect the power supply (only MAC800)
The power supply for the control circuitry is connected through the expansion module
at the terminals called P+ and P- or directly at the internal power supply connector.
The power circuitry must be applied according to the illustration below.
MAC800 supply connections
Remove the lit to access the internal supply terminals
L1
N
PE (Earth)
PE (Earth)
PD
BO
CM
Only MAC800
Control power (+18-30VDC) must
be connected to the P+ and P- terminal
at the expansion module.
See the actual module used, for details
Main power, internal bus voltage and power
dump are accessible through these spring
contacts placed under the top lid.
Mains power must be 115 or 230VAC.
TT0990GB
Terminal descriptions:
L1 115/230VAC input (phase). (The voltage range is set by solder jumper)
N 115/230VAC input (neutral). (The voltage range is set by solder jumper)
See Using 115V supply voltage (only MAC800), page 67.
PE Earth must be used with the DC-bus and the PD terminals.
PD Power dump output - see also Connecting an external power dump resistor, page 68.
BO Bus output (nom. 325VDC).
CM Common. Ground for the internal DC-bus.
Important notes:
- If 115VAC is used as supply voltage the MAC800 must be set up for this. See
Using 115V supply voltage (only MAC800), page 67.
- Screened cables is recommended.
CAUTION
shock. Disconnect all power and
wait 5 m in. before servicin g
- Risk of electric
3.2.16 MAC800 Grounding
Make sure that the machine part on which the MAC800 is mounted is properly grounded
to the main part (body) of the machine in order to avoid major ground/earth current to
flow through the motor and cause interference to other signal groups such as interface
cables.
66 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.2 Power Supply
j
This solder jumper
must be shorted
if 115V is used as
supply voltage
Warnings:
Make always sure to switch
off power for 5 min. before
operating inside the motor.
Do not short-ciruit this
umper if 230V is used
as supply voltage.
Internal damaged
will occur.
TT1057GB
3.2.17 Using 115V supply voltage (only MAC800)
When using 115VAC supply voltage, the MAC800 will be able to operate within a limited
speed range.
The motor efficiency and dynamic response will however not be optimal.
To optimise the performance it is recommended the internal jumper shown above is soldered. By doing this the internal bus voltage will remain at the nominal value of 325VDC
when 115VAC is applied.
To check that the jumper is set properly, the bus voltage displayed in the MacTalk main
screen must show approximately 325VDC. If the jumper is not set correctly, the voltage
shown will only be half of this value (160-170VDC).
Only MAC800
Important !:
Make sure that the jumper is not short-circuited if 230VAC is applied since this will cause
fatal damage to internal components.
The MAC800 motor is configured by default for 230VAC supply (jumper not shortcircuited) on delivery.
CAUTION
shock. Disconnect all power and
wait 5 m in. before servicin g
- Risk of electric
3.2.18 Prefuse when using 115V supply (only MAC800)
To fulfil UL requirements, the prefuse must be a class RK5 such as the type FRN-R-15
(15Amp.) from manufacturer: Cooper Bussmann INC.
See also Power supply circuitry (only MAC800), page 65
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 67
3.2 Power Supply
t
3.2.19 Connecting an external power dump resistor
MAC800 with external power dump connection.
Only MAC800
Connector box for power and power dump.
L1
N
PE (Earth)
PE (Earth)
PD
BO
CM
TT1013GB
Main earth.
Always make sure that
the motor is connected
to earth.
Note ! : Its only necessary to
connect screen to signal source.
Screen
Shielding/housing must
be connected to earth
Terminal description for the “Dump” connector.
CM =
Common. Is internally connected to the ground of the DC bus.
Is only intended to be used if multiple motors share DC-bus.
Bus output. The internal DC bus is connected to this terminal.
BO =
Power Dump output. Behind this terminal is placed a switch
PD =
(IGBT transistor) which connect the terminal to the internal
bus ground if the voltage become higher than 400VDC.
R
Not less than
68 Ohm/100W
Wirewound
BO-PD (V)
Volt ag e ( V)
Velo cit y
PD activated
when voltage
exceeds 400V
Energy fed back from
he motor to the DC bus
Nom. 325VDC
Time
400V
Time
Time
The internal power dump can absorb up to 9W continuously and 2.5kW peak, which is
considered as appropriate for most applications.
However should a situation occur in which the connected load inertia is too large or the
deceleration too fast, the internal power dump will not be able to absorb all the returned
energy and will report the error message “regenerative overload”.
In this situation the only possible solutions are as follows:
1. Decrease the acceleration/deceleration parameter.
2. Lower the attached load inertia.
3. Connect an external power resistor.
The drawing above shows how to connect an external power resistor. A wirewound
type is recommended since it will be able to absorb higher peak power than other types
of resistors.
Warnings: Ensure that the resistor value is not lower than 68 Ohm since the output can
be damaged. Also avoid short-circuit of the output.
CAUTION
shock. Disconnect all power and
wait 5 m in. before servicin g
- Risk of electric
68 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.3 Serial interface
3.3.1 Interface Connection
The Controller Interface is based on an asynchronous serial interface.
3 interface signals, Rx, Tx and ground are used. The interface can be used directly with
the serial COM port of any standard PC or PLC by using the optional cable type RS2329-1-MAC which has an integrated RS232 converter. Another possibility is to use one of
the expansion modules for the MAC motor which also include an RS232 and RS485 con
verter. See also Accessories, page 291.
Asynchronous
Serial Interface
Connector located inside the Basic MAC motor
4 - Ground
3 - Transmit Tx (5V level)*
2 - Receive Rx (5V level)
1 - +5VDC out (max. 30mA)
Connector cable part:
Manufacturer : JST
Type : ZHR-4 (1.5mm pitch)
Crimp contacts : SZH-002T-P0.5
-
* MAC400 and 800 uses 3.3V as Tx level
3.3.2 RS232 Interface signal levels
Please note that the signal levels are 0 to +5V(3.3V)DC and are thus not according to
the RS232 standard which requires +/-12V nominal at the RX and TX signals. However
the protocol used is equivalent to the RS232 protocol.
If the Basic MAC motor is implemented in an OEM application where an internal processor communicates with the MAC motor, the TX and RX terminals can normally interface directly.
TT0912GB
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 69
3.4 User I/O
p
g
User I/O
1 - GND
2 - AIN
3 - O1
4 - O2
5 - A+
6 - A7 - B+
8 - B-
Connector cable part:
Manufacturer: AMP
Housing: 770602-8 (2.54mm pitch)
Crim
contacts: 770601-1
3.4.1 Analogue input
The analogue input can be used for two purposes in the basic MAC motor.
1. As an analogue control input when the MAC motor is used for either velocity control
or torque control.
2. As a Zero Sensor input when the MAC motor is used in position or gear mode.
For further information see Mechanical zero search, page 26
Note ! : screen only
connected to signal source.
