MMC Smart Drive

TM

and
Digital MMC Control

Hardware Manual

Version 2.1

G & L Motion Control Inc.

NOTE

Progress is an on-going commitment at G & L Motion Control Inc. We continually strive to offer the
most advanced products in the industry; therefore, information in this document is subject to change
without notice. The text and illustrations are not binding in detail. G & L Motion Control Inc. shall not
be liable for any technical or editorial omissions occurring in this document, nor for any consequential
or incidental damages resulting from the use of this document.

G &L Motion Control Inc. makes every attempt to ensure accuracy and reliability of the specifications
in this publication. Specifications are subject to change without notice. G & L Motion Control Inc.
provides this information “AS IS” and disclaims all warranties, express or implied, including, but not
limited to, implied warranties of merchantability and fitness for a particular purpose. It is the
responsibility of the product user to determine the suitability of this product for a specific application.

DO NOT ATTEMPT to use any G & L Motion Control Inc. product until the use of such product is
completely understood. It is the responsibility of the user to make certain proper operation practices
are understood. G & L Motion Control Inc. products should be used only by qualified personnel and
for the express purpose for which said products were designed.

Should information not covered in this document be required, contact the Customer Service
Department, G & L Motion Control Inc., 672 South Military Road, P.O. Box 1960, Fond du Lac, WI
54936-1960. G & L Motion Control Inc. can be reached by telephone at (920) 921–7100 or (800) 558-
4808 in the United States or by e-mail at [email protected].

Catalog No. (Order No.) M.1301.5524

Electronic Version Part No. M.1302.8699
Release 2109
©2005, G & L Motion Control Inc.
Third party brands and trademarks are the property of their respective owners
 Table of Contents:
MMC Smart Drive and Digital MMC Control
Hardware Manual
1 Introduction to the MMC Smart Drive (MMC-SD) ............................................... 8
1.1 Overview........................................................................................................ 8
1.2 Contents of This Manual................................................................................ 9
1.3 Software and Manuals ................................................................................... 9
1.3.1 Required Software and Manuals .......................................................... 9
1.3.2 Suggested Manuals .............................................................................. 10
1.4 G&L Motion Control Support Contact .......................................................... 10
2 Safety Precautions................................................................................................... 11
2.1 System Safety ................................................................................................ 11
2.1.1 User Responsibility .............................................................................. 11
2.1.2 Safety Instructions ............................................................................... 12
2.2 Safety Signs ................................................................................................... 12
2.3 Warning Labels.............................................................................................. 13
2.4 Safety First ..................................................................................................... 13
2.5 Safety Inspection .......................................................................................... 14
2.5.1 Before Starting System ........................................................................ 14
2.6 After Shutdown ............................................................................................ 14
2.7 Operating Safely ............................................................................................ 14
2.8 Electrical Service & Maintenance Safety ...................................................... 15
2.9 Safe Cleaning Practices ................................................................................. 17
3 Installing the Drive ................................................................................................. 18
3.1 Storing the Drive Before Installation ............................................................ 18
3.2 Unpacking the Drive ...................................................................................... 18
3.3 Handling an MMC Smart Drive .................................................................... 18
3.4 Inspecting the Drive Before Installation ........................................................ 19
3.5 Complying with European Directives............................................................ 19
3.6 Conforming with UL and cUL Standards...................................................... 19
3.7 General Installation and Ventilation Requirements....................................... 19
3.8 Controlling Heat Within the System.............................................................. 21
3.9 Bonding ...................................................................................................... 22
3.9.1 Bonding a Subpanel Using a Stud ....................................................... 22
3.9.2 Bonding a Ground Bus Using a Stud ................................................... 22
3.9.3 Bonding a Ground Bus or Chassis Using a Bolt .................................. 23
3.9.4 Grounding Multiple Drive Cabinets .................................................... 23
3.9.5 Bonding Multiple Subpanels ............................................................... 24
3.10 Drive Mounting Guidelines ......................................................................... 24
3.11 Drive System Grounding Procedures .......................................................... 25
3.11.1 Grounding Requirements ................................................................... 27
3.11.2 Grounding Multiple Drives in the Same Cabinet .............................. 29

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 3
 3.12 System Wiring Guidelines ........................................................................... 29
3.12.1 Recommended Signal Separation ...................................................... 30
3.12.2 Building Your Own Cables ............................................................... 32
3.12.3 Routing Cables ................................................................................. 32
3.13 Wiring the Drive .......................................................................................... 32
3.13.1 Sizing the 24V Power Supply ........................................................... 32
3.13.2 System AC Power Wiring Guidelines ............................................ 34
3.13.3 Connecting Interface Cables .......................................................... 35
3.13.4 Preparing Motor Connection Wires ................................................ 36
4 System Power Protection and Related Devices ...................................................... 39
4.1 Motor Overload Protection ............................................................................ 39
4.2 Fuses .............................................................................................................. 39
4.2.1 Fuse Sizing ......................................................................................... 39
4.2.2 Device Protection ................................................................................. 40
4.3 Short Circuit Protection ................................................................................. 41
4.4 Line Reactors ................................................................................................. 42
4.4.1 Specifications and Dimensions for Required Line Reactors ................ 43

4.5 Isolation Transformers ................................................................................... 46

4.6 External Shunts .............................................................................................. 47
4.6.1 Choosing an External Shunt ............................................................. 47
4.6.2 External Shunt Resistor Kits ................................................................ 48
4.6.3 Mounting Dimensions for External Shunts ........................................ 49
4.7 Line Filters ..................................................................................................... 53
4.7.1 Line Filters and CE Compliance ......................................................... 53
4.7.2 Part Numbers for AC Line Filters ..................................................... 55
4.8 Technical Data for AC Line Filters ............................................................... 55
4.8.1 Technical Data for 230V Line Filters ............................................... 55
4.8.2 Technical Data for 460V Line Filters ................................................ 56
4.8.3 Dimensions for AC Line Filters .......................................................... 57
4.8.4 230V Line Filter Dimensions ............................................................. 57
4.8.4.1 460V Line Filter Dimensions .............................................. 58
5 230V Single Phase MMC Smart Drive................................................................... 59
5.1 LEDs ........................................................................................................... 59
5.2 Connectors and Switches on the 230V Drive ............................................. 60
5.2.1 PiCPro Communication Port ............................................................... 61
5.2.1.1 PiCPro Port (P1) .................................................................. 61
5.2.2 Node Address Rotary Switch (Digital Interfaced MMC-SD Only) .... 63
5.2.3 Digital Link Connector (IN/OUT)
(Digital Interfaced MMC-SD Only) ................................................ 63
5.2.4 Feedback Connector (F1) ..................................................................... 65
5.2.5 Feedback Connector (F2) (Digital Interfaced MMC-SD Only) ......... 68
5.2.6 User I/O Connector (IO) ...................................................................... 70
5.2.7 24 VDC IN/Brake Terminal Strip ....................................................... 73
5.2.8 Motor Terminal Strip .......................................................................... 74
5.3 Specifications - 230V MMC Smart Drive .................................................. 75

4 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 5.3.1 General Data for all 230V Models ............................................ 75
5.3.2 Physical and Electrical Data for 230V Drives ..................................... 78
5.4 Dimensions for 230V MMC Smart Drive .................................................... 80
5.4.1 230V 500W Drive - Front View ........................................................ 80
5.4.2 230V 500W Drive - Side View .......................................................... 81
5.4.3 230V 1kW and 2kW Drive - Front View ........................................... 82
5.4.4 230V 1kW and 2kW Drive - Side View ............................................. 83
6 460V 3-Phase MMC Smart Drive .......................................................................... 84
6.1 LEDs .............................................................................................................. 84
6.2 Connectors on the 460V Drive ...................................................................... 85
6.2.1 Size 1 460V Drive Connectors ........................................................... 85
6.2.1.1 Shunt/DC Bus Terminals ............................................... 86
6.2.1.2 AC Power Terminal Strip ................................................... 87
6.2.1.3 Motor Terminals ................................................................. 87
6.2.1.4 24V Power Connector (J1) ................................................ 88
6.2.1.5 Motor Brake Terminals (X101) ......................................... 89
6.2.2 Size 2 460V Drive ............................................................................... 90
6.2.2.1 AC Power Terminals .......................................................... 91
6.2.2.2 Motor Power Terminals ...................................................... 92
6.2.2.3 24V Power Connector (J1) ................................................ 93
6.2.2.4 Motor Brake Terminals (X101) ......................................... 94
6.2.3 Size 3 460V Drive ............................................................................... 95
6.2.3.1 AC Power Terminals .......................................................... 96
6.2.3.2 Motor Power Terminals .................................................... 97
6.2.3.3 24V Power Connector (J1) ................................................ 98
6.2.3.4 Motor Brake Terminals (X101) ......................................... 99
6.3 Typical 460V Drive Connection Layout ....................................................... 100
6.4 Specifications - 460V MMC Smart Drive .................................................... 101
6.4.1 Common Data for Size 1/Size 2/Size 3 (All Models) ........................ 101
6.4.2 Physical/Electrical Data for 460V Size 1 Drives ................................ 104
6.4.3 Physical/Electrical Data for 460V Size 2 Drive ................................ 106
6.4.4 Physical/Electrical Data for 460V Size 3 Drive ............................... 108
6.5 Dimensions for the 460V Drives ................................................................. 110
6.5.1 Size 1 460V Drive - Front View ......................................................... 110
6.5.2 Size 1 460V Drive - Side View .......................................................... 111
6.5.3 Size 2 460V Drive - Front View ......................................................... 112
6.5.4 Size 2 460V Drive - Side View .......................................................... 113
6.5.5 Size 3 460V Drive - Front View ......................................................... 114
6.5.6 Size 3 460V Drive - Side View .......................................................... 115
7 Cables and Connections to External Devices ......................................................... 116
7.1 I/O Cable Pin Assignments ........................................................................ 116
7.2 LSM and MSM Motors Cable Pin Assignments ......................................... 117
7.3 XSM Motors Cable Pin Assignments ......................................................... 119
7.4 NSM Motors Cable Pin Assignments ......................................................... 121
7.5 HSM and FSM Motors Cable Pin Assignments ......................................... 123
7.6 YSM Motors Cable Pin Assignments ......................................................... 125

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 5
 7.7 Connecting Shunt Modules ........................................................................... 127
7.7.1 Connecting the 230V MMC Smart Drive to 300 W Shunt Module .... 127
7.7.2 Connecting the 460V MMC Smart Drive to G&L Motion Control
Shunt Modules ................................................................................. 128
8 Maintenance and Troubleshooting.......................................................................... 130
8.1 Maintenance ................................................................................................ 130
8.2 Diagnostics..................................................................................................... 130
8.2.1 Power-On Diagnostics ........................................................................ 130
8.2.1.1 Power LED .......................................................................... 130
8.2.1.2 Diagnostic LEDs .................................................................. 131
8.2.2 Run-Time Diagnostics ....................................................................... 131
8.3 Troubleshooting ............................................................................................. 132
8.3.1 General Troubleshooting ..................................................................... 132
8.3.2 Troubleshooting Drive Diagnostic Error Codes .................................. 132
8.3.3 Troubleshooting Warning Error Codes ................................................ 138
9 Resolver Interface Option Module ......................................................................... 139
9.1 Theory of Operation ..................................................................................... 139
9.2 Installing the Resolver Module .................................................................... 139
9.3 Specifications ............................................................................................ 141
10 MMC Smart Drive Control................................................................................... 142
10.1 Introduction.................................................................................................. 142
10.1.1 Overview ............................................................................................ 142
10.1.2 Major Components ............................................................................ 143
10.2 Installing the MMC Smart Drive Control.................................................... 144
10.2.1 Installing the MMC Smart Drive Control into a
Digital Interfaced 230V MMC-SD Drive ........................................ 144
10.2.2 Installing the MMC Smart Drive Control into a Digital Interfaced
460V MMC-SD Drive ..................................................................... 145
10.3 System Wiring Guidelines ........................................................................... 146
10.4 Starting an Operation ................................................................................... 148
10.4.1 Connecting the MMC to the Application .......................................... 148
10.4.2 Basic Setup and Maintenance Procedures ......................................... 149
10.4.3 Start-up Diagnostics ........................................................................... 150
10.4.3.1 Power LED ....................................................................... 150
10.4.3.2 Scan LED ........................................................................... 150
10.4.3.3 MMC Start-Up Diagnostic LEDs ...................................... 150
10.4.4 MMC Run-Time Diagnostics ............................................................ 151
10.5 MMC Connections to External Devices for Machine Control .................... 152

10.5.1 PiCPro Port (P1) ................................................................................ 152

10.5.2 Block I/O Port (C1) ............................................................................ 153
10.5.3 User Port (C3) .................................................................................... 153
10.5.4 Ethernet Port (C4) .............................................................................. 154
10.5.5 General I/O Port (C5) ........................................................................ 155
10.6 Specifications .............................................................................................. 159

6 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
11 Part Numbers ........................................................................................................ 160
11.1 Drives ........................................................................................................ 160
11.2 Option Modules ........................................................................................... 161
11.2.1 Resolver Interface Option Module ................................................... 161
11.2.2 MMC Smart Drive Control ............................................................ 161
11.3 Direct Connect Cables ................................................................................ 161
11.3.1 Drive Programming Cable ................................................................ 161
11.3.2 Standalone MMC to MMC Smart Drive I/O Cable .......................... 161
11.4 Digital Link and Networking Cables ......................................................... 162
11.5 Connector Kits .......................................................................................... 162
11.6 Breakout Boards/Flying Leads Cables and Kits ......................................... 163
11.6.1 Mounted Breakout Boards ................................................................ 163
11.6.2 Panel Mounted Breakout Boards ...................................................... 163
11.6.3 Breakout Board Kits ......................................................................... 163
11.6.4 Breakout Board Cables ..................................................................... 164
11.6.5 User I/O Flying Lead Cables ........................................................... 165
11.7 Motor Cables (LSM/MSM Motors) ......................................................... 166
11.7.1 Feedback Cables (LSM/MSM Motors) ............................................ 166
11.7.2 Power Cables for Blower Fan (LSM/MSM Motors) ......................... 166
11.7.3 Motor Power Cables (LSM/MSM Motors) ...................................... 167
11.8 Optional External Devices .......................................................................... 168
11.8.1 AC Line Filters ................................................................................. 168
11.8.2 AC Line Reactors ........................................................................... 168
11.8.3 External Shunt Resistor Kits ............................................................ 169
11.9 Software .................................................................................................... 169
12 Declarations of Conformity ................................................................................. 170
Appendix A - 460V MMC Smart Drive DC Bus Sharing ......................................... A1-1
1 Introduction....................................................................................................... A1-1
2 DC Bus Sharing with AC Power to All Drives ................................................ A1-1
3 DC Bus Sharing with AC Power to One Drive ................................................ A1-3
INDEX ...................................................................................................................... IND-1

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 7
Introduction to the MMC Smart Drive (MMC-SD)

1 Introduction to the MMC Smart Drive (MMC-SD)

1.1 Overview
This manual covers two distinct products:
• The Analog Interfaced MMC-SD which receives motion com-
mands via a +10V analog input
• The Digital MMC-SD which receives motion commands via a
digital connection (Digital Link)
Unless otherwise noted, all of the information in this manual applies to both
drives.
Features include:
• 230V, Single Phase drives available with power ratings of .5kW,
1kW, and 2 kW
• 460V, Three Phase drives available with power ratings of 1.3kW
through 24kW
• Drive firmware in user upgradeable Flash memory
• Serial port for communications with PC-resident PiCPro
• Internal switch to control a mechanical brake
• Green Power LED and yellow Diagnostic LED
• Motor feedback types include incremental encoder, high resolu-
tion encoder, and resolver.
• Eight General Purpose 24VDC Inputs
• Four General Purpose 24VDC outputs
• +10V command input (Analog Interfaced MMC-SD only)
• Digital Link digital connections (Digital MMC-SD only)
• Optional MMC-SD Control (for Digital MMC-SD only)
• UL Listed and CE Marked.

8 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Introduction to the MMC Smart Drive (MMC-SD)

1.2 Contents of This Manual

This manual includes the following major topics:
• Information to safely operate and maintain the equipment in a
safe manner.
• User responsibilities for product acceptance and storage.
• Power and environmental information for general power, control
cabinet, grounding, heat control and handling.
• Procedures for mounting, wiring, and connecting the MMC
Smart Drive and standard G&L Motion Control motors recom-
mended for use with the MMC Smart Drive.
• Recommended drive system wiring guidelines for signal separa-
tion and differential devices. Methods to ensure ElectroMagnetic
Compatibility.
• The location of connectors on the drive and descriptions of their
functionality including I/O, encoder, serial interface and motor/
brake connector locations and signal descriptions.
• Physical, electrical, environmental and functional specifications/
dimensions.
• Description of the minimal maintenance necessary.
• A troubleshooting chart of potential problems and possible solu-
tions.
• Part numbers and descriptions for the drive and related equip-
ment.

1.3 Software and Manuals

1.3.1 Required Software and Manuals

• PicPro V15.1 (one of the following)
• Professional Edition
• MMC Limited Edition
• Monitor Edition

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 9
Introduction to the MMC Smart Drive (MMC-SD)

1.3.2 Suggested Manuals

• Function/Function Block Reference Guide V15.1
• Motion Application Specific Function Block Manual V15.0.1
• Ethernet Application Specific Function Block Manual V15.1.1
• General Purpose Application Specific Function Block
Manual V13.0.1

1.4 G&L Motion Control Support Contact

Contact your local G&L Motion Control representative for:
• Sales and order support
• Product technical training
• Warranty support
• Support service agreements
G&L Motion Control Technical Support can be reached:
• In the United States, telephone (800) 558-4808
• Outside the United States, telephone (920) 921-7100
• In Europe, telephone (+44)151-546-2010,
fax (+44)151-547-2801
• E-mail address:
[email protected]

10 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Safety Precautions

2 Safety Precautions

READ AND UNDERSTAND THIS SECTION IN ITS ENTIRETY

BEFORE UNDERTAKING INSTALLATION OR
ADJUSTMENT OF THE MMC SMART DRIVE AND ANY
ASSOCIATED SYSTEMS OR EQUIPMENT

The instructions contained in this section will help users to operate and maintain the
equipment in a safe manner.

PLEASE REMEMBER THAT SAFETY IS EVERYONE'S RESPONSIBILITY

2.1 System Safety

The basic rules of safety set forth in this section are intended as a guide for
the safe operation of equipment. This general safety information, along with
explicit service, maintenance and operational materials, make up the
complete instruction set. All personnel who operate, service or are involved
with this equipment in any way should become totally familiar with this
information prior to operating.

2.1.1 User Responsibility

It is the responsibility of the user to ensure that the procedures set
forth here are followed and, should any major deviation or change
in use from the original specifications be required, appropriate
procedures should be established for the continued safe operation
of the system. It is strongly recommended that you contact your
OEM to ensure that the system can be safely converted for its new
use and continue to operate in a safe manner.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 11
Safety Precautions

2.1.2 Safety Instructions

1. Do not operate your equipment with safety devices bypassed
or covers removed.
2. Only qualified personnel should operate the equipment.
3. Never perform service or maintenance while automatic con-
trol sequences are in operation.
4. To avoid shock or serious injury, only qualified personnel
should perform maintenance on the system.

ATTENTION

Do not touch the main power

supply fuses or any components
internal to the power modules
while the main power supply
switch is ON. Note that when the
main power switch is OFF, the
incoming supply cable may be
live.

5. GROUNDING (Protective Earth)

The equipment must be grounded (connected to the protective
earth connection) according to OEM recommendations and to
the latest local regulations for electrical safety. The grounding
(protective earth) conductor must not be interrupted inside or
outside the equipment enclosures. The wire used for equip-
ment grounding (connection to protective earth) should be
green with a yellow stripe.

2.2 Safety Signs

The purpose of a system of safety signs is to draw attention to objects and
situations which could affect personal or plant safety. It should be noted that
the use of safety signs does not replace the need for appropriate accident
prevention measures. Always read and follow the instructions based upon the
level of hazard or potential danger.

12 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Safety Precautions

2.3 Warning Labels

Hazard warning

Danger Electric
Shock Risk

When you see this safety sign on a system, it gives a warning of a hazard or
possibility of a hazard existing. The type of warning is given by the pictorial
representation on the sign plus text if used.
To ignore such a caution could lead to severe injury or death arising from an
unsafe practice.
Danger, Warning, or Caution warning

Symbol plus DANGER, WARNING or CAUTION:

These notices provide information intended to prevent
potential personal injury and equipment damage.

Hot Surface warning

Symbol plus HOT SURFACE:

These notices provide information intended to prevent
potential personal injury.

2.4 Safety First

G&L Motion Control equipment is designed and manufactured with
consideration and care to generally accepted safety standards. However, the
proper and safe performance of the equipment depends upon the use of sound
and prudent operating, maintenance and servicing procedures by trained
personnel under adequate supervision.
For your protection, and the protection of others, learn and always follow
these safety rules. Observe warnings on machines and act accordingly. Form
safe working habits by reading the rules and abiding by them. Keep these
safety rules handy and review them from time to time to refresh your
understanding of them.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 13
Safety Precautions

2.5 Safety Inspection

2.5.1 Before Starting System

1. Ensure that all guards and safety devices are installed and
operative and all doors which carry warning labels are closed
and locked.
2. Ensure that all personnel are clear of those areas indicated as
potentially hazardous.
3. Remove (from the operating zone) any materials, tools or
other objects that could cause injury to personnel or damage
the system.
4. Make sure that the control system is in an operational condi-
tion.
5. Make certain that all indicating lights, horns, pressure gauges
or other safety devices or indicators are in working order.

2.6 After Shutdown

Make certain all controlled equipment in the plant is safe and the associated
electrical, pneumatic or hydraulic power is turned off. It is permissible for
the control equipment contained in enclosures to remain energized provided
this does not conflict with the safety instructions found in this section.

2.7 Operating Safely

1. Do not operate the control system until you read and understand the
operating instructions and become thoroughly familiar with the system
and the controls.
2. Never operate the control system while a safety device or guard is
removed or disconnected
3. Where access to the control system is permitted for manual operation,
only those doors which provide that access should be unlocked. They
should be locked immediately after the particular operation is com-
pleted.
4. Never remove warnings that are displayed on the equipment. Torn or
worn labels should be replaced.
5. Do not start the control system until all personnel in the area have been
warned.
6. Never sit or stand on anything that might cause you to fall onto the con-
trol equipment or its peripheral equipment.

14 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Safety Precautions
7. Horseplay around the control system and its associated equipment is
dangerous and should be prohibited.
8.

ATTENTION

Know the emergency stop

procedures for the system.

9. Never operate the equipment outside specification limits.

10. Keep alert and observe indicator lights, system messages and warnings
that are displayed on the system.
11. Do not operate faulty or damaged equipment. Make certain proper ser-
vice and maintenance procedures have been performed.

2.8 Electrical Service & Maintenance Safety

1. ALL ELECTRICAL OR ELECTRONIC MAINTENANCE AND
SERVICE SHOULD BE PERFORMED BY TRAINED AND
AUTHORIZED PERSONNEL ONLY.
2. It should be assumed at all times that the POWER is ON and all condi-
tions treated as live. This practice assures a cautious approach which
may prevent accident or injury.
3. To remove power:
LOCK THE SUPPLY CIRCUIT DISCONNECTING MEANS IN
THE OPEN POSITION.
APPLY LOCKOUT/TAGOUT DEVICES IN ACCORDANCE
WITH A DOCUMENTED AND ESTABLISHED POLICY.
4. Make sure the circuit is safe by using the proper test equipment. Check
test equipment regularly

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 15
Safety Precautions

5.

ATTENTION

Care should be taken if you are manually dis-

charging the bus capacitors.

WARNING

Even after power to the drive is removed, it

may take up to 10 minutes for bus capacitors
to discharge to a level below 50 VDC. To be
sure the capacitors are discharged, measure
the voltage across the + and - terminals for the
DC bus.

6. There may be circumstances where troubleshooting on live equipment

is required. Under such conditions, special precautions must be taken:
• Make sure your tools and body are clear of the areas of equipment
which may be live.
• Extra safety measures should be taken in damp areas.
• Be alert and avoid any outside distractions.
• Make certain another qualified person is in attendance.
7. Before applying power to any equipment, make certain that all per-
sonnel are clear of associated equipment.
8. Control panel doors should be unlocked only when checking out elec-
trical equipment or wiring. On completion, close and lock panel
doors.
9. All covers on junction panels should be fastened closed before leav-
ing any job.
10. Never operate any controls while others are performing maintenance
on the system.
11. Do not bypass a safety device.
12. Always use the proper tool for the job.
13. Replace the main supply fuses only when electrical power is OFF
(locked out).

16 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Safety Precautions

2.9 Safe Cleaning Practices

1. Do not use toxic or flammable solvents to clean control system
hardware.
2. Turn off electrical power (lock out) before cleaning control system
assemblies.
3. Keep electrical panel covers closed and power off when cleaning an
enclosure.
4. Always clean up spills around the equipment immediately after they
occur.
5. Never attempt to clean a control system while it is operating.
6. Never use water to clean control equipment unless you are certain that
the equipment has been certified as sealed against water ingress. Water
is a very good conductor of electricity and the single largest cause of
death by electrocution.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 17
Installing the Drive

3 Installing the Drive

Note: The National Electrical Code and any other governing regional or local codes
overrule the information in this manual. G & L Motion Control Inc. does not as-
sume responsibility for the user’s compliance or non-compliance with any code,
national, local or otherwise, for the proper installation of this drive and associ-
ated systems or equipment. Failure to abide by applicable codes creates the haz-
ard of personal injury and/or equipment damage.

3.1 Storing the Drive Before Installation

The drive should remain in the shipping container prior to installation. If the
equipment is not to be used for a period of time, store it as follows:
• Use a clean, dry location
• Maintain the storage temperature and humidity as shown in the
specifications section of this manual.
• Store it where it cannot be exposed to a corrosive atmosphere
• Store it in a non-construction area

3.2 Unpacking the Drive

Remove all packing material, wedges, and braces from within and around the
components. After unpacking, check the name plate Material Number
against the purchase order of the item(s) against the packing list. The model
number, serial number and manufacturing date code are located on the side
of the unit.
3.3 Handling an MMC Smart Drive
The case protects the MMC Smart Drive’s internal circuitry against
mechanical damage in shipping and handling.
However, like any electronic device, the circuitry can be destroyed by:
• Conditions exceeding those detailed in the specifications tables
shown in the Specifications sections in this manual.
• moisture condensing inside the module
• static discharge
• exposure to a magnetic field strong enough to induce a current in
the circuitry
• vibration, and other hazards

18 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

3.4 Inspecting the Drive Before Installation

Inspect the unit for any physical damage that may have been sustained during
shipment.
If you find damage, either concealed or visible, contact your buyer to make a
claim with the shipper. If degraded performance is detected when testing the
unit, contact your distributor or G&L Motion Control. Do this as soon as
possible after receipt of the unit.