Screen
1 = Main signal ground
2 = Analogue input +/- 10V
Axis controller
or
Potentiometer
Ground
±10V out
TT0913GB
These 7 modes uses the
ue input as reference.
analo
The input is automatically used as an analogue ±10V input when the Start-up
mode in the MacTalk main window is set
to one of the 7 modes such as Analogue
Torque, Velocity or Velocity/Gear as
shown in the accompanying illustration.
TT0915GB
70 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.4 User I/O
S
tatus outputs of the MAC motor
User I/O
1 - GND
2 - AIN
3 - O1
4 - O2
5 - A+
6 - A7 - B+
8 - B-
Connector cable part:
Manufacturer: AMP
Housing: 770602-8 (2.54mm pitch)
Crimp contacts: 770601-1
TT0917GB
3.4.2 Status Outputs
The status outputs O1 and O2 indicate the actual status of the MAC motor.
Each output is an NPN (!) type, which means that the load must be placed between the
output and a positive supply. Note that several of the expansion modules for the MAC
motor offer PNP output (source output). For further details about a specific expansion
module, please see other sections of this manual.
Power Suppl y
Max. 32VDC
Max. 25mA per output
Note: The outputs are not shortcircuit protected
MAC motor NPN outputs
+
Load Load
470pF
EMC filter
470pF
EMC filter
O1
O2
GND
O1 This output functions as an “In Position” or “at velocity” output depending on
which mode is selected. The position interval can be setup using the MacTalk pro
-
gram.
O2 This output is normally passive but if an unrecoverable error occurs, it will be ac-
tivated to indicate that normal operation of the motor has been interrupted and
no further operation is possible until a reset or power down has been made.
An unrecoverable error can be one of the following conditions:
(!) : Please note that when mounting an expansion module in the motor the output
type and performance may change. Please check the description of the actual
module to make sure how the outputs are configured.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 71
3.4 User I/O
8GB
Multifunction I/O's of the MAC motor
User I/O
1 - GND
2 - AIN
3 - O1
4 - O2
5 - A+
6 - A7 - B+
8 - B-
Connector cable part:
Manufacturer: AMP
Housing: 770602-8 (2.54mm pitch)
Crimp contacts: 770601-1
Internal
circuitry in the MAC motor
Bidirectional
transceiver
at each I/O
Signal GND
Twisted pair cable is recommended
Channel A
Channel B
Warning ! : Do not connect voltages
> 5V to the multifunction I/O
Multifunction I/O
A+
A -
B+
B -
GND
TT091
3.4.3 Multifunction I/O general description
The Multifunction I/O can be set up for different purposes depending on the actual mode
of operation of the MAC motor.
• Pulse inputs
When the motor is set to Gear mode, it will follow pulses at the A and B inputs. 2
input formats can be selected: pulse and direction or quadrature.
• Encoder output
The internal encoder-pulses are output as a quadrature signal.
• RS422 communication
A master controller can send commands, for example velocity or position commands. This interface is intended for permanent connection.
72 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.4 User I/O
B
3.4.4 Multifunction I/O used as pulse inputs
The Multifunction I/O can be set up as pulse inputs, which is necessary to run the MAC
motor in Gear mode or Analogue velocity/gear mode.
When the motor is set to Gear mode, it will follow pulses at the A and B inputs.
2 input formats can be selected.
Pulse and direction.The A input must be applied with the pulses and the B input must be
applied with the direction signal.
Quadrature.Also called encoder format. The pulses at the A and B channel are 90 degree
phase-shifted to determine direction.
Multifunction I/O's used as balanced pulse input
User I/O
1-GND
2-AIN
3-O1
4-O2
5-A+
6-A
7-B+
8-B
Connector :
Manufacturer : AMP
Type : 770602-8 (2.54mm/0.1" pitch)
Twisted pair cable is recommended
External pulse source
Signal GND
A
From internal
Control circuitry
B
RS422 outputs (balanced)
TT0927G
The Multifunction I/O’s must be set up in MAC-Talk to function as inputs. Also, an input
filter and the preferred direction of movement can be selected.
The pulse inputs are
only used in
and
Gear
TT0928GB
Gear
Analogue Velocity/
mode.
The pulse input can be set to fast
or slow bandwith which means
2.5MHz or 150kHz. Also, the
direction of movement can be inversed.
The input format
quadrature or pulse
and direction can be
selected here.
The Multifunction I/O's
are setup as inputs
See also the descriptions of Gear and Analog Velocity/Gear modes for further details
about functionality.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 73
3.4 User I/O
yp
)
t
3.4.5 Multifunction I/O used as pulse outputs
The Multifunction I/O can be set up as pulse outputs. When this configuration is selected,
the internal encoder signal will be available at the outputs.
This can be useful in modes in which the internal encoder signal must be used as feedback to external electronics for monitoring the real-time position, or as a part of a closedloop regulation.
This feature is especially relevant in the following 4 modes: Velocity, Position, Analogue
Torque and Analogue Velocity.
A quadrature signal will appear at the A and B channel. Quadrature means that the two
channels are 90 degree phase shifted either positively or negatively, which determines
the actual direction of movement of the motor.
Multifunction I/O's used as balanced pulse output
User I/O
External pulse receiver
1 - GND
2 - AIN
3 - O1
4 - O2
5 - A+
6 - A
7 - B+
8 - B
Connector :
Manufacturer : AMP
T
e : 770602-8 (2.54mm/0.1" pitch
Twisted pair cable is recommended
Signal GND
Termination resistors 120270 Ohm are recommended
A
B
RS422 inputs (balanced)
To in t e rn a l
control circuitry
TT0930GB
The Multifunction I/O’s must be set up in MAC-Talk to function as pulse outputs.
The pulse output can
be useful in one of
hese 4 modes.
TT0929GB
The Multifunction I/O's
are setup as outputs in this field
See also the respective mode descriptions for further details about functionality.
74 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
3.4 User I/O
3.4.6 Multifunction I/O used as serial communication interface
The Multifunction I/O can be set up as a serial communication interface.
When this configuration of the Multifunction I/O is selected, the A and B channels function as a receive and transmit channel via which commands to the MAC motor can be
transmitted from, for example, a PC or PLC.
This feature can be used in all modes of operation.
The communication protocol is described in the MAC motor Technical Reference Guide,
which must be requested separately and is not part of this user manual. See also
communication, page 283.
Multifunction I/O's used as balanced serial interface
User I/O
1-GND
2-AIN
3-O1
4-O2
5-A+
6-A
7-B+
8-B
Connector :
Manufacturer : AMP
Type : 770602-8 (2.54mm/0.1" pitch)
Twisted pair cable is recommended
External RS422 com. port
Signal GND
Termination resistor 120270 Ohm is recommended
A
RS422 I/O (balanced)
To / f r o m i n t e r n a l
control circuitry
B
TT0932GB
MacTalk
The Multifunction I/O’s must be set up in MacTalk to function as a serial communication
interface.