3.5 Complying with European Directives

For industrial products installed within the European Union or EEC regions,
certain directives and standards apply. See "Conformity" in the
Specifications sections of Chapters 5 and 6 for applicable directives.
Servo amplifiers are considered to be subsystems when incorporated into
electrical plants and machines for industrial use. The G&L Motion Control
servo amplifiers have been designed and tested as such. They bear the CE
mark and are provided with a Declaration of Conformance. However, it is the
overall machine or system design that must meet European Directives and
standards. To help the manufacturer of the machine or plant meet these
directives and standards, specific guidelines are provided in this
documentation. These include such things as shielding, grounding, filters,
treatment of connectors and cable layout.

3.6 Conforming with UL and cUL Standards

G&L Motion Control drives meet safety and fire hazard requirements as
outlined in "Conformity" in the Specifications sections of Chapters 5 and 6.

3.7 General Installation and Ventilation

Requirements
• The drive must be enclosed in a grounded NEMA12 enclosure
offering protection to IP55 such that they are not accessible to an
operator or unskilled person, in order to comply with UL and
CE requirements. A NEMA 4X enclosure exceeds these require-
ments providing protection to IP66.
• The environmental conditions must not exceed those detailed in
the specifications tables shown in the Specifications sections in
this manual.
• Install the panel on a properly bonded, flat, rigid, non-painted gal-
vanized steel, vertical surface that won’t be subjected to shock,
vibration, moisture, oil mist, dust, or corrosive vapors.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 19
Installing the Drive

• Maintain minimum clearances for proper airflow, easy module

access, and proper cable bend radius.
• Plan the installation of your system so that you can perform all
cutting, drilling, tapping, and welding with the drive removed
from the enclosure. Because the drive is of the open type con-
struction, be careful to keep any metal debris from falling into it.
Metal debris or other foreign matter can become lodged in the cir-
cuitry, which can result in damage to components.
The MMC Smart Drive is suitable for operation in a pollution degree 2
environment (i.e., normally, only non-conductive pollution occurs). Install
the drive away from all sources of strong electromagnetic noise. Such noise
can interfere with MMC Smart Drive operation.
Protect the MMC Smart Drive system from all the following:
• conductive fluids and particles
• corrosive atmosphere
• explosive atmosphere
Diagrams included with this manual and recommendations may be modified
if necessary so the wiring conforms to current NEC standards or government
regulations.

Table 3-1: Cabinet Clearance Dimensions

Minimum Clearance
Location 230V Drive 460V Drive
Above Drive Body 2.0 in. ( 50.8 mm) 4.0 in. ( 100 mm)

Below Drive Body 2.0 in. ( 50.8 mm) 4.0 in. ( 100 mm)

Each Side of Drive .50 in. ( 12.7 mm) None

In Front of Drive (for cabling) 3.0 in. ( 76.2 mm) 3.0 in. ( 76.2 mm)

NOTE

Use filtered or conditioned air in ventilated cabinets. The air should

be free of oil, corrosives, or electrically conductive contaminants.

20 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

3.8 Controlling Heat Within the System

The MMC Smart Drive hardware case is designed to promote air circulation
and dissipate heat. Normally no fans or air conditioners are needed.
However, if the environment outside the control cabinet is hot or humid, you
may need to use a fan, heat exchanger, dehumidifier or air conditioner to
provide the correct operating environment.
Make sure that the temperature and humidity within the drive cabinet does
not exceed that which is shown in the specifications sections of this manual.
Make sure that components installed in the cabinet with the MMC Smart
Drive do not raise the temperature above system limits and that any hot spots
do not exceed specifications. For example, when heat-generating
components such as transformers, other drives or motor controls are
installed, separate them from the drive by doing one of the following:
• Place them near the top of the control cabinet so their heat output
rises away from the MMC Smart Drive.
• Put them in another control cabinet above or to one side of the
cabinet with the MMC Smart Drive. This protects the MMC
Smart Drive from both heat and electrical noise.
The MMC Smart Drive itself is a source of heat, though in most installations
its heat dissipates without harmful effects. System heat is generated from
power dissipated by:
• the drive
• field side input/output components
• other drives in the cabinet
• the logic power supply
• external shunt resistors
• line reactors

CAUTION

If the MMC Smart Drive is operated outside the recommended envi-

ronmental limits, it may be damaged. This will void the warranty.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 21
Installing the Drive

3.9 Bonding
Connecting metal chassis, assemblies, frames, shields and enclosures to
reduce the effects of electromagnetic interference (EMI) is the process of
bonding.
Most paints act as insulators. To achieve a good bond between system
components, surfaces need to be paint-free or metal plated. Bonding metal
surfaces creates a low-impedance exit path for high-frequency energy.
Improper bonding blocks this direct exit path and allows high-frequency
energy to travel elsewhere in the cabinet. Excessive high-frequency energy
can negatively affect the operation of the drive.

3.9.1 Bonding a Subpanel Using a Stud

1. Weld threaded mounting studs to the back of the enclosure.
2. Brush off any non-conductive materials (e.g. paint) from the
studs.
3. Remove any non-conductive materials from the front of the
subpanel.
4. Position the mounting holes on the subpanel over the mounting
studs on the back of the enclosure and slide the subpanel onto
the studs.
5. Attach the subpanel to the mounting stud by sliding a star
washer over the stud and then turn and tighten a nut onto the
stud.

3.9.2 Bonding a Ground Bus Using a Stud

1. Weld threaded mounting studs to the back of the subpanel.
2. Brush off any non-conductive materials (e.g. paint) from the
studs.
3. Slide a flat washer over the studs.
4. Remove any non-conductive materials from around the mount-
ing hole on the chassis mounting bracket or ground bus.
5. Position the mounting hole of the chassis or ground bus over the
studs on the back of the subpanel and slide the mounting
bracket or ground bus onto the stud.
6. Attach the subpanel to the subpanel stud by sliding a star
washer and then a flat washer over the stud. Turn and tighten a
nut onto the stud.

22 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

3.9.3 Bonding a Ground Bus or Chassis Using a Bolt

1. Brush off any non-conductive materials (e.g. paint) from the
threaded bolt (s).
2. Slide a star washer over the threaded bolt (s).
3. Use a subpanel having tapped mounting holes. Remove any
non-conductive materials from around the mounting holes on
both sides of the subpanel.
4. Turn the threaded bolts into the subpanel mounting holes.
5. Slide a star washer onto the threaded end of the bolt.
6. Turn and tighten a nut onto the stud.
7. Slide a flat washer onto the threaded end of the bolt.
8. Position the mounting holes on the groundbus or mounting
bracket over the threaded bolts and turn the bolts until they
come through the grounding bus or mounting bracket.
9. Slide a star washer onto the threaded end of the bolt.
10. Slide a flat washer onto the threaded end of the bolt.
11. Turn and tighten a nut onto the bolt.

3.9.4 Grounding Multiple Drive Cabinets

1. Mount one bonded ground bus in each cabinet.
2. Designate the cabinet ground bus in one and only one of the
cabinets as the common ground bus for all of the cabinets in the
system.
3. Connect the ground wires from the ground bus in each individ-
ual cabinet ground bus to the designated common ground bus
(mounted in only one of the cabinets).
4. Connect the common cabinet ground bus to an external ground
system that is connected to a single point ground.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 23
Installing the Drive

3.9.5 Bonding Multiple Subpanels

G&L Motion Control recommends bonding both the top and
bottom of subpanels sharing the same enclosure. Use a 25.4 mm
(1.0 in.) x 6.35 mm (0.25) wire braid. Be sure the area around each
wire braid fastener is clear of any non-conductive materials. Bond
the cabinet ground bus to at least one of the subpanels.

NOTE

Subpanels that are not bonded together may not share a

common low impedance path. This difference in impedance
may affect networks and other devices that span multiple
panels.

3.10 Drive Mounting Guidelines

• A control cabinet for the MMC Smart Drive should have a NEMA-12 rat-
ing or better. A cabinet with this rating protects its contents from dust and
mechanical damage.
• The cabinet must be large enough to provide adequate air circulation for
the MMC Smart Drive and other components. Always allow for adequate
air flow through the MMC Smart Drive vents.
• The cabinet must have a rigid non-painted galvanized metal surface to
mount the MMC Smart Drive on.
• The cabinet door should open fully for easy access.

IMPORTANT

Post warnings according to National, State, or local codes for the volt-
age present in the control cabinet. Diagrams included with this man-
ual and recommendations may be modified if necessary so the wiring
conforms to current NEC standards or government regulations.

NOTE

This drive contains parts and assemblies that are sensitive to

ESD (Electrostatic Discharge). Follow static control precautions
during installation, testing, service, or repair of this assembly.
Parts and assemblies can be damaged if proper precautions are
not taken.

24 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

1. Lay out the positions for the drive and accessories in the enclosure.
2. Attach the drive to the cabinet, first using the upper mounting slots of
the drive and then the lower. The recommended mounting hardware is
M5 metric(#10-32).
3. Tighten all mounting fasteners.

3.11 Drive System Grounding Procedures

The ground of the MMC Smart Drive power source must be connected
directly to a Single Point Ground (SPG) tie block. The tie block should be
made of brass or copper, bolted or brazed to the control cabinet. If the tie
block is bolted rather than brazed, scrape away paint or grease at the point of
contact. Put star washers between the tie block and the cabinet to ensure
good electrical contact.
Metal enclosures of power supplies, drives, etc., should also have good
electrical contact with the SPG.

CAUTION

The Single Point Ground should be the only common point for all the
ground lines. If not, ground loops may cause current flow among
components of the system which can interfere with proper operation
of the MMC Smart Drive.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 25
Installing the Drive

Devices to be connected directly to the Single Point Ground include:

• Plant safety ground.
• Protective earth ground(s) from the MMC Smart Drive power ter-
minals.
• The metal panel or cabinet on which the MMC Smart Drive is
mounted.
• "Common" or "0 V" lines from power supplies that provide +24
power to devices and external power to the I/O modules and the
devices to which they are connected.
• Protective grounds from the devices themselves, such as device
drivers, machinery, and operator interface devices.
• Protective earth ground from line and load sides of any AC line
filters.
• The ground of the power source of the computer workstation or
laptop, if any, from which you monitor the system operation. An
AC outlet in the control cabinet is recommended.
• Single point grounds from other control cabinets, if any, in the
system.

IMPORTANT

You must ensure that the "0V" or "Common" of all devices connected
to the MMC Smart Drive are connected to Single Point Ground
(SPG). Failure to do so may result in erratic operation or damage to
the MMC Smart Drive and devices connected to it. Examples of de-
vices connected to the MMC Smart Drive include the power source
that supplies power to the MMC Smart Drive and devices connected
to the MMC Smart Drive PiCPro Port. Note that some devices (for ex-
ample, a Personal Computer) may have their "0V" and "Protective
Earth Ground" connected together internally, in which case only one
connection has to be made to SPG for that device. Also note that the
AC/DC converter for some portable PCs have chassis connected from
the wall plug to the PC. The ground for the AC outlet must be con-
nected to the SPG.
Also, you must ensure that the MMC Smart Drive "Protective Earth
Ground" connection is connected to SPG, and that the MMC Smart
Drive is mounted to a metal panel or enclosure that is connected to
SPG.

26 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

3.11.1 Grounding Requirements

Figure 3-1: Example of Grounding Required for CE Compliant Single Phase
230V Drive System

In-coming
AC Power (Mains)

In-coming
Supply
Ground
Terminal ENCLOSURE

Supply Circuit P
Disconnecting 24V Power
1

Means Supply
I
N
+24V
COM
O
U
BR+ T
PE BR-

F
DC BUS
1

AC Line B+

SCPD Filter B-

M L1 F
2
L2

M U
V
W
I
O User I/O

CAUTION - Risk of Electric Shock

High Voltage may exist up to 10 minutes after removing power

Motor
Feedback
Auxiliary Motor Power
Single Point Power
Ground (SPG)* Grounding
Clamp

* Equipment Ground, AC Common, and DC Common are To Workstation

or other Device Machine
tied together at one point only, Single Point Ground (SPG). Base

1. Mount the filter as close to the Drive as possible. If the distance

exceeds 600 mm (2.0 ft), use shielded cable between the Drive and the
filter, strapping the shield to chassis at each end of the cable. This is
particularly important for attenuation of higher frequency emissions (5-
30 MHz).

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 27
Installing the Drive

2. Shield or separate the wires connecting the AC power to the filter from
other power cables (e.g., connections between the Drive and the filter,
motor power cable, etc.). If the connections are not separated from each
other, the EMI on the Drive side of the filter can couple over to the
source side of the filter, thereby reducing or eliminating the filter’s
effectiveness. The coupling mechanism can radiate or allow stray
capacitance between the wires.
3. Bond the filter and the Drive to a grounded conductive surface (the
enclosure) to establish a high frequency (HF) connection. To achieve
the HF ground, the contact surface interface between the filter, Drive,
and the enclosure should be free from paint or any other type of insula-
tor.
4. Size the filter following manufacturer recommendations.
5. Provide a large enough ground bar to connect all wires with no more
than two wires per connection.
6. Clamp motor power cable shield for EMC termination.