The serial communication can
be used in all
modes
The Multifunction I/O's are setup
as a serial data communication
TT0931GB
interface in this field
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 75
76 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4 Expansion Modules
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 77
4.1 Expansion Modules MAC00-CS
4.1.1 Expansion module MAC00-CS — overall description
The MAC00-CS module is the simplest expansion module in the series of modules since
no electronics are included. The MAC00-CS is simply a rear plate rated for IP67, but in
cludes cables for power and I/O signals. The MAC00-CS connects directly into the basic
MAC motor with all connectors available except for the serial communication (asynchro
nous com port).
Applications:
- Closed loop operation with a master controller.
- “Stand alone” axis with pulse and direction input.
- Simple speed control of conveyor system or feeding mechanism.
- Dispenser systems.
- .....and many more.
-
-
MAC00-CS is available in following versions:
Type Cable length
MAC00-CS-02 2m / 79”
MAC00-CS-10 10m / 394”
MAC00-CS-20 20m / 787”
The cable connections are as follows:
Power cable I/O cable
“Power supply” connector in basic motor
“P+” (Main PWR) / pin 1 Red “GND” / pin 1 Signal ground White/Orange
“P-” (GND) / pin 2
Wire
colour
Black
Screen
“I/O” connector
in basic motor
“AIN” / pin 2
“O1” / pin 3
“O2” / pin 4 Output 2 Green
“A+” / pin 5 Multifunction I/O “A+” Max 5V ! White/Blue
“A-” / pin 6 Multifunction I/O “A-” max 5V ! Blue
“B+” / pin 7 Multifunction I/O “B+” max 5V ! White/Brown
“B-” / pin 8 Multifunction I/O “B-” max 5V ! Brown
The housing (GND) of the motor is connected to the cable screen
Function Wire
colour
Analogue input Orange
Output 1 White/Green
For details of the description of each signal and how to connect and use these, please refer to the description of the basic motor: section 3
78 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4.2 Expansion Modules MAC00-B1/B2/B4
MAC00-B4
MAC00-B2
MAC00-B1
With DSUB connectors
With cable glands
4.2.1 Expansion modules MAC00-B1, B2 and B4 — overall description
The expansion modules MAC00-B1, B2 and B4 can be mounted in all the standard MAC
motors up to MAC800. These modules are among the simplest and lowest cost modules
in the product range. The modules contain no intelligence (microprocessor).
The MAC00-B1, B2 or B4 expansion module offers an industrial interface that mates with
the standard MAC motor and offers a number of feature enhancements, including:
With M12 connectors
• Different kinds of connectors for more reliability (compared to the basic motor itself).
• Full RS232 protocol support for use with standard serial cable.
• Full RS485 protocol support for multipoint communication up to 100m.
• Sourcing (PNP) outputs for status signals O1 and O2 instead of sinking (NPN).
• Only MAC00-B1: LEDs to indicate: O1, O2 output status. Zero switch (analogue input) status and Input power status.
• Only MAC00-B2 and B4: Dual supply. The main supply can be removed but the control circuitry is kept active and position data and communication are still functional.
Typical applications for these expansion modules are:
• Closed loop systems with an overall controller involved.
• Replacement for pneumatic cylinders using the “Air Cylinder mode”
• Dispenser systems
• Simple velocity or torque control via +/-10V input.
• Machine adjustment/setup by sending RS232 or RS485 commands.
The B1, B2 and B4 are equivalent except for the following hardware differences:
Type Protection
MAC00-B1
MAC00-B2
MAC00-B4
Note*: IP65 on MAC400-800
Class
IP42 DSUB 9 pole 3 pole Phoenix Yes No
IP67/IP65* Cable glands Cable glands No Yes
IP67/IP65* M12 M12 No Yes
Connectors Dual
Supply
I/O and interface Power supply LEDs at I/O
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 79
4.2 Expansion Modules MAC00-B1/B2/B4
A
A
C00
A
4.2.2 General hardware aspects
All internal and external main connections can be seen in the illustration below.
Please note that a few features are only available in MAC00-B4 and partly in B2.
Power supply
MAC50-141: +12-48V
MAC800: +12-32V
Analogue input
or Zero search input
±10V nom. or up to 32V
Multifunction I/O
Status outputs
RS485 Interface
These terminals are
not available at the
external connector at
MAC00-B4. Use the
internal switch to
enable the feature
RS232 Interface
Basic MAC motor with MA
MAC00-B1/B2/B4 expansion module
P+
P-
AIN
GND
A+
A -
B+
B -
O+
O1
O2
OCM
TERM
A
B
Tx
Tx-PD
Rx
GND
Fuse F10 A
Power ground (P-) is not connected in the MAC00-Bx module
Control
Supply
This GND is only available at the MAC00-B1
At the MAC00-B2 and B4 the P- or OCM is
used as ground for AIN
Overvoltage
protection
PNP Output
Driver
2 channel
differential
Tr a n s c e i v e r
synchronous
serial interface
-B1, B2 or B4 module inserted.
Control supply only in MAC00-B2 and B4.
This feature makes it possible to keep
communication and position data active
while main power P+ is removed.
Interface
Control
Basic MAC motor
(MAC050 to 800)
P+
Power supply
P-
IN
nalogue input
GND
A+
A
Multifunction I/O
(Bidirectional)
B+
B
O1
Status outputs
O2
RX
Asynchronous
TX
interface
GND
TT1052GB
4.2.3 General hardware description
The MAC00-B1, B2 and B4 modules offer the following external connections.
• Power supply (P+/P-)
These terminals are used for the main supply of the motor. A voltage between +12
and 48VDC (MAC50-141) and +12-32VDC (MAC400-800) must be connected.
• Analogue input (AIN)
The analogue input is used either as an analogue input or digital input. When used as
an analogue input, it can control velocity, torque or position depending on which
mode is set for motor operation. When used for digital input, it can be used in posi
tion-related modes for the external zero-search sensor. Also in “Air Cylinder Mode”
the analogue input is used as a trigger input.
For a functional description, please refer to General Analogue input (AIN) description
when using MAC00-Bx, page 83.
(continued)
80 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4.2 Expansion Modules MAC00-B1/B2/B4
• Multifunction I/O (A+,A- , B+and B-)
The functionality of these terminals is the same as for the basic MAC motor. They
can be set up in 3 different configurations.
- Pulse inputs - for functional description please refer to Multifunction I/O used as
pulse inputs, page 73 and General description: “General description: “Multifunction
I/O” when using a Bx module, page 86
- Pulse outputs - for functional description please refer to Multifunction I/O used as
pulse outputs, page 74 and
- RS422 interface - for functional description please refer to Multifunction I/O used
as serial communication interface, page 75.
Important !:
Remember to configure “I/O type” as “Pulse Input” in MacTalk if none of the 4 ter-
minals A+, A-, B+ and B- is used (the multifunction I/O’s). This must be done to
avoid random function of the motor since the multifunction I/Os are defined as “Se
rial data” as default.
• Status outputs (O1, O2, O+, and OCM)
The status outputs O1 and O2 (PNP outputs) indicate the actual status of the MAC
motor.
O1 This output functions as an “In Position” or “at velocity” output depending on
which operating mode is selected. The position interval can be set up using the
MacTalk program.
O2 This output is normally passive but if an unrecoverable error occurs, it will be
activated to indicate that normal operation of the motor has been interrupted
and no further operation is possible until a reset or power down has been made.
-
• RS485 Interface (A-, B+ and GND)
Serial balanced interface for connection to a PC or a controller. The protocol is similar to the RS232 or USB interface, which means that all registers/parameters in the
motor can be monitored or changed. The RS485 is recommended for longer distanc
es or in noisy environments.
• RS232 Interface (Rx, Tx and GND)
Serial unbalanced interface for connection to a PC or a controller. The protocol is
similar to the USB or RS485 interface, which means that all registers/parameters in
the motor can be monitored or changed. RS232 is not recommended for long dis
tances (>10m).
The MAC motor uses “binary” communication protocol which makes it possible to access all the internal registers. Please consult MacTalk communication, page 283 for further
details.
-
-
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 81
4.2 Expansion Modules MAC00-B1/B2/B4
4.2.4 General power supply description
The power supply must be connected to the terminals marked P+ and P-.
MAC50, 95, 140 or 141:
A supply voltage in the range 12VDC to 48VDC can be used. However the maximum
speed of the motor (4000 RPM) is based on 48VDC. A lower voltage will decrease the
speed/torque performance, and in general it is not recommended to run the motor at
more than 2000 RPM if, for example, 24VDC is used as the supply.
Optionally, the MAC00-B2 and B4 modules also offer a control voltage input (O+) which
means that the internal control circuitry will be kept powered when the main supply
(P+) is removed. See also the description:
MAC400 or 800
For the MAC400-800, the main supply is 115/230VAC connected at separate terminals.
The P+ power supply terminal only serves as a supply to the internal control circuitry.
The voltage must stay in the range +12-32VDC. See also the
MAC400), page 61 or Power supply circuitry (only MAC800), page 65.
Power supply connections to a MAC140 and a MAC800
mounted with a MAC00-B1, B2 or B4 modules.
Power supply (only MAC050 to 141), page 59.
Power supply circuitry (only
Make sure that all
involved units are
connected to the same
potential
MAC50-141 Motor
with MAC00-B1,
B2 or B4
Power
Supply
Control voltage
Only MAC50-141 with
B2 or B4 (Optional)
P+
P-
O+
MAC800 Motor
with MAC00-B1,
B2 or B4
Power supply
GND
+12-48VDC
(Bus voltage)
+12-32VDC
(control voltage)
It is recommended
that a separate supply
line is used for each motor.
Power
Supply
Main supply
P+
P-
Max. 32VDC !
Mains 230VAC
TT1053GB
82 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4.2 Expansion Modules MAC00-B1/B2/B4
Analogue input connection at the MAC motor
mounted with a MAC00-B1, B2 or B4 modules.
Connected to a external controller
Position or
velocity
controller
±10V out
Ground
Screen
Note ! : screen only
connected to signal source.
MAC motor
+MAC00-B1, B2 or B4
AIN
(analogue input)
GND
Connected to a potentiometer
If only 24V supply is available
insert a 2.7k resistor here.
Power supply
10VDC
2kOhm potentiometer
(JVL typeno. “POT2K”)
This example only covers 0-10V but other configurations do of course also exist, such as 0-5V or +/-10V.
Screen
Note ! : screen only
connected to signal source.
MAC motor
+MAC00-B1, B2 or B4
AIN
(analogue input)
GND
Connected to a zero search switch
MAC motor
+MAC00-B1, B2 or B4
Zero search switch
AIN
(analogue input)
Power supply
10-32VDC
GND
Make sure that all
involved units are
connected to the same
potential
(ground) *
Make sure that all
involved units are
connected to the same
potential
(ground) *
Make sure that all
involved units are
connected to the same
potential
(ground) *
TT1055GB
* The GND used with the AIN is not equal for all modules. See the specific hardware description of the actual module
to make sure that the intended GND terminal is used.
Note: Do not apply voltages higher than 32V to the analogue input (AIN)
4.2.5 General Analogue input (AIN) description when using MAC00-Bx
When a MAC00-B1, B2 or B4 module is mounted in the MAC motor, the analogue input
is available in the same manner as in the basic motor itself.
The analogue input can be used for several applications and the function of the analogue
input is determined by the mode in which the motor is set to operate.
Typically the input is used for controlling the velocity, torque or position of the motor
but the input is also used as digital input for zero search or in “Air Cylinder Mode” where
it is used as trigger input for the movement done by the motor.
For further information concerning physical connections, see the individual chapters for
each module type:
General description MAC00-B1, page 88, General description MAC00-
B2, page 89, or General description MAC00-B4, page 91.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 83
4.2 Expansion Modules MAC00-B1/B2/B4
4.2.6 RS232 - General description when using a MAC00-Bx module
The RS232 interface is considered the main interface to the
motor when the motor is set
up using the MacTalk win
dows software from a PC or
from any kind of controller us
ing a RS232 interface.
RS232 network with 2 x MAC140 and 1 x MAC800
mounted with MAC00-B1, B2 or B4 modules.
Central
-
Controller
(for example a PC)
Opto isolation *
Make sure that all
involved units are
connected to the same
potential
Power supply
Note:The basic MAC motor
does not fully support RS232
since the interface signals are
only 5V levels. See also the ba
sic description - Serial interface,
page 69.
When connecting the RS232
interface to a PC or control
ler, the following rules must
be followed:
1 Ensure that Tx-PD is con-
nected to TX on one of the
units in the system. Note
that the B1, B2 and B4
modules all contain a termi
nation resistor which can be
activated.
2 Use screened cable.
3 Ensure that GND is also
connected.
4 Ensure that all units have a
proper connection to safety
ground (earth) in order to
refer to the same potential.
5 Ensure that the supply lines
are connected individually
in order to minimise the
voltage drop between the
motors.
6 Master Controller RS485
interface:
If available, it is strongly rec-
ommended a type with op-
tical isolation is used.
7 The interface cable length
should not exceed 10 me
-
tres.
Connectors:
Please read the individual description for the MAC00-B1,
B2 or B4 to see the RS232
connector layout.
Tx
Rx
GND
Screen connected
to GND in each end
GND
+12-32VDC
(control voltage)
+12-48VDC
(Bus voltage)
-
MAC50-141
Motor
*** Address=1
Rx
RS232
**
ScreenScreen Screen
-
Up to 7
Motors
* Opto isolation is recommended.