IMPORTANT

Filter AC power to the drives to be compliant to CE

emission requirements.

WARNING

High voltage exists in AC line filters. The filter must

be grounded properly before applying power. Filter
capacitors retain high voltages after power removal.
Before handling the equipment, voltages should be
measured to determine safe levels. Failure to observe
this precaution could result in personal injury.

28 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

3.11.2 Grounding Multiple Drives in the Same Cabinet

1. Mount a common bonded ground bus in the cabinet.
2. Connect the ground wires for all drives to the common bonded
cabinet ground bus.
3. Connect the common bonded cabinet ground bus to an external
ground system that is connected to a single point ground.

3.12 System Wiring Guidelines

The MMC Smart Drive relies on electrical signals to report what is going on
in the application and to send commands to it. In addition, signals are
constantly being exchanged within the system. The MMC Smart Drive is
designed for use in industrial environments, but some guidelines should be
followed.
This section contains common system wiring configurations, size, and
practices that can be used in a majority of applications. National Electrical
Code, local electrical codes, special operating temperatures, duty cycles, or
system configurations take precedence over the values and methods
provided.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 29
Installing the Drive

Wherever possible, install wiring and related components in the following

order:
1. main power line disconnecting means
2. transformer (optional)
3. fuses (SCPD)
4. motor control
5. line reactor (as required)
6. line filter (optional)
7. device protection fuses (as required)
8. drive
9. shunt resistors (optional)

3.12.1 Recommended Signal Separation

G&L Motion Control recommends separation of low level signals
(encoder, analog, communications, fast DC inputs) from high
voltage or high current lines. Maintain at least two inches of
separation.
Inside a control cabinet, connect the shields of shielded cables at
the MMC Smart Drive. It is recommended that factory cables (from
G&L Motion Control) are used between MMC drives, controls, and
motors to ensure CE compliance.

WARNING

Use care when wiring I/O devices to the MMC

Smart Drive and when plugging in cables. Wiring
the wrong device to the connector or plugging a
connector into the wrong location could cause inter-
mittent or incorrect machine operation or damage to
equipment.

30 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

Figure 3-2: Recommended Signal Separation

PICPRO COMMUNICATIONS CABLE

MOTOR FEEDBACK CABLE

MMC MOTOR POWER CABLE

Smart
Drive

USER I/O CABLE

Power
Connector
COM
24V

Capacitor
(.001 uF)

INCOMING
AC POWER
+
(MAINS) DC POWER SUPPLY

GND

SINGLE-POINT GROUND

SINGLE-POINT GROUND

SINGLE POINT GROUND (SPG)

To prevent excessive conducted emissions from a DC power

source (typically 24V) used for digital I/O, a .001 micro farad
capacitor should be used. Connect the capacitor from the +24V DC
to COMMON at the distribution terminals.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 31
Installing the Drive

3.12.2 Building Your Own Cables

• Connect the cable shield to the connector shells on both
ends of the cable for a complete 360 degree connection.
• Use a twisted pair cable whenever possible, twisting differ-
ential signals with each other, and single-ended signals with
the appropriate ground return.

NOTE

G & L Motion Control Inc. cables are designed to min-

imize EMI and are recommended over hand-built ca-
bles.

3.12.3 Routing Cables

Guidelines for routing cables in a cabinet include the following:
• Always route power and control cables separately.
• Do not run high and low voltage wires/cable in the same
wireway.
• Cross high and low voltage conductors at 90 degree angles.
• On parallel cable runs, maximize the distance between high
and low voltage cables.
• Maintain the least amount of unshielded cable leads.
3.13 Wiring the Drive
These procedures assume you have bonded and mounted your MMC Smart
Drive to the subpanel and that there is no power applied to the system.
3.13.1 Sizing the 24V Power Supply
When you size your power supply, you must ensure that the supply
is large enough to handle the total load. Refer to the specification
tables for the +24VDC input power requirements.
In most cases, one power supply can be used for an entire control
system. However, depending upon the drives and external I/O used
in the application, the power distribution may be split into two or
more power supplies.
Use of switches in series with the 24VDC power input is not
recommended. The drive contains energy storage capacitors at the
inputs. While no harm is done to the drive, this much capacitance
across the 24VDC source may cause voltage dips when the switch
in series with the 24VDC power is closed.

32 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

CAUTION

A possible ignition hazard within the MMC Smart Drive exists if exces-
sive current is drawn from the 24 VDC powering the MMC Smart
Drive. To prevent this possibility (due to improper wiring or 24 VDC
supply failure), a fuse should be used in series with the 24 VDC to the
MMC Smart Drive. Specifically, a 4 A max. "UL248 Series" fuse
should be used. In addition, the 24 VDC shall be supplied by an isolat-
ing source such that the maximum open circuit voltage available to the
MMC Smart Drive is not more than 30 VDC.

The +24V power to the MMC Smart Drive is connected through a Phoenix 5-
pin connector with a plug-in terminal block. The ground from the power
source and the ground from the MMC Smart Drive must be connected to the
Single-Point Ground (SPG). Devices connected to the User I/O Port may
have their own power sources for input or output control signals provided
that each one is:
• at the correct voltage and current levels for the module and the
device.
• connected to the same Single-Point Ground that the MMC Smart
Drive uses.
It is recommended that the same main disconnect switch be used for the
MMC Smart Drive and for all devices in the application.

IMPORTANT

No matter how the system is installed, before you connect the MMC
Smart Drive to the application, make sure that power is off to the sys-
tem and to the devices that are wired to the MMC Smart Drive.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 33
Installing the Drive

3.13.2 System AC Power Wiring Guidelines

NOTE

In addition to the guidelines listed below, follow all national and local
electrical codes and regulations.

• Install a supply circuit disconnecting means.

• Install a Short Circuit Protective Device (SCPD).
• Due to high inrush current at power-up, use dual element time delay
fuses for the SCPD.
• Install additional device protection fusing (460V models). Only high
speed type fuses provide proper protection.
• Refer to the Specifications sections in Chapter 4 of this manual for
device and conductor requirements.
• Clamp the motor power cable shield to the drive using the G&L Motion
Control supplied bracket. Maximum tightening torque for bracket
screws is 10 lb-in.
• Use shielded cables and AC line filters (for CE Compliance). Make
sure that wiring from the drive to the line filter is as short as possible.
Locate common grounding bus bars as close as possible to the drive.
The braid shield of the cable should be clamped at the drive or mount-
ing panel.
• Power connections for each drive in a system should be separately con-
nected directly to the AC power supply. Do not daisy chain drive power
connections.
• Make sure the phase to neutral ground voltage does not exceed the
input ratings of the drive when using an autotransformer.

34 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

3.13.3 Connecting Interface Cables

IMPORTANT

This drive contains ESD (Electrostatic Discharge) sen-

sitive parts and assemblies. Follow static control pre-
cautions when installing, testing, servicing, or repairing
components in a drive system.

• Plug the 9-pin D-shell, serial PiCPro cable into the PiCPro
port.
• Plug the one 15-pin D-shell, Feedback cable into the FBK1
connector.
• Plug the 26-pin D-shell, User I/O cable into the I/O connec-
tor.
• Tighten the attachment screws for all cables to the drive
connectors.

WARNING

To avoid personal injury and/or equipment damage:

• Ensure installation complies with specifications
regarding wire types, conductor sizes, branch
circuit protection, and disconnect devices. The
National Electrical Code (NEC) and local codes
outline provisions for safely installing electrical
equipment.
• Ensure motor power connectors are used for
connection purposes only. Do not use them to
turn the unit on and off.
• To avoid personal injury and/or equipment dam-
age, ensure shielded power cables are grounded
to prevent potentially high voltages on the
shield.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 35
Installing the Drive

3.13.4 Preparing Motor Connection Wires

NOTE

It is recommended that G & L Motion Control Inc.

cables be used. G & L Motion Control Inc. cables are
designed to minimize EMI and are recommended
over hand-built cables.

1. Strip back cable jacket approximately 152 mm (6.0 in.) from the
end of the cable.
2. Strip approximately 12 mm (0.50 in.) of insulation from the end
of each conductor. Do not tin ends after stripping.

IMPORTANT

Do not nick, cut or damage wire strands while re-

moving wire insulation.

3. Strip the cable jacket away from the cable until the shield braid
is visible. Expose 17 mm (0.68 in.) of cable shield braid.

Figure 3-3: : Motor Cable

Dimension varies
by Drive Model
(1U2)

(1V2)
(1W2)
Ground
Expose 17 mm (0.68 in.) of braid

36 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 Installing the Drive

4. Attach the individual wires from the motor cable to their

assigned terminal. Refer to Chapters 5 and 6 for front panel
connectors and terminal assignments.
5. Tighten each terminal screw.
6. Gently pull on each wire to make sure it does not come out of
its terminal. Reinsert and tighten any loose wires.
7. Attach the plastic cover to terminal block
Factory supplied motor power cables for LSM, MSM, FSM, HSM,
XSM, YSM and NSM Series motors are shielded, and the power
cable is designed to be terminated at the drive during installation. A
small portion of the cable jacket is removed which exposes the
shield braid. The exposed shield braid must be clamped to the drive
chassis using the provided clamp and clamp screws

Figure 3-4: Terminating Motor Power Cable for 230V Drive

I
O
Shield

CAUTION - Risk of Electric Shock

High Voltage may exist up to 10 minutes after removing power

Motor Cable
Jacket
Clamp
Clamp
Screw Clamp
Screw
Motor
Cable

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 37
Installing the Drive

Figure 3-5: Terminating Incoming AC Power (Mains) Cable for 460V Drive

FROM MAINS
Cable
Jacket

Shield
Clamp Screw Shield Clamped
to Mounting Panel
Clamp Screw

Maximum 10 cm from Cable Jacket

the Edge of the Drive

MMC-SD 460 DRIVE

Shield

Clamp
Shield Clamped
Cable to Bottom of Drive
Clamp Jacket
Screw

TO MOTOR

38 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

4 System Power Protection and Related Devices

4.1 Motor Overload Protection
The MMC Smart Drive utilizes solid state motor overload protection in
accordance with UL508C that operates:
• within 8 minutes at 200% overload
• within 20 seconds at 600% overload
4.2 Fuses
4.2.1 Fuse Sizing
Branch Circuit Protection must be provided for the MMC Smart
Drive in accordance with NFPA 79 7.2.3 and 7.2.10. Bussmann or
equivalent Class RK1, J, or CC dual element time delay type fuses
should be used as the branch circuit SCPD (Short Circuit Protection
Device). Supplemental UL1007 protectors shall not be used to
provide Branch Circuit Protection. Fuses are sized based on the
drive input current rating and maximum SCPD rating designations
shown in NFPA 79 Table 7.2.10.1. Input mains conductor size is
based on designations shown in NFPA Table 7.2.10.4 and 13.5.1.
Table 4-1: AC Input Power Requirements

Requirements

Nominal Branch
Input Current Circuit Fuse Conductor Transformer
Drive Model (AmpsRMS) (Amps) (AWG) (kVA)*

MMC-SD-0.5-230 5 12 14 1

MMC-SD-1.0-230 9 15 14 2

MMC-SD-2.0-230 18 30 14 4

MMC-SD-1.3-460 2.44 4 14 1.94

MMC-SD-2.4-460 4.18 7 14 3.33

MMC-SD-4.0-460 7 12 14 5.6

MMC-SD-6.0-460 10.8 17.5 14 8.6

MMC-SD-8.0-460 14.8 25 12 11.8

MMC-SD-12.0-460 16.7 25 12 13.3

MMC-SD-16.0-460 21.1 35 10 16.8

MMC-SD-24.0-460 33.1 50 8 26.3

* See Section 4.5 for calculating application transformer requirements.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 39
System Power Protection and Related Devices

Table 4-2: NFPA 79 Table 7.2.10.1 (Extraction)

Full Load Current (%)
Fuse Class with Time Delay AC-2
RK-1 150
J 150
CC 150

Table 4-3: NFPA 79 Table 7.2.10.4 (Extraction)

Maximum Rating
Conductor Size (AWG) Time Delay-Dual Element Fuse (amps)
14 30
12 40
10 50
8 80
6 100

4.2.2 Device Protection

To comply with UL508C, additional device protection is required
for the MMC-SD 460V model drives. High Speed (semiconductor)
type fuses must be applied in series with the Branch Circuit
protection and wired directly before the drive input mains.
Reference Figure 4-9 on page 54.