** At least one unit on the line must be terminated. The MAC00-B1, B2
and B4 contain this feature. See the individual module descriptions.
*** Each unit connected must be setup with an address via The MacTalk program.
If only one unit is connected no address is needed.
Tx
Interface
Tx-PD
GND
Power
Supply
Control voltage
Only MAC50-141
with B2 or B4
MAC50-141
Motor
*** Address=2
Rx
RS232
Tx
Interface
Tx-PD
GND
Power
Supply
Control voltage
Only MAC50-141
with B2 or B4
MAC800
Motor
*** Address=3
Rx
RS232
Tx
Interface
Tx-PD
GND
Power
Supply
Main supply
P+
P-
O+
P+
P-
O+
P+
P-
Max. 32VDC !
Mains 230VAC
TT0907GB
84 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4.2 Expansion Modules MAC00-B1/B2/B4
S
4.2.7 RS485 - General description when using a MAC00-Bx module
The RS485 offers more noise-
485 network with 2 x MAC140 and 1 x MAC800
immune communication com
pared to the RS232 interface.
Up to 32 motors can be connected to the same line.
When connecting the RS485
interface to a central control
ler, the following rules must
be followed:
1 Use twisted-pair cable
2 Use screened cable
3 Ensure that GND is also
connected.
4 Ensure that all units have a
proper connection to safety
ground (earth) in order to
refer to the same potential.
5 The last unit in each end of
the network must be termi
nated. Note that the B1, B2
and B4 modules all contain a
termination resistor which
can be activated.
6 Ensure that the supply lines
are connected individually
in order to minimise the
voltage drop between the
motors.
-
-
-
R
mounted with MAC00-B1, B2 or B4 modules.
Central
Controller
(for example a PC)
Opto isolation *
**
B
A
GND
Screen connected
to GND in each end
Make sure that all
involved units are
connected to the same
potential
Power supply
GND
MAC50-141
Motor
*** Address=1
A
RS485
B
Interface
GND
P+
Power
Supply
Control voltage
Only MAC50-141
with B2 or B4
ScreenScreen Screen
P-
O+
MAC50-141
Motor
*** Address=2
A
RS485
B
Interface
GND
P+
Power
Supply
Control voltage
Only MAC50-141 with
B2 or B4 (Optional)
P-
O+
(con trol voltage)
+12-48VDC
(Bu s voltage)
+12-32VDC
7 Master Controller RS485
interface:
If available, it is strongly recommended a type with optical isolation is used.
Connectors:
Please read the individual description for the MAC00-B1,
B2 or B4 to see the connector
layout.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 85
Up to 32
Motors
* Opto isolation is recommended.
** The last unit at each end of the line must be terminated. The MAC00-B1, B2
and B4 contain this feature. See the individual module descriptions.
*** Each unit connected must be setup with an address via The MacTalk program.
If only one unit is connected no address is needed.
MAC800
Motor
A
**
B
GND
Power
Supply
Main supply
*** Address=3
RS485
Interface
P+
P-
Max. 32VDC !
Mains 230VAC
TT1049GB
4.2 Expansion Modules MAC00-B1/B2/B4
t
Input type setup for all common output types
The Dip switch is located at the rear side on all
3 module types MAC00-B1, B2 and B4.
Dip-Switch setting
Balanced or "push-pull" output connected
to the A and B input
ON ON ON
11 122 2
NPN
+
A
PNP
INPUT
SETUP
NPN
+
B
PNP
NPN (sink) output connected to the A and B input
NPN
+
A
PNP
INPUT
SETUP
NPN
+
B
PNP
PNP (source) output connected to the A and B inpu
NPN
+
A
PNP
INPUT
SETUP
NPN
+
B
PNP
4.2.8 General description: “Multifunction I/O” when using a Bx module
The function of the Multifunction I/O is equal to that of the basic motor with the excep-
tion that the B1, B2 or B4 modules include an overvoltage protection and a dip-switch to
set up what kind of signal source feeds the input (if the Multifunction I/O is set up as in
puts).
The illustration above shows how to set up the Multifunction I/O terminals as balanced/
push pull, NPN or PNP input. The illustrations below show examples of connections for
each of these signal types.
OFF
OFF
OFF
OFF
33 344 4
OFF
OFF
OFF
OFF
Dipswitch 5+6 only at MAC00-B4. Please consult the B4 chapter.
ON
OFF
ON
OFF
Dipswitch 5+6 only at MAC00-B4. Please consult the B4 chapter.
OFF
ON
OFF
ON
Dipswitch 5+6 only at MAC00-B4. Please consult the B4 chapter.
TT0937GB
-
4.2.9 Connecting an NPN signal source to the Multifunction I/O
The drawing below shows how to connect an NPN source to the MAC00-B1, B2 or B4
multifunction I/Os. The diagram shows the A channel. The B channel must be connected
in the same manner. Ensure that the A- and B- terminals are unconnected in order to
maintain proper function.
Warning: Voltages higher than 5V must under no circumstance be connected directly to
the input since this will damage the input permanently.
NPN (sink) output connected to the A and B input
T h e a n d t e r m i n a l s m u s t b e l e f t u n c o n n e c t e d .
A- B-
Signal source (PLC)
NPN
Output
switch
If used, t h e B + t e r m i n a l m u s t b e c o n n e c t e d i n t h e s a m e m a n n e r a s t h e A + t e r mi n a l .
Ground
MAC motor with MAC00-B1, B2 and B4 expansion module
Dip-Switch setting:
NPN
+
A
PNP
INPUT
NPN
SETUP
+
B
PNP
A+
A-
B+
B-
GND
Dipswitch 5+6 only at MA C00-B4.
Please consult the B4 chapter.
Warn ing:
Never connect voltages
higher than 5V directly to
the A or B terminals since
this can damage the inputs.
12
34
ON
ON
OFF
ON
OFF
TT0942GB
86 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4.2 Expansion Modules MAC00-B1/B2/B4
W
t
t
W
t
t
4.2.10 Connecting a PNP signal source to the Multifunction I/O
The drawing below shows how to connect a PNP source to the MAC00-B1, B2 or B4
multifunction I/Os. The diagram shows the A channel. The B channel must be connected
in the same manner.
Ensure that the A- and B- terminals are unconnected in order to maintain proper function.
Warning: Voltages higher than 5V must under no circumstance be connected directly to
the input since this will damage the input permanently. Use a proper resistor as indicated
in the table below.
PNP (source) output connected to the A and B input
Supply:
Resistor size
5VDC
0 Ohm (none)
8VDC
390 Ohm
12VDC
1 kOhm
15VDC
1.2 kOhm
18VDC
Signal source (PLC)
PNP
+
Power
Supply
5-32VDC
If used, the B+ terminal must be connected in the same manner as the A+ terminal.