Table 4-4 on page 40 lists the maximum I2t allowed for each drive.
Table 4-5 on page 41 provides a list of Bussman High Speed fuses
that meet these requirements.
Table 4-4: Device Protection

Drive Model * Maximum Load Value 1)

MMC-SD-1.3-460 2
< 310A s

MMC-SD-2.4-460 < 310A2s

MMC-SD-4.0-460 < 450A s

2

MMC-SD-6.0-460 < 450A s

2

MMC-SD-8.0-460 2
< 450A s

MMC-SD-12.0-460 < 1, 500A s

2

MMC-SD-16.0-460 < 1,500A2s

MMC-SD-24.0-460 < 1,500A s

2

* Drive Model pertains to Analog (no dash suffix) and Digital (-D)
1)
Use fuses that fall in the operating point below the stated release integral (I2t)

40 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

Table 4-5: Fuses for Device Protection

Drive Model * High Speed Device Protection Fuse

MMC-SD-1.3-460 25A / 690V Bussmann 170M1561

MMC-SD-2.4-460 25A / 690V Bussmann 170M1561

MMC-SD-4.0-460 25A / 690V Bussmann170M1561

MMC-SD-6.0-460 25A / 690V Bussmann 170M1561

MMC-SD-8.0-460 40A / 690V Bussmann 170M1563

MMC-SD-12.0-460 63A / 690V Bussmann 170M1565

MMC-SD-16.0-460 63A / 690V Bussmann 170M1565

MMC-SD-24.0-460 80A / 690V Bussmann 170M3811

* Drive Model pertains to Analog (no dash suffix) and Digital (-D)

NOTE

Fuses from other manufacturers can be used if they meet the

requirements in Figure 4-4 on page 40. The approved fuses in
Table 4-5 are UL recognized.

4.3 Short Circuit Protection

Table 4-6: Motor Short Circuit Protection Ratings

Short Circuit Current

Short Circuit Current Rating with
Drive Rating with Fuse
No Fuse Restrictions Restrictions

230V Drives Suitable for use on a circuit capable of Suitable for use on a circuit
delivering not more than 5000 RMS capable of delivering not more
symmetrical short circuit Amperes, 240 than 200,000 RMS
Volts maximum. symmetrical Amperes, 240
Volts maximum, when
protected by high interrupting
capacity, current limiting fuses
as the SCPD (Fuse Class RK-1,
J, or CC).

460V Drives Suitable for use on a circuit capable of Suitable for use on a circuit
delivering not more than 5000 RMS capable of delivering not more
symmetrical short circuit Amperes, 480 than 18,000 RMS symmetrical
Volts maximum. Amperes, 480 Volts maximum,
when protected by high speed
(semiconductor) fuses as listed.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 41
System Power Protection and Related Devices

4.4 Line Reactors

AC Line Reactors are required when using some models of the MMC Smart
Drive. They protect the drive from impermissible rates of current change and
reduce harmonic current distortions. When required, they are mounted
between the drive and the mains input power source.

NOTE

Multiple drives or inverters on a common power line require one reac-

tor per drive. Individual reactors provide filtering between each drive
(and thereby reduce crosstalk) and also provide optimum surge protec-
tion for each unit. A single reactor serving several drives does not pro-
vide adequate protection, filtering or harmonic reduction when the
system is partially loaded. Refer to Figure 4-1 for an example of one
line reactor connected to one drive.

WARNING

Danger Electric
Shock Risk

The frame of line/load reactors must be grounded at one of the reactor

mounting holes typically by using a star washer under the heads of the
mounting bolts. INJURY OR DEATH MAY RESULT IF THESE
SAFETY PRECAUTIONS ARE NOT OBSERVED.

Figure 4-1: Line Reactor Connection (Simplified)

L1 L2 L3 SCPD LINE REACTOR

A1 A2

MMC SMART DRIVE

MOTOR
B1 B2

C1 C2

Line reactors are not necessary for the 230V MMC Smart Drives or the 460V
size 1 and 2 MMC Smart Drives. Line reactors are required for the 460V size
3 MMC Smart Drives.

42 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

4.4.1 Specifications and Dimensions for

Required Line Reactors

Table 4-7: MMC-SD-12-460 Line Reactor Specifications

Fundamental Power
Amperage Loss Inductance Weight Part Number

25A 52W 1.2 mH 14 lbs. M.1302.7373

0.38 x 0.75
3.00
(4 SLOTS)

3.43 2.35 LABEL

MAX WIRE RANGE: 22-5 AWG

CAUTION - TERMINAL SCREW TIGHTENING

TORQUE: 16 in-lb MAX

6.00
MAX

7.25 MAX

G & L Motion Control Inc. MMC Smart Drive Hardware Manual 43

System Power Protection and Related Devices

Table 4-8: MMC-SD-16-460 Line Reactor Specifications

Fundamental Power
Inductance Weight Part Number
Amperage Loss

35A 54W 0.8 mH 16 lbs. M.1302.7374

0.38 x 0.75
3.00
(4 SLOTS)

4.00 2.63 LABEL WIRE RANGE: 22-5 AWG

MAX

CAUTION - TERMINAL SCREW TIGHTENING

TORQUE: 16 in-lb MAX

5.75
MAX

7.25 MAX

44 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

Table 4-9: MMC-SD-24-460 Line Reactor Specifications

Fundamental Power
Inductance Weight Part Number
Amperage Loss

45A 62W 0.7 mH 28 lbs. M.1302.7375

0.38 x 0.75
3.00 (4 SLOTS)

4.75
MAX 3.16 LABEL
WIRE RANGE: 18-4 AWG

CAUTION - TERMINAL SCREW TIGHTENING

TORQUE: 16 in-lb MAX

7.35
MAX

9.00 MAX

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 45
System Power Protection and Related Devices

4.5 Isolation Transformers

The MMC Smart Drive does not require the use of isolation transformers.
However, a transformer may be required to match the voltage requirements
of the controller to the available service. To size a transformer for the main
AC power inputs, the power output (KVA) of each axis must be known. This
can be derived by calculating the horsepower for each axis and converting
that horsepower into units of watts. If power is being supplied to more than
one motor and a drive, simply add the kW ratings together from each
calculation to get a system kW total.
For an autotransformer, ensure that the phase to neutral/ground voltages do
not exceed the input voltage ratings of the drive.
If you are using the Motions Solutions Sizing Software, the average speed
and average torque data has already been calculated and can be used in the
equation. If you are not sure of the exact speed and torque in your
application, record the speed/torque curve for your drive/motor combination
and use the resulting values as a worst case continuous speed and torque.
Calculations are multiplied by a factor to compensate for the power and loss
elements within a power system. A factor of 2.0 is used with a single phase
system and a factor of 1.5 is used with a three phase system. This factor
should minimize the effects of the secondary line voltage sagging in the
transformer during peak current periods.
The speed/torque curve information for 230V motors is based upon a drive
input voltage of 230V AC. For a 115V AC input voltage, the maximum
speed can be reduced up to one half.
Example 230V Formula:

( RPM ) ⋅ Torque ( lb – in ) ⋅ 0.746 ⋅ KVA- ⋅ 2.0

KVA = Speed
------------------------------------------------------------------------------ -----------------------------
63, 025 HP

Example 460V Formula:

( RPM ) ⋅ Torque ( lb – in ) ⋅ 0.746 ⋅ KVA- ⋅ 1.5

KVA = Speed
------------------------------------------------------------------------------ -----------------------------
63, 025 HP

NOTE

The 3-Phase source powering the drive has to be a center-grounded "Y"

configuration. Do not exceed 304 Volts RMS from any phase to
ground.

46 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

4.6 External Shunts

4.6.1 Choosing an External Shunt

Power from the motor is returned to the MMC Smart Drive during
motor deceleration. Excessive power may have to be dissipated
from the MMC Smart drive when large inertia loads are present.
External shunts should be used to avoid excessive bus over voltage
faults.
G&L Motion Control recommends you use the Motion Solutions
Sizing Software to determine the need for and type of external
shunt. However, you may perform the following calculations to
choose the external shunt for your application.
1. Obtain the Peak Generating Power for the drive in watts (W).
2. Perform the following calculation:
W x T = Watts/sec or Joules
where:
W is watts from Step 1 above,
T is decel time required by the application
3. Obtain the Absorption Energy in Joules for the drive from the
Specifications section of the drive manual.
4. Determine the Peak Shunt Power from the drive that would be
delivered to the shunt resistor for your application:
• (Number calculated in Step 2 above) - (Absorption
Energy from the drive Specifications table in either
Chapter 5 or 6)
= Watt-seconds
• (Watt-seconds computed in 5a. above) (Decel
Time for the application) = Peak Shunt Power in
Watts
5. Determine the Continuous Shunt Power that would be deliv-
ered to the shunt resistor for this application:
• (Duty Cycle of Peak or Peak x Decel Time)
(Total Cycle Time) = Continuous Shunt Power
in Watts
6. Choose an external shunt from Figure 4-10 on page 48.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 47
System Power Protection and Related Devices

4.6.2 External Shunt Resistor Kits

Table 4-10: Shunt Resistors

Part
For Drive Shunt Resistor Module Number
MMC-SD-0.5-230
MMC-SD-1.0-230 100Ω, 300W, 600V, Dynamic M.1015.7046
MMC-SD-2.0-230
130Ω, 450W Cont. Power, 5.4kW Peak Pow-
MMC-SD-1.3-460
er, 820 V, 240 sec. Time Constant, 121 mm x M.1302.7048
MMC-SD-2.4-460
93 mm x 605 mm
95Ω, 700W Cont. Power, 8kW Peak Power,
MMC-SD-4.0-460 820 V, 250 sec. Time Constant, 121 mm x 93 M.1302.7049
mm x 705 mm
50Ω, 1400W Cont. Power, 17kW Peak Pow-
MMC-SD-6.0-460
er, 850V, 250 sec. Time Constant, 130 mm x M.1302.7060
MMC-SD-8.0-460
182 mm x 710 mm
25 Ω, 2800W Cont. Power, 32kW Peak Pow-
MMC-SD-12.0-460
er, 850V, 60 sec. Time Constant, 171 mm x M.1302.7061
MMC-SD-16.0-460
430 mm x 550 mm
18Ω, 3900W Cont. Power, 70kW Peak Pow-
MMC-SD-24.0-460 er, 850V, 70 sec. Time Constant, 180 mm x M.1302.7063
445 mm x 490 mm

48 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

4.6.3 Mounting Dimensions for External Shunts

Figure 4-2: Mounting Dimensions for 230V External Shunt (P/N M.1015.7046)

2.56
65.10

1.50 .52 CLEARANCE HOLES FOR #10

.25 38.10 13.30
[6.30] (M5) SCREWS.
.25 .73
6.30 18.60

NOTE:
1. ALLOW 3.0” (76.2 mm) CLEARANCE
IN FRONT OF UNIT FOR CABLES.
2. ALLOW .50” (12.7 mm) ON BOTH SIDES
OF UNIT.
NOTE: 2.0” (5 cm) ABOVE AND BELOW.
3. ALLOW
7.35 1. ALLOW 3.0” (76.2 mm) CLEARANCE IN FRONT OF
186.70
UNIT FOR CABLES.

2. ALLOW .50” (12.7 mm) ON BOTH SIDES OF UNIT

3. ALLOW 2.0” (5 cm) ABOVE AND BELOW

.22 (REF)
5.50

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 49
 System Power Protection and Related Devices

Figure 4-3: Mounting Dimensions for 460V External Shunt (P/N M.1302.7048)

4.76 in. (121 mm)

20.71 in. (526 mm) 0 5, 5 x 8

2.52 in. (64 mm)

3.66 in. (93 mm) 23.82 in. (605 mm)

Figure 4-4: Mounting Dimensions for 460V External Shunt (P/N M.1302.7049)
4.76 in. (121 mm)

24.65 in. (626 mm) 0 5, 5 x 8

2.52 in. (64 mm)
3.66 in. (93 mm) 27.76 in. (705 mm)

Figure 4-5: Mounting Dimensions for 460V External Shunt (P/N M.1302.7060)
5.12 in. (130 mm)

20.71 in. (526 mm)

5.90 in. (150 mm)
0 5, 5 x 8
23.82 in. (605 mm)
7.28 in. (185 mm)

50 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

Figure 4-6: Mounting Dimensions for 460V External Shunt (P/N M.1302.7061)
19.80 in. (503 mm) 13.62 in. (346 mm)

6.73 in (171 mm)

13.38 in. (340 mm)

20.70 in. (526 mm)

11.81 in. (300 mm)
21.65 in. (550 mm)

5.91 in. (150 mm) 5.91 in. (150 mm)

0 5, 5 x

16.93 in. (430 mm)

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 51
System Power Protection and Related Devices

Figure 4-7: Mounting Dimensions for 460V External Shunt (P/N M.1302.7063)

19.80 in. (503 mm) 13.62 in. (346 mm)

6.73 in (171 mm)

13.38 in. (340 mm)

20.70 in. (526 mm)

11.81 in. (300 mm)
21.65 in. (550 mm)

5.91 in. (150 mm) 5.91 in. (150 mm)

0 5, 5 x 8

16.93 in. (430 mm)

52 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

4.7 Line Filters

Line Filters consist of combinations of capacitors, reactors, resistors and
voltage limiters that are intended to reduce the electromagnetic influence of
the environment.

4.7.1 Line Filters and CE Compliance

The direction of influence is bi-directional, i.e. there is a reaction in
the units of emission of conducted disturbances, and, at the same
time, an improvement in the immunity of the drive to interference
that occurs in the case of lightning strikes, tripped fuses, or simple
switching activities.
1. The filter should be mounted to a grounded conductive
surface.
2. The filter must be mounted close to the drive input terminals.
If the distance exceeds 2 feet (600 mm), then a shielded cable
should be used to connect the drive and filter, rather than a
wire.
3. The wires connecting the AC source to the filter should be
shielded from, or at least separated from the wires (or strap)
connecting the drive to the filter. If the connections are not
segregated from each other, then the EMI on the drive side of
the filter can couple over to the source side of the filter,
thereby reducing, or eliminating the filter effectiveness. The
coupling mechanism can be radiation, or stray capacitance
between the wires. The best method of achieving this is to
mount the filter where the AC power enters the enclosure.
Figure 4-8 shows a good installation and a poor installation.

Figure 4-8: Block Diagram Simplified for 3-Phase Line Filter

1L1
2L1
L1 1U1

1L2 2L2
L2 1V1

1L3 2L3
L3 1W1

PE
PE

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 53
System Power Protection and Related Devices

Figure 4-9: Connection Diagram for 3-Phase Line Filter

L1 L2 L3 PE

Power
PE
Unit
PE PE
1L3 2L3
1U1
1L2 LINE FILTER 2L2
1V1
1L1 2L1
1W1

SCPD

Fuses required
Main Line Reactor for 460V models
Contactor (if necessary)

WARNING

High leakage currents exist in AC line

filters. The filters must be grounded
properly before applying power. Filter
capacitors retain high voltages after re-
moval. Measure voltages to determine
safe levels prior to handling the equip-
ment. Failure to do so could result in se-
vere bodily injury.

NOTE

To be able to route the interference currents at low impedance

back to the interference sources, the filter, the power unit, and
the contact area of the motor cable shield must have a junction
with the common mounting plate over as wide a surface as
possible that has good conductive properties. The best way to
ensure this is to use unpainted zinc-coated mounting plates.

54 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

4.7.2 Part Numbers for AC Line Filters

Table 4-11: Part Numbers for AC Line Filters

Current For Drive Part Number

MMC-SD-0.5-230
6A, 250V, 1 Phase M.1015.6922
MMC-SD-1.0-230
10A, 250V, 1 Phase MMC-SD-2.0-230 M.1015.6917
MMC-SD-1.3-460
7A, 480V, 3 Phase MMC-SD-2.4-460 M.1302.5241

MMC-SD-4.0-460
16A, 480V, 3 Phase MMC-SD-6.0-460 M.1302.5244
MMC-SD-8.0-460
MMC-SD-12.0-460
30A, 480V, 3 Phase M.1302.5245
MMC-SD-16.0-460
42A, 480V, 3 Phase MMC-SD-24.0-460 M.1302.5246
56A, 480V, 3 Phase For filtering multiple drives M.1302.5247
75A, 480V, 3 Phase For filtering multiple drives M.1302.5248

4.8 Technical Data for AC Line Filters

4.8.1 Technical Data for 230V Line Filters

M.1015.6922 M.1015.6917 M.1015.6918

Voltage/Freq. 250VAC @ 50/50Hz 250VAC @ 50/50Hz 250VAC @ 50/50Hz
Current 6A @ 50°C 10A @ 50°C 23A @ 50°C

Overload Current 150% 1 minute 150% 1 minute 150% 1 minute

200% 1 second 200% 1 second 200% 1 second
Temperature -25 to 95°C -25 to 95°C -25 to 95°C
Leakage Current 5mA @ 240V, 50 Hz 46mA @ 240V, 50 Hz 200mA @ 250V, 50Hz
Electric Strength 2500VAC/1 minute 2500VAC/1 minute 2500VAC/1 minute
Power Loss 3.5W (Full Load) 2.7W (Full Load) 10W (Full Load)
Terminals 2mm sq. spring clamp M4 screw cross/ sq. M4 screw cross/ sq.
2x 2.5mm 2x 2.5mm

Weight 0.3Kg (0.66 Lb.) 0.95Kg (2.0 Lb) 1.6Kg (2.5 Lb)
Back Mounting 4 x M4 4 x M4 4 x M4
Side Mounting 2 x M5 2 x M6 2 x M6

Line filters are manufactured to millimeter dimensions (inches are approximate conversions).

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 55
 System Power Protection and Related Devices

4.8.2 Technical Data for 460V Line Filters

Part Number
Item
M.1302.5241 M.1302.5244 M.1302.5245 M.1302.5246 M.1302.5247 M.1302.5248

Maximum 3 x 480VAC, 50/60Hz

Supply Voltage

Rated current 7A 16A 30A 42A 56A 75A

(at 40°C)

Peak current 1.5 x IN for < 1 min. per hour at TB = 40°

Test Voltage
Phase/Phase 2.1 kVDC for 2 sec. at 25°C
Phase/Ground 2.7 kVDC for 2 sec. at 25°C

Maximum 4mm2 4mm2 10mm2 10mm2 4mm2 25mm2

Connection
Cross-section

Operational
Environmental -25°C ... +55°C
Temperature Reduction of rated current from 40°C onwards by 1.4% / °C
Range TB

Power Loss 4W 8W 12W 15W 18W 24W

(typical)

Site Altitude Below 2000 m above sea level (higher altitudes on request)

Storage
Temperature -25°C ... +85°C
Range

Type of IP20
Protection

Weight 0.6kg 1.0kg 1.3kg 1.6kg 1.9kg 2.6kg

56 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 System Power Protection and Related Devices

4.8.3 Dimensions for AC Line Filters

4.8.4 230V Line Filter Dimensions

B2

NOTE: Spring clips replace

Terminal screws on 6 Amp
Filter (P/N 401-30222-00)

B1 B

A
A2 A1
C1
C

SINGLE PHASE SINGLE PHASE SINGLE PHASE

6A 10A 23A
M.1015.6922 M.1015.6917 M.1015.6918
MEASUREMENT mm in mm in mm in
A 170 6.7 214 8.4 214 8.4
A1 152 6.0 192 7.6 192 7.6
A2 9 0.4 11 0.4 11 0.4

B 92 3.6 145 5.7 204 8.0

B1 55 2.2 104 4.1 164 6.6
B2 18 0.7 20 0.8 20 0.8

C 25 1.0 40 1.6 47 1.8

C1 10 0.4 16 0.6 19 0.8

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 57
System Power Protection and Related Devices

4.8.4.1 460V Line Filter Dimensions

Part Number A B C D E F L G H
M.1302.5241 190 40 70 20 180 160 185
M.1302.5244 250 50 70 25 235 220 245 M5
M.1302.5245 270 50 85 30 255 240 265 5.4
M.1302.5246 310 50 85 30 295 280 305
M.1302.5247 250 85 90 60 235 220 258 M6
M.1302.5248 270 80 135 60 255 240 278 6.5

58 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

5 230V Single Phase MMC Smart Drive

5.1 LEDs
Table 5-1: LEDs Description for 230V Single Phase MMC Smart Drive
LED Color Description
P Green Power LED. Indicates when illuminated that power
is being supplied to the 24V input terminal strip.
D1 Yellow Status LED. Drive status and fault information.
DC BUS Orange Bus Voltage LED. Indicates when illuminated that
the DC bus is at a hazardous voltage.

DANGER
DC bus capacitors may retain hazardous voltages
for up to ten minutes after input power has been
removed. Always use a voltmeter to ensure that
the DC bus voltage is below 50VDC before servic-
ing the drive. Failure to observe this precaution
could result in severe bodily injury or loss of life.

Figure 5-1: Location of LEDs on 230V Single Phase MMC Smart Drive

J1

D1 P
Status LED (D1)
(Yellow) Power LED (P)
(Green)
P
1

I
N

+24V
COM
O
Bus Voltage LED U
BR+
(DC BUS) T
BR-
(Orange)
DC BUS

F
1

B+

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 59
 230V Single Phase MMC Smart Drive

5.2 Connectors and Switches on the 230V Drive

Figure 5-2: Front Panel, 230V Single Phase (500W, 1kW, 2 kW)

Digital Interfaced
MMC-SD Only
Node
8
7
9 01
2
3
Address
6 5 4
Rotary
8
9 01
2 Switches D1 P PiCPro Port (P1)
7 3
6 5 4
9-Pin Standard D-Shell on
Analog Interfaced MMC-SD
PiCPro
Connector Miniature Circular on
P Digital Interfaced MMC-SD
1

I
N

+24V
24VDC COM Digital Link Connectors
24VDC IN/Brake IN (RJ45)
O
Terminal Strip BR+ U (Digital Interfaced MMC-SD
(5-Position Screw Brake BR-
T
only)
Terminal Strip)
DC BUS

F
1 Feedback Connector (F1)
(15-Pin High Density D-Shell)
B+

B-

L1 Feedback Connector (F2)

F
2 (15-Pin High Density D-Shell)
L2 (Digital Interfaced MMC-SD Only)
Line Power/
Motor Terminal Strip
(9-Position Screw
U
Terminal Strip)
V
I
O User I/O Connector (IO)
W (26-Pin High Density D-Shell)

CAUTION - Risk of Electric Shock

High Voltage may exist up to 10 minutes after removing power

60 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

5.2.1 PiCPro Communication Port

5.2.1.1 PiCPro Port (P1)
The PiCPro (P1)port provides RS232 level serial communication
for the PiCPro programming interface.
Table 5-2: Pin Description - PiCPro Port (P1)
(Analog Interfaced MMC-SD)

PiCPro Port (P1) Signals

Function Notes Pin
Receive Data Receives parameter and control data from the 2
PiCPro software loaded on a PC.
Transmit Data Transmits data from the user application via the 3
drive to the PiCPro software loaded on a PC.
Data Terminal Ready Indicates that the drive is ready to send data to the 4
PiCPro software loaded on a PC.
Signal Ground Provides the return path for signals 5
Request to send Sends a request to the PiCPro software loaded on a 7
PC to send data from the drive to PiCPro.
Protective Ground Provides a path for the ground signal to an external Connector
single point ground. Shell

Table 5-3: Pin Assignment - PiCPro Port (P1)

(Analog Interfaced MMC-SD)

Pin Assignment
PiCPro Port (P1) - 230V Single Phase (500W, 1kW, 2kW)
Pin Label In/Out Pin Sequence
1 NC N/A 9-pin Male D-sub
2 RS232 Receive Data In
3 RS232 Transmit Data Out
9 5
4 RS232 Data Terminal Ready Out
5 RS232 Signal Ground In/Out
6 NC N/A
7 RS232 Request to Send Out
8 NC N/A 6
1
9 NC N/A
Connector Shield In Connector
Shell Shell

Table 5-4: Pin Description - PiCPro Port (P1)

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 61
 230V Single Phase MMC Smart Drive

(Digital Interfaced MMC-SD)

PiCPro Port (P1) Signals

Function Notes Pin
Receive Data Receives parameter and control data from the 1
PiCPro software loaded on a PC.
Transmit Data Transmits data from the user application via the 2
drive to the PiCPro software loaded on a PC.
Signal Ground Provides the return path for signals 3 and 5
Protective Ground Provides a path for the ground signal to an external Connector
single point ground. Shell

Table 5-5: Pin Assignment - PiCPro Port (P1)

(Digital Interfaced MMC-SD)

Pin Assignment
PiCPro Port (P1) - 230V Single Phase (500W, 1kW, 2kW)
Pin Label In/Out Pin Sequence
1 RS232 Receive Data In Miniature Circular
2 RS232 Transmit Data Out 4 6
2
3 Signal Ground In/Out
4 NC N/A
5 Signal Ground In/Out
1 3 5
6 NC N/A
Connector Shield In
Shield

62 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

5.2.2 Node Address Rotary Switch (Digital Interfaced

MMC-SD Only)
Two rotary switches are used to set the drive address. Rotate the
switch to the desired address.

Addresses can be set to any number from 1 through 64. The top
switch represents values of base ten. The bottom switch represents
values of base 1.

As an example, rotating the switch to a setting of 2 on the top

switch equals the value of 20 (2 x 10). Rotating the switch on the
bottom switch to a setting of 5 equals the value of 5. The actual
address setting is 25 (20 + 5).

10s

1s

5.2.3 Digital Link Connector (IN/OUT)

(Digital Interfaced MMC-SD Only)
The Digital Link connectors allow digital interfaced MMC-SD
drives to communicate with one another.

Table 5-6: Pin Description - Digital Link Connector (IN/OUT)

(Digital Interfaced MMC-SD Only)

Digital Link Connector (IN/OUT) Signals

Pin
Function Notes In Connector Out Connector
Receive Data + Receives data from connected drives. 1 3
Receive Data - Receives data from connected drives. 2 6
Transmit Data + Transmits data to connected drives. 3 1
Transmit Data - Transmits data to connected drives. 6 2
Protective Provides a path for the ground signal to an external Connector Connector
Ground single point ground. Shell Shell

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 63
 230V Single Phase MMC Smart Drive

Table 5-7: Pin Assignment - Digital Link Connector (IN/OUT)

(Digital Interfaced MMC-SD Only)

Pin Label In/Out Contact Sequence

IN Connector
1 Receive + In
2 Receive - In
3 Transmit + Out
4 Not Used N/A
5 Not Used N/A
RJ-45 Connector
6 Transmit - Out
Connector Provides a path for the In 1
Shield ground signal to an
external single point 6
ground.

OUT Connector
1
1 Transmit + Out
6
2 Transmit - Out
3 Receive + In
4 Not Used N/A
5 Not Used N/A
6 Receive - In
Connector Provides a path for the In
Shield ground signal to an
external single point
ground.

64 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

5.2.4 Feedback Connector (F1)

• All signals (other than the encoder inputs) are bussed internally
between the two feedback connectors F1 and F2. The bussed
signals include motor commutation inputs, temperature input,
and encoder power outputs.
• F1 can interface with incremental encoders, sinewave encoders,
and resolvers (using the optional resolver interface module).
These signals are conditioned and routed to the I/O connector.