The and terminals must be left unconnected.
A- B-
Output
switch
Ground
24VDC
30VDC
1.8 kOhm
2.7 kOhm
3.3 kOhm
Optional
resistor
See table
MAC motor with MAC00-B1, B2 or B4 expansion module
B+
B-
A+
A-
GND
Dip-Switch setting:
+
A
INPUT
SETUP
+
B
Dipswitch 5+6 only at MAC00-B4.
Please consult the B4 chapter.
arning:
Never connect voltages
higher than 5V directly to
he A or B terminals since
his can damage the inputs.
NPN
PNP
NPN
PNP
12
34
ON
OFF
ON
OFF
ON
TT0941GB
4.2.11 Connecting a balanced/push-pull signal to the Multifunction I/O
The drawing below shows how to connect a balanced or push-pull signal source to the
MAC00-B1, B2 or B4 multifunction I/Os. Use twisted-pair cable for the balanced signals
in order to ensure noise immunity.
Note: If inputs are used in pulse-direction format input A (A+/A-) is pulse input and input
B (B+/B-) is direction input.
Warning: Voltages higher than 5V must under no circumstance be connected directly to
the input since this will damage the input permanently. Use a proper resistor as indicated
in the table below.
Balanced or push-pull output connected to the A and B input
MAC motor with MAC00-B1, B2 or B4 expansion module
Dip-Switch setting:
External pulse source
From internal
Control circuitry
RS422 outputs (balanced)
A
B
Signal GND
Twisted pair cable is recommended
A+
A-
B+
B-
GND
+
A
Puls/dir
INPUT
SETUP
+
B
Dipswitch 5+6 only at MAC00-B4.
Please consult the B4 chapter.
Form at
Qua d ratu re
A
B
arning:
Never connect voltages
higher than 5V directly to
he A or B terminals since
his can damage the inputs.
NPN
PNP
NPN
PNP
ON
12
34
OFF
OFF
OFF
OFF
TT0943GB
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 87
4.2 Expansion Modules MAC00-B1/B2/B4
f
T
4.2.12 General description MAC00-B1
The MAC00-B1 expansion module is an industrial interface that mates with the standard
MAC motor and offers a number of feature enhancements, including:
• Standard 9-pin D-SUB connectors for additional reliability.
• Addition of a Zero switch input for locating a mechanical zero point of the actuator
when used in position-related modes.
• Plugable screw terminal connector for power supply and Zero switch.
• LEDs to indicate: O1 and O2 output status, Zero switch (analogue input) status.
Input power status.
• Full RS232 and RS485 protocol support for use with standard 9-pin DSUB.
• Sourcing (PNP) outputs for status signals O1 and O2 instead of sinking (NPN).
The following illustration shows all the connectors on the MAC00-B1 module.
MAC00-B1 connector descriptions
General I/O
Balanced pulse in- or outputs used for
Pulse and direction signals or
Quadrature encoder signal
Optional these terminals can be
used for the MAC high speed
communication using RS422
Signal ground
RS232 Connections
Gnd
Tx
Rx
SETUP
1
2
3
4
5
MAC00-B1
Gnd
Tx
Rx
RS485 Connections
RS232 Rx
RS232 TX
RS485 A-
Signal ground
(for RS232 and RS485
RS232 Interface between MAC motor and a PC.
PC
5
3
7
2
1
GND
B-
B+
A-
A+
IN/ OUT
Option
RS232 Note !
he TX-PD terminal must
be connected to Tx (pin 3)
if the MAC motor is not
6
using addressing
7
Tx-PD
8
9
Te r m i n a t o r
RS485 B+
5
3
7
2
1
IN/OU T
5
4
3
2
1
Industri Elektronik
SETUP
MAC00-B1
9
8
7
6
Status outputs
O+
Default:
O2
O1 = In position output
O2 = Error output
O1
Analogue input +/-10V.
AIN
Optional zero sensor input
LED’s for showing the output status o
O1 and O2. Notice that LED’s are only
active if the O+ terminal is supplied.
O1
LED for showing the voltage level at
O2
the analogue input (AIN).
LED for showing the voltage level at
the power supply input (P+)..
Power/Analogue input
P+
(Main power +12-48(32)VDC *)
AIN
(Analog input / zero switch input **)
P-
(Power ground - also for AIN)
Notes :
MAC50-141:
*
P+ is main supply terminal
Apply +12-48VDC.
MAC800:
P+ is the control supply terminal
Apply +12-32VDC (max 32V!)
Do not apply higher voltages
**
than 32VDC to the AIN terminal.
Use JVL programming cable type RS232-9-1
for connecting to PC.
TT0900GB
88 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4.2 Expansion Modules MAC00-B1/B2/B4
e
S
hown from front:
Shown from rear (inside):
O+
O1
Status Outputs
RS485 Balanced
serial interface
RS232 Unbalanced
serial interface
GND
TERM
GND
RX
TX
TXPD
B
A
O2
OCM
“IN/OUT SETUP” cable enters here
DipSwitch for setting signal source typ
for the Multifunction I/O when used as
pulse inputs.
-
B
+
B
Multifunction I/O
-
A
+
A
“POWER” cable enters here
P+
AIN
P-
TT0935GB
Power Supply and
analogue input
4.2.13 General description MAC00-B2
The MAC00-B2 expansion module is an industrial interface that mates with the standard
MAC motors and offers a number of feature enhancements, including:
• IP67 protection if mounted on basic MAC050-141 motor with the IP67 option, and
IP65 on MAC400-600
• Direct cable connection through sealed compression cable glands.
• Addition of a Zero switch input for locating a mechanical zero point of the actuator
when used in position-related modes.
• Screw terminals (internal) for all signal lines, power supply and Zero switch.
• Full RS232 protocol support
Note: The basic MAC motor is only equipped with a low-voltage serial interface that
requires the use of the RS232-9-1-MAC option cable which has integrated electron
-
ics to boost the voltage levels.
• Full RS485 protocol support for multipoint communication up to 100m.
• Sourcing (PNP) outputs for status signals O1 and O2. The basic MAC motors offers
sinking (NPN).
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 89
4.2 Expansion Modules MAC00-B1/B2/B4
4.2.14 MAC00-B2 option with cables
The ‘MAC00-B2’ type number designation only covers the basic module without any cables.
If a number is added after the basic type number, for example MAC00-B2-10, this suffix
indicates that the module is fitted with 2x10m of cable. One cable is used for the power
supply and analogue input, and the other cable covers all the signal lines, i.e. RS232,
RS485, status outputs and multifunction I/O. See the following tables.
Power cable (Cable 1) - Internal connector J4
Signal name Pin no. Description Wire colour
P- 3 Power supply ground White
AIN
P+ 1 Power supply +12-48VDC Nom.
Signal cable (Cable 2) - Internal connectors J5-8
Signal name Pin no. Description Wire colour
O+ J5/1 Status Outputs. Positive supply - Max. 30VDC Red
O1
O2 J5/3 Status Outputs. Output 2 - PNP(sourcing) max. 25mA Pink
OCM J5/4 Status Outputs. Output ground Blue
B- J6/1 Multifunction I/O. Terminal B-. Brown/Green
B+ J6/2
A- J6/3 Multifunction I/O. Terminal A-. Grey/Pink
A+ J6/4
TXPD * J7/1
TX J7/2
RX J7/3 RS232 Interface. Receive. Connect to ground if not used. White
GND J7/4 RS232 Interface. Ground for RS232 Brown
TERM ** J8/1
A- J8/2
B+ J8/3
GND J8/4 RS485 Interface. Signal ground. Black
Cable Screen
The cable-screen is internally connected to motor housing. Externally it must be connected to earth.
2 Analogue input (AIN) Green
Yellow /
Brown
J5/2 Status Outputs. Output 1 - PNP(sourcing) max. 25mA Grey
Multifunction I/O. Terminal B+.
Connect to ground (GND J7/4 or J8/4) if not used ***
Multifunction I/O. Terminal A+.
Connect to ground (GND J7/4 or J8/4) if not used ***
RS232 Interface. Transmit pull-down
(Connect to TX if addressing is not used).
RS232 Interface. Transmit
(Connect to TXPD if addressing is not used).
RS485 Interface. Terminator. Connect to “A” (J8/2) if MAC
motor is the last node on the interface bus.
Important: Do not connect if not used.
RS485 Interface. A terminal.
Important: Do not connect if not used.
RS485 Interface. B terminal
Important: Do not connect if not used.
White/Green
Red/Blue
Green
Yellow
Purple
Yellow/Brown
White/Yellow
*Connect to the TX terminal if the module is the only or the last node on the line in order to terminate the line.
**Connect to the A terminal if the module is the only or the last node on the line in order to terminate the line.
***Remember to configure “I/O type” as “Pulse Input” in MacTalk if none of the 4 terminals A+, A-, B+ and B-
are used (the multifunction I/Os). This must be done to avoid random function of the motor since the multi
function I/Os are defined as “Serial data” by default.
Important: Please note that the cables are a standard type. They are not recommend-
ed for use in cable chains or where the cable is repeatedly bent. If this is
required, use a special robot cable (2D or 3D cable).
90 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
-
4.2 Expansion Modules MAC00-B1/B2/B4
Expansion module MAC00-B4 front plate
IO
Basic I/O’s
M12 - 8pin male
connector including:
Multifunction I/O’s (A+...)
and O1, O2, GND and
the analogue input AIN
COM1
Communication 1
M12 - 8pin female
connector including:
RS232, RS485 and
USB interface
TT1015GB
4.2.15 General description MAC00-B4
The MAC00-B4 expansion module is protection class IP67 (MAC050-141) and is basically similar to the B1 and B2 modules except that it offers M12 circular industrial connectors which makes the module flexible and robust.
Additional features are:
- Secondary power supply input which can be used to keep the control core alive during emergency situations
- Dual interface connectors make it easy to daisy chain with other motors at the RS232
or RS485 interface.
PWR
Power supply
M12 - 5pin male
connector including:
P+ (primary supply), and O+
(secondary supply) P-
and
COM2
Communication 2
M12 - 5pin female
connector including:
RS232, RS485
4.2.16 Expansion MAC00-B4 hardware description
The MAC00-B4 offers IP67 (MAC050-141) protection and M12 connectors which
makes it ideal for automation applications where no additional protection is desired. The
M12 connectors offer solid mechanical protection and are easy to unplug compared to
the B2 module with cable glands.
The connector layout:
“PWR” - Power input. M12 - 5pin male connector
Signal name Description Pin no.
P+ Main supply +12-48VDC. Connect with pin 2 * 1 Brown 1
P+ Main supply +12-48VDC. Connect with pin 1 * 2 White 1
P- Main supply ground. Connect with pin 5 * 3 Blue 1
O+ Output supply / Control voltage +12-30VDC. 4 Black 1
P- Main supply ground. Connect with pin 3 * 5 Grey 1
* Note: P+ and P- are each available at 2 terminals. Make sure that both terminals are connected in order
to split the supply current in 2 terminals and thereby avoid an overload of the connector.
(Continued next page)
JVL Cable
WI1000M12F5T05N
Isolation
group
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 91
4.2 Expansion Modules MAC00-B1/B2/B4
“IO” - Basic I/O’s. M12 - 8pin male connector.
JVL Cable
Signal name Description Pin no.
A+ Multifunction I/O terminal A+ 1 White 1
A- Multifunction I/O terminal A- 2 Brown 1
B+ Multifunction I/O terminal B+ 3 Green 1
B- Multifunction I/O terminal B- 4 Yellow 1
O1
O2 Digital output 2 - PNP output 6 Pink 1
OCM
AIN
Digital output 1 - PNP output 5 Grey 1
Ground intended to be used together with the
other signals in this connector.
Analogue input +/- 10V or used for zero search 8 Red 1
7 Blue 1
WI1000-M12
F8T05N
“COM1” - Communication connector 1. M12 - 8pin female connector.
JVL Cable
Signal name Description Pin no.
Not used 1 White
RS232: TX
RS232: RX
GND
RS485: A- RS485 interface. Leave open if unused 5 Grey 1
RS485: B+ RS485 interface. Leave open if unused 6 Pink 1
RS232 interface. Transmit terminal
Leave open if unused.
RS232 interface. Receive terminal
Leave open if unused.
Ground intended to be used together with the
other signals in this connector,
Not used 7 Blue
Not used 8 Red
2 Brown 1
3 Green 1
4 Yellow 1
WI1000-M12
M8T05N
“COM2” - Communication connector 2. M12 - 5pin female connector
JVL Cable
Signal name Description Pin no.
RS232 Rx
RS232 Tx
RS485 A- RS485 interface. Leave open if unused 3 Blue 1
RS485 B+ RS485 interface. Leave open if unused 4 Black 1
GND Interface ground (same as main ground). 5 Grey 1
RS232 interface receive terminal.
Leave open if unused
RS232 interface transmit terminal.
Leave open if unused
1 Brown 1
2 White 1
WI1000M12
M5T05N
Isolation
group
Isolation
group
Isolation
group
92 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4.2 Expansion Modules MAC00-B1/B2/B4
4.2.17 MAC00-B4 dip-switch setup
The 6 pole dip-switch is placed on the rear side of the MAC00-B4 module. The following
illustration shows how to set up the switch.
MAC00-B4 Dip switch settings
Mini dip-switch
OFF ON
Dip-Switch for
Input type setup
Dip 5 - RS232 TxPD
Dip 6 - RS485 Term.