NOTE

Because of the variety of feedback devices that can

be used, the following table contains signal descrip-
tions only (no pin numbers). Refer to Table 5-9 for
feedback device specific pin numbers.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 65
 230V Single Phase MMC Smart Drive

Table 5-8: Pin Description for Feedback Connector (F1)

F1 Feedback Signals
Signal Type Signal Name Notes Pin
Incremental Encoder In- A1, A1/, B1, B1/, I1, I1/ Differential A quad B en- Pin Assignments
puts coder signals. vary depending on
the type of Feed-
Sinewave Encoder Inputs Sin, Sin/, Cos, Cos/ Sinewave Encoder signals back Device used.
Refer to Table 5-9
Sinewave Encoder Data RS-485 Data +, RS-485 Rs-485 signals for connect- for pin
Channel In/Out Data -, RS-485 Clock+, ing the Sinewave Encoder assignments.
RS-485 Clock- Data Channel to the drive
Motor Commutation Hall Commutation Track S1, Hall device input signals that
Sensor Inputs S2, S3 are used to initialize the
commutation angle. They
consist of a 74HC14 input
with 10µs filter and 1 K pull
up to +5V. Shared with F2.
Sinewave Encoder Com- Commutation Sin+, Sinewave signals that are
mutation Inputs Commutation Sin- used to initialize the motor
commutation angle when a
Heidenhein Sincoder is used
as the motor feedback de-
vice.
Resolver Inputs Sin+, Sin-, Cos+, Cos- Resolver rotor feedback sig-
nals used when optional Re-
solver Interface Board is
installed.
Resolver Outputs Carrier+, Carrier- Resolver rotor excitation
signals used when optional
Resolver Interface Board is
installed.
Temperature Input Temperature Thermostat (normally-
closed) or Thermistor (Phil-
lips KTY84-130 PTC or
equivalent recommended)
input for detecting over tem-
perature conditions within
the motor.
Travel Limit Inputs + Travel Limit, -Travel Over travel limit inputs (Re-
Limit served for future use).
Encoder Power +5V Source, +9V Source Regulated +5VDC and regu-
Outputs lated +9VDC for powering
the attached encoder.
Sinewave Encoder Refer- Ref Mark/ Reference Mark input used
ence Mark Input with some Sinewave Encod-
ers used to indicate motor
position within one revolu-
tion.
Signal and Power Com- Common Return path for feedback
mon signals and power supplies
(+5V and +9V).

66 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 230V Single Phase MMC Smart Drive

Table 5-9: Encoder/Resolver Pin Assignments for Feedback Connector (F1)

Encoder/Resolver Pin Assignments for Motor Feedback 15 Pin Connector (F1)
230V Single Phase (500W, 1kW, 2kW)
Feedback Device
Sinewave Encoder
In/
Pin Digital Stegmann Heidenhain Out Pin
Incremental Hiperface Endat*** SSI*** Sincoder*** Resolver
* Sequence
1 A1 Cos Cos+ In 15-pin Female
HD D-Sub
2 A1/ Cos/ Cos-
10
3 B1 Sine Sin+ 5
4 B1/ Sine/ Sin-
5 I1 RS-485 Data+ Ref Mark Carrier+ ** 15
6 Common In/Out
7 N/U +9V Source N/U N/U N/U N/U Out
8 Commutation N/U N/U N/U N/U N/U In
Track S3
9 + Travel Limit Commutation +Travel 11
Cos+ Limit
10 I1/ RS-485 Data- Ref Mark/ Carrier- ** 1
Connector
11 Temperature In Shell 6
12 Commutation N/U RS-485 Commutation N/U In
Track S1 Clock+ Sin+ ****
13 Commutation N/U RS-485 Commutation N/U
Track S2 Clock- Sin-
14 +5V Source N/U +5V Source N/U Out
15 - Travel Limit Commutation -Travel Lim- In
Cos- it
Shell Shield N/A

*
Requires installation of optional resolver board.
**
The direction of data flow for pins 5 and 10 is as follows:
Stegmann Hiperface, ENDAT: I/O
Digital Incremental, SSI, Heidenhain Sincoder: IN
Resolver: OUT
***
For future use.
****
Pins 12 and 13 are outputs when ENDAT or SSI is installed.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 67
 230V Single Phase MMC Smart Drive

5.2.5 Feedback Connector (F2) (Digital Interfaced

MMC-SD Only)
• All motor signals (other than the encoder inputs) are bussed
internally between the two feedback connectors F1 and F2. The
bussed signals include motor commutation inputs, temperature
input, travel limit inputs, and encoder power outputs.
• F2 can be designated (in PiCPro) as the motor feedback connec-
tor but only if F1 is not (either one or the other must be desig-
nated as such).
• Travel Limits can be defined in PiCPro software as either com-
ing into the MMC Smart Drive at the F2 connector or at the
User I/O connector.
• F2 can interface with only incremental type encoders.
• The hall sensor inputs on F1 and F2 are connected together,
allowing either F1 or F2 to accept the hall sensor signal, but
NOT both. Only one feedback may be connected to motor hall
sensor inputs.

Table 5-10: Pin Description for Feedback Connector (F2)

F2 Feedback Signals
Signal Type Notes Pins
Incremental Encoder Input Differential A quad B encoder signals. 1,2, 3,
4, 5,
10
Motor Commutation Hall-device input signals that are used to ini- 8, 12,
Hall Sensor Inputs tialize the motor commutation angle. They 13
consist of a 74HC14 input with a 10µs filter
and a 1K pull-up to +5V. Shared with F1.
Temperature Input Thermostat (normally-closed) or Thermistor 11
(Phillips KTY84-130 PTC or equivalent rec-
ommended) input for detecting over tempera-
ture conditions within the motor.
Travel Limit Inputs Over-travel limit inputs. They consist of a 9, 15
74HC14 input with a 10µs filter and a 1K pull-
up to +5V.
Encoder Power Outputs Regulated +5VDC and regulated +9V VDC 7, 14
for powering the attached encoder.
Signal and Power Common Return path for feedback signals and power 6
supplies (+5V and 9 V).

68 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

Table 5-11: Pin Assignments for Feedback Connector (F2)

(Digital Interfaced MMC-SD Only)

Pin Assignments
F2 Feedback 15 Pin Connector
230V Single Phase (500W, 1kW, 2kW)
Pin Label In/Out Pin Sequence
1 A2 In 15-pin Female HD D-Sub
2 A2/ In
10
3 B2 In
4 B2/ In 15 5
5 I2 In
6 Common In/Out
7 +9V Out
8 S3 In
9 Travel Limit+ In 11 1

10 I2/ In 6
Connector
11 Temperature In Shell

12 S1 In
13 S2 In
14 +5V Out
15 Travel Limit- In
Shell Shield In

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 69
 230V Single Phase MMC Smart Drive

5.2.6 User I/O Connector (IO)

Table 5-12: Pin Description for User I/O Connector (IO)

Signals for User I/O Connector (IO)

Signal Type Notes Pins
Analog Command • Analog velocity or torque commands of 0 to +/- 10V 14, 15
Inputs • Separate scale and offset parameters are used relative to the
(Analog Interfaced command signal being velocity or torque
MMC-SD only)
Fast Inputs Used for latching encoder position. 8, 9, 11,
(Digital Interfaced 12
MMC-SD only)
General Purpose Soft- 24VDC sourcing type. Default assignments: Pin 17 (GPIN1) = 17, 18,
ware Assignable In- Drive Enable, Pin 18 (GPIN2) = Fault Reset 19, 20,
puts 21, 22
Buffered F1 • RS485 drivers are used and the signal that is output depends 1, 2, 3, 4,
Encoder Output on the encoder or resolver type used. See Specifications in 5, 6
Chapter 5 of this manual.
• These signals are generated after the feedback from the
F1connector is filtered and processed.

General Purpose Soft- 24VDC sourcing type. Default assignment: 23, 24,
ware Assignable Out- Pin 26 (GPOUT4) = Drive Ready 25, 26
puts
IO24V, IO24COM 24 VDC inputs for powering GPIN and GPOUT I/O. 10, 16

70 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

Table 5-13: Pin Assignment for User I/O Connector (IO)

Pin Assignment
User I/O Connector 26-Pin 230V Single Phase (500W, 1kW, 2kW)
PiCPro PiCPro
Wiring I/O Wiring I/O Pin
Pin Label Label In/Out Pin Label Label In/Out Sequence
1 FDBK1B A Out 14 CMD + In 26-pin Female
HD D-Sub
2 FDBK1B A/ Out 15 CMD - In
3 FDBK1B B Out 16 IO24COM In
4 FDBK1B B/ Out 17 GPIN1 Input1 In 18
9
5 FDBK1B I Out 18 GPIN2 Input2 In 26
6 FDBK1B I/ Out 19 GPIN3 Input3 In
7 Shield Out 20 GPIN4 Input4 In
8 GPIN7 + Input7 In 21 GPIN5 Input5 In
9 GPIN7 - In 22 GPIN6 Input6 In
10 IO24V In 23 GPOUT1 Output1 Out 19 1
11 GPIN8 + Input8 In 24 GPOUT2 Output2 Out 10
12 GPIN8 - In 25 GPOUT3 Output3 Out
13 Shield 26 GPOUT4 Output4 Out

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 71
 230V Single Phase MMC Smart Drive

Figure 5-3: Wiring Diagram for User I/O Connector (IO)

Drive

IO 24 V
24 V
Power IO 24 COM
Supply

GPIN
Input
Device To
To Single Drive
Point
Ground
From
GPOUT Drive
Output
Device

GPIN7 +
Sourcing
Input
To
GPIN7 - Drive

GPIN8 +

To
Drive
GPIN8 -
Sinking
Input (Analog Interfaced MMC-SD only)
MMC or CMD +
other To
External Drive
CMD -
Source
(Analog Interfaced MMC-SD only)

3 FDBK1B A, B, I

MMC or
other From F1
External Connection
Control 3 X3
FDBK1B A/, B/, I/

Drive

72 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

5.2.7 24 VDC IN/Brake Terminal Strip

Table 5-14: Pin Assignment for 24 VDC IN/Brake Terminal Strip

24VDC IN/Brake Terminal Strip

PiCPro
Terminal Signal I/O
Terminal Label Signal Type Description Label In/Out
+24V Logic Power +24V user sup- N/A In
+24V plied power sig-
nal terminal.
COM
COM Common +24V Common N/A In
Protective Must be con- N/A In
BR+ Ground nected to Protec-
BR- tive Earth
Ground (SPG)
BR+ Brake Relay + Refer to Figure Output5/ Out
5-3 below. Relay
BR- Brake Relay - Out

NOTE

Use of a diode (as shown) or an external RC type snubber is highly

recommended for use with inductive loads, especially DC inductive
loads.

Figure 5-4: BR+ and BR- Wiring Examples

Using 24V Power Source Using External Power Source

+24V
COM
External
Power +24V
BR+ Supply
COM
COM
Brake
BR-
BR+

1N4004 Brake
BR-

1N4004

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 73
 230V Single Phase MMC Smart Drive

5.2.8 Motor Terminal Strip

Table 5-15: Pin Assignment for Motor Terminal Strip

Motor Terminal Strip

Terminal Signal
Terminal Label Signal Type Description In/Out
B+ DC Bus Power from Out
drive to active
B+ B- shunt
B- L1 AC Power 100-240VAC In
single phase
L1 L2 power in to
L2 drive.
Protective Must be con- In
Ground nected to Protec-
U
tive Earth
V Ground (SPG).
W U Motor Power Power U-phase Out
from the drive to
the motor.
V Power V-phase Out
from the drive to
the motor.
W Power W-Phase Out
from the drive to
the motor.
Protective Connection for In
Ground motor ground.

74 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

5.3 Specifications - 230V MMC Smart Drive

5.3.1 General Data for all 230V Models

General Drive Data

Minimum wire size for input power wires 1.5mm2 (16 AWG) 75° C copper.

Maximum tightening torque for power 1.17 Nm (10.4 in-lbs.)

wire terminals

Commutation Three Phase Sinusoidal

Current Regulator Digital PI 125 µsec. update rate

Velocity Regulator Digital PID - 250 µsec. update rate

Environmental Data

Operating Temperature Range o o o

7 C to 55 C (45 F to 131 F)
o

Storage Temperature Range o o o

-30 C to 70 C (-22 F to 158 F)
o

Humidity 5% to 95% non-condensing

Altitude 1500 m (5000 ft)

Derate 3% for each 300 m above 1500m

Vibration Limits (per IEC 68-2-6) 10-57 Hz (constant amplitude.15 mm)

Operating/Non-operating 57 - 2000 Hz (acceleration 2 g)

Shock (per IEC 68-2-27) Four shocks per axis (15g/11 msec)
Non-operating

F1 and F2 Feedback Inputs

Input receiver type Maxim 3098 A quad B differential RS422 receiver

Encoder signals Differential quadrature

Input threshold ±200 mV

Input termination 150Ω, provided internally

Maximum input voltage 5V peak to peak differential -10 to +13.2V common mode

Maximum input signal frequency 720 K Hz (2.88 M feedback counts per second)

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 75
 230V Single Phase MMC Smart Drive

General Purpose Inputs

Configuration • 8 optically isolated 24V DC inputs

• Active high
• 6 are current sourcing only (current flow into input)
• 2 are sink or source

Guaranteed On 15 VDC

Guaranteed Off 5 VDC

Time delay on 1 ms max.