Default switch setting:
As shown above. Dip1-6=OFF,ON,OFF,ON,ON,OFF
- Input A and B is setup for PNP outputs.
- RS232 TxPD (Transmit pull-down) is enabled.
- RS485 Termination is disabled.
Input type setup (only switch 1-4)
Balanced or "push-pull" output connected
to the A and B input
1
OFF
OFF
2
OFF
3
OFF
4
-
5
-
6
SW1
1
2
3
4
5
6
SW1
NPN (sink) output connected to the A and B input
1
2
3
4
5
6
SW1
ON
OFF
ON
OFF
-
-
PNP (source) output connected to the A and B input
1
2
3
4
5
6
SW1
Rear side of the MAC00-B4
expansion module
OFF
ON
OFF
ON
-
-
Main fuse 10Amp.
Replace only with:
Schurter type
“3402.0040.11”
or
Littlefuse type
“451-10A”
TT1031GB
RS232 TxPD setup (only switch 5)
One of the motors connected to an RS232 line must have this switch set to “ON” but only at one !.
1
-
-
2
-
3
-
4
ON/OFF
5
-
6
SW1
RS485 Term. setup (only switch 6)
The last motors connected to an RS485 line must have this switch set to “ON” but only at one !.
1
-
-
2
-
3
-
4
-
5
ON/OFF
6
SW1
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 93
4.2 Expansion Modules MAC00-B1/B2/B4
4.2.18 Cables for the MAC00-B4
The following cables equipped with M12 connector can be supplied by JVL.
MAC00-B4 Connectors Description JVL Order no. Picture
“IO”
8pin
Male
“COM1”
8pin
Female
“COM2”
5pin
Female
X
X
“PWR”
5pin
Male
X
X
RS232 Interface cable. Connects
directly from MAC00-R4 to PC
Length: 5m (197 inch)
Cable (Ø5.5mm) with M12 female
5-pin connector loose wire ends
0.35mm² (22AWG) and foil screen.
Length: 5m (197 inch)
Same as above but 20m (787 inch)
Cable with M12 male 5-pin connector loose wire ends 0.35mm²
(22AWG) and screen.
See also type RS232-M12-1-5-5.
RS232-M12-1-5-5
WI1000-M12F5T05N
WI1000-M12F5T20N
WI1000-M12M5T05N
X
X
X
X
X
Same as above but 20m (787 inch)
Cable with M12 female 8-pin
connector loose wire ends
0.22mm² (24AWG) and screen.
Length: 5m (197 inch)
Same as above but 20m (787 inch)
Cable with M12 male 8-pin
connector loose wire ends
0.22mm² (24AWG) and screen.
Length: 5m (197 inch)
Same as above but 20m (787 inch)
WI1000-M12M5T20N
WI1000-M12F8T05N
WI1000-M12F8T20N
WI1000-M12M8T05N
WI1000-M12M8T20N
Protection caps. Optional if connector is not used to protect from dust / liquids.
X X
X X
IP67 protection cap for M12
female connector.
IP67 protection cap for M12
male connector.
WI1000-M12FCAP1
WI1000-M12MCAP1
Important: Please note that the cables are a standard type. They are not recommended for use in cable chains or where the cable is repeatedly bent. If this is required, use a special robot cable (2D or 3D
cable).
94 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
4.3 Expansion module MAC00-B41
seen from rear side
TT1133GB
4.3.1 Expansion module MAC00-B41 — overall description.
The expansion module MAC00-B41can ONLY be mounted in the MAC400 and
newer versions of the MAC800 motor (consult JVL)
This module is among the simplest and lowest cost modules in the product range.
The modules contain no intelligence (microprocessor) meaning that all functionalety
is controlled via the basic motor.
The MAC00-B41expansion module offers an industrial interface (M12 connectors)
and a number of feature enhancements, including:
Only MAC400&800
MAC00-B41
• Standard M12 connectors for optimum reliability
• Optical isolated communication covering RS232, RS485.
• Full RS232 protocol support for use with standard serial cable.
• Full RS485 protocol support for multipoint communication up to 100m.
• 6 high speed I/O channels that individually can be used as inputs or outputs. Each
channel can (when used as output) source up to 300mA.
• Dual supply. The main supply can be removed but the control circuitry is kept active
and position data and communication are still functional.
• Standard M12 connectors for optimum reliability
Typical applications for these expansion modules are:
• Closed loop systems with an overall controller involved.
• Replacement for pneumatic cylinders using the “Air Cylinder mode”
• Dispenser systems.
• Machine adjustment/setup by sending RS232 or RS485 commands.
• Standalone PLC with userprogram stored in the basic motor.
JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800 95
4.3 Expansion module MAC00-B41
A
4.3.2 Overall hardware description
All internal and external main connections can be seen in the illustration below.
Basic MAC motor with MAC00-B41 module inserted.
MAC00-B41 expansion module
Fuse F10A
Power ground (P-) is not connected in the MAC00-B41 module
Control
Self healing fuse
Itrip = 750mA
Overvoltage
protection
and
Dipswitch
setup
PNP Output
source driver
or
Input
RS485 Termination dipswitch
2 channel
differential
Tr a n s c e i v e r
Asynchronous
serial interface
Supply
2
Not used
Interface
isolation
Power supply
: (
MAC400) +12-32V
P+
(MAC400) +12-32V
CVI :
2 Analogue inputs
or Zero search input
±10V nom. or up to 32V
Multifunction I/O 1
and
Multifunction I/O 2
High speed I/O’s
RS485 Interface
RS232 Interface
P+
P-
CVI
AIN1/2
GND
A1/2+
A1/2 -
B1/2+
B1/2 -
CVO
IO1
IO2
IO3
IO4
IO5
IO6
GND
A
B
Tx
Rx
GND
Only MAC400&800
Basic MAC motor
(MAC400)
P+
Power supply
P-
AIN1/2
GND
A1/2+
A1/2
B1/2+
B1/2
(-)
RX
TX
GND
O1
O2
nalogue input
Multifunction I/O
(Bidirectional)
Status outputs
I/O channel
(Bidirectional)
Asynchronous
interface
TT1136GB
4.3.3 General hardware description
The MAC00-B41 module offers the following external connections.
• Power supply (P+/P-/CVI)
These terminals are used for the main supply of the motor. A voltage between +12
and 32VDC (MAC400) must be connected.
• Analogue inputs (AIN1 and AIN2)
The analogue inputs are used either as analogue input or digital input. The primary
analogue input is AIN1. When used as analogue input, it can control velocity, torque
or position depending on which mode is set for motor operation. When used for dig
ital inputs, it can be used in position-related modes for the external zero-search sensor. Also in “Air Cylinder Mode” the analogue input is used as a trigger input.
For a functional description, please refer to Analogue input, page 70.
(continued)
96 JVL Industri Elektronik A/S - User Manual - Integrated Servo Motors MAC050 - 800
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