Time delay off 1 ms max.

Input voltage Nominal 24 VDC, maximum 30 VDC

General Purpose Outputs

Configuration • 4 optically isolated 24V DC outputs

• Active high
• Current sourcing only (current into load)
• Short circuit and overload protected

Maximum current 50mA per output

Voltage range 24VDC +15%-10%

Time delay on for resistive loads 50 µsec. max

Time delay off for resistive loads 50 µsec. max

Leakage current in off state 0.5 mA max

Command Input (Analog Interfaced Digital MMC-SD only)

Command Input • Analog velocity or torque, 0 to + 10V

• 14 bit effective resolution

76 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

Digital Link In/Out Ports (Digital Interfaced MMC-SD only)

"In" port Sends and receives high speed data to and from connected
MMC-SD’s "Out" port.

"Out" port Sends and receives high speed data to and from connected
MMC-SD’s "In" port.

User I/O Connector Encoder Emulation Output

F1 Motor Feedback Type Input Limit

Encoder Emulation Output
(A quad B Differential Output)

Incremental Encoder 720 KHz

2.88 M counts/sec.
The motor encoder A/B/I inputs are electrically buffered and
retransmitted via the User I/O connector.

High Resolution Encoder 100 KHz

400 K counts/sec.
The encoder SIN/COS signals are electrically squared and
retransmitted as A/B. The index mark "I" is synthesized by the
drive control DSP. Absolute position information is not
available via the Encoder Emulation Output.

Resolver 500 RPS

2.00 M counts/sec.
The field-installable resolver interface module converts the
motor resolver to 1024 lines/4096 counts per revolution of A/
B encoder output. The module synthesizes the index mark "I"
once per revolution of the resolver. Absolute position
information is not available via the Encoder Emulation
Output.

Conformity

CE Marked Conforms to Low Voltage Directive 73/23/EEC (amended by

93/68/EEC) and EMC Directive 89/336/EEC (amended by 92/
31/EEC and 93/68/EEC).
Conformance is in accordance with the following standards:
EN 50178 and EN61800-3 (Pending)

UL and C/UL Listed E233454 (Pending)

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 77
 230V Single Phase MMC Smart Drive

5.3.2 Physical and Electrical Data for 230V Drives

Model

MMC-SD-0.5-230 MMC-SD-1.0-230 MMC-SD-2.0-230

Physical

Weight 4.9 lbs. (2.23 kg) 5.6 lbs. (2.55 kg) 5.7 lbs. (2.59 kg)

Electrical Specifications

AC Input Specifications

Nominal Input Power 1.0 kVA 2.0 kVA 4.0 kVA

Input Voltage 100-240 VAC (nominal), Single Phase, 88-265 VAC (absolute limits)

Input Frequency 47 - 63 Hz

Nominal Input 5A RMS 9A RMS 18A RMS

Current

Maximum Inrush 70A 70A 70A

Current (0-Peak)

Power Loss 22W 37W 70W

AC Output Specifications

Continuous Output 2.5A 5A 10A

Current (0-Peak)

Continuous Output Power

Input = 115 VAC 250W 500W 1kW

Input = 230 VAC 500W 1kW 2kW

Peak Output Current 7.5A 15A 30A

(0-Peak)

Output Frequency 0-266 Hz

DC Input Power Specifications (24VDC)

Input Voltage Range 24 VDC +15% -10%

Typical Input Current 350 mA 650 mA

Typical Input Wattage 9W 16 W

Inrush Current 1.5 A for 10 ms

78 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

Relay Contact for Motor Mechanical Brake

Rating (resistive load)

Nominal 24 VDC
switching
capacity

Maximum 831 VA
switching power

Maximum 250 VAC / 100 VDC

switching
voltage

Maximum 5 A (AC) / 2.5 A (DC)

switching
current

Energy Absorbtion Specifications

DC Bus Capacitance 1410 µF 1880 µF

(Internal)

Bus overvoltage 420 VDC

threshold

Joules available for energy absorption

230V motor w/ 94 joules 126 joules

115V line input

230V motor w/ 38 joules 51 joules

230V line input

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 79
 230V Single Phase MMC Smart Drive

5.4 Dimensions for 230V MMC Smart Drive

5.4.1 230V 500W Drive - Front View

80 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

5.4.2 230V 500W Drive - Side View

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 81
 230V Single Phase MMC Smart Drive

5.4.3 230V 1kW and 2kW Drive - Front View

82 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
230V Single Phase MMC Smart Drive

5.4.4 230V 1kW and 2kW Drive - Side View

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 83
 460V 3-Phase MMC Smart Drive

6 460V 3-Phase MMC Smart Drive

6.1 LEDs
Table 6-1: LEDs Description for 460V 3-Phase MMC Smart Drive
LED Color Description

P Green Power LED. Indicates when illuminated that DC voltage is being supplied
to the drive.

D1 Yellow Status LED. Indicates drive status and fault information.

Figure 6-1: LEDs on the Size 1, Size 2 and Size 3 460V Drives

J1
Power LED
(Green)
6
D1 P

Status LED
(Yellow)

P
1

84 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.2 Connectors on the 460V Drive

6.2.1 Size 1 460V Drive Connectors
Figure 6-2: Connectors on the Size 1 460V Drive

24V Power
Connector (J1)
Ba- Pin
1 +24V
Ba+ Shunt/DC Bus 2 +24V
Terminals 3 Mains On
ZK+
4 Shunt On
ZK-
5 24V Com
PE 6 24V Com
1U1
AC Input Power
1V1 (Mains) Terminals
Analog Interfaced Digital Interfaced
1W1 MMC-SD MMC-SD
Node Address
PiCPro Port (P1) Rotary Switches
PiCPro Port (P1)

Digital Link
Not Used Connectors
(IN/OUT)

Feedback Feedback
Connector (F1) Connector (F1)

Not Used Feedback

Connector (F2)

User I/O User I/O

Connector (IO) Connector (IO)

*See NOTE on next page *See NOTE on next page

Motor Brake
Terminals (X101)
Pin
1 +24VBRK
PE
2 Brake+
1U2
1 3 Brake-
Motor
4 24VCOM
1V2 Terminals
5 N/C
1W2 6 N/C

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 85
 460V 3-Phase MMC Smart Drive

NOTE

The functionality and descriptions for the software control, motor

feedback and I/O connectors for the Size 1, Size 2, and Size 3 460V
MMC Smart Drives are the same as those used for the 230V MMC
Smart Drive. Refer to Chapter 5, 230V Single Phase MMC Smart Drive,
Section 5.2.1, PiCPro Communication Port, Section 5.2.4, Feedback
Connector (F1), Section 5.2.5, Feedback Connector (F2) (Digital Inter-
faced MMC-SD Only), and Section 5.2.6, User I/O Connector (IO).

6.2.1.1 Shunt/DC Bus Terminals

Table 6-2: 460V Size 1 Shunt/DC Bus Terminals

Signal Description Terminal

Signal Type Label In/Out Terminal

Power External Shunt Resis- Ba- Out

tor. Used to dissipate
energy returned to the Ba-
Ba+
drive by the motor. Ba+

DC Bus Power Direct DC bus connec- ZK+ N/A ZK+

tion
ZK-
ZK-

NOTE

The shunt resistor (if installed) across Ba+ and Ba- will be con-
nected across the DC bus when the DC bus reaches the "shunt
switch threshold" as shown in the specfication table; or when the
"Shunt On" input on the J1 connector is active.

NOTE

If a 460V drive is connected to 220V to run a 220V motor, enable

the "220V Shunt on 440V Drive" feature using PiCPro, connect
GPOUT3 on the USER I/O (IO) connector to the "Shunt On" in-
put on the J1 connector, and install the appropiate shunt resistor
across the Ba+ and Ba- terminals. The shunt resistor will be ap-
plied across the DC bus when the DC bus voltage rises above 415
volts, and will be removed when the DC bus voltage falls below
400 volts.

86 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.2.1.2 AC Power Terminal Strip

Table 6-3: 460V Size 1 AC Power Terminals

Signal Terminal
Signal Type Description Label In/Out Terminal

Protective Protective PE Out

Ground Earth Ground
PE
Power 3 phase input 1U1 In 1U1
power AC
source must be 1V1 1V1
center ground-
ed Y system. 1W1
1W1

6.2.1.3 Motor Terminals

Table 6-4: 460V Size 1 Motor Terminals

Signal Signal Terminal

Type Description Label In/Out Terminal

Protective Protective Earth PE Out

Ground Ground
PE
Power Drive output 1U2 Out 1U2
power to motor.
1V2 1V2
1W2
1W2

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 87
 460V 3-Phase MMC Smart Drive

6.2.1.4 24V Power Connector (J1)

Table 6-5: 460V Size 1 24V Power Connector (J1)

Signal Pin Terminal

Signal Type Description Label In/Out Terminal

Power 24 VDC input 1 +24V In Top

power
2 +24V 1 +24V
2 +24V
24V Logic Reserved for 3 Mains On Out Mains On
Output future use, do 3
not use ! 4 Shunt On
5 24 Com
24V Logic When this input 4 Shunt On In 6 24 Com
Input is active, the
shunt resistor
(if installed) be-
tween Ba+ and
Ba- is connect-
ed across the
DC bus.

Power 24 VDC input 5 24V Com In

common to the
drive. 6 24V Com

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460V 3-Phase MMC Smart Drive

6.2.1.5 Motor Brake Terminals (X101)

Table 6-6: 460V Size 1 Motor Brake Terminals (X101)

Signal Pin Terminal

Signal Type Description Label In/Out Terminal

Power 24 VDC brake in- 1 +24VBRK In

put power Top

Brake control Brake connections 2 Brake + Out 1 +24VBRK

2 Brake +
3 Brake - In 3 Brake -
4 24VCOM
Power 24 VDC common 4 24VCOM Out 5 N/C
6 N/C
Not Used. 5 N/C Not
Used
6

Figure 6-3: Wiring Example for X101 Connector

Drive
Connector
4A
+24VBRK
+24V
BRAKE +
24V Power
Brake
Supply
BRAKE -
1N4004
24V
MOSFET
COM
+24VCOM

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 89
 460V 3-Phase MMC Smart Drive

6.2.2 Size 2 460V Drive

Figure 6-4: Connectors on the Size 2 460V Drive

24V Power
460V Size 2 AC Power Terminals Connector (J1)
Pin
1 +24V
1U1 1W1 ZK+ Ba-
2 +24V
PE 1V1 Ba+ 3 Mains On
ZK-
4 Shunt On
5 24V Com
6 24V Com

Analog Interfaced Digital Interfaced

MMC-SD MMC-SD
Node Address
PiCPro Port (P1) Rotary Switches
PiCPro Port (P1)

Digital Link
Not Used Connectors
(IN/OUT)

Feedback Feedback
Connector (F1) Connector (F1)

Feedback
Not Used Connector (F2)

User I/O User I/O

Connector (IO) Connector (IO)

*See NOTE on next page *See NOTE on next page

Motor Power
Terminals
Motor Brake
Pin Terminals (X101)
1 +24VBRK
2 Brake+
3 Brake-
4 24VCOM
PE 1V2 5 N/C
1U2 1W2 6 N/C

90 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

NOTE

The functionality and descriptions for the software control, motor

feedback and I/O connectors for the Size 1, Size 2, and Size 3 460V
MMC Smart Drives are the same as those used for the 230V MMC
Smart Drive. Refer to Chapter 5, 230V Single Phase MMC Smart Drive,
Section 5.2.1, PiCPro Communication Port, Section 5.2.4, Feedback
Connector (F1), Section 5.2.5, Feedback Connector (F2) (Digital Inter-
faced MMC-SD Only) and Section 5.2.6, User I/O Connector (IO).

6.2.2.1 AC Power Terminals

Table 6-7: 460V Size 2 AC Power Terminals

1U1 1W1 ZK+ Ba-

PE 1V1 Ba+
ZK-

Signal Terminal
Signal Type Description Label In/Out

Ground Protective Ground PE Out

(Earth)

Power Three phase AC in- 1U1 In

put power in to
drive 1V1

1W1

DC Bus Power Direct DC bus con- ZK- Out

nection
ZK+

Power External Shunt Re- Ba+ Out

sistor used to dissi-
pate energy Ba-
returned to the
drive from motor

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 91
 460V 3-Phase MMC Smart Drive

NOTE

The shunt resistor (if installed) across Ba+ and Ba- will be con-
nected across the DC bus when the DC bus reaches the "shunt
switch threshold" as shown in the specfication table; or when the
"Shunt On" input on the J1 connector is active.

NOTE

If a 460V drive is connected to 220V to run a 220V motor, enable

the "220V Shunt on 440V Drive" feature using PiCPro, connect
GPOUT3 on the USER I/O (IO) connector to the "Shunt On" in-
put on the J1 connector, and install the appropiate shunt resistor
across the Ba+ and Ba- terminals. The shunt resistor will be ap-
plied across the DC bus when the DC bus voltage rises above 415
volts, and will be removed when the DC bus voltage falls below
400 volts.

6.2.2.2 Motor Power Terminals

Table 6-8: 460V Size 2 Motor Power Terminals

Signal Terminal
Signal Type Description Label In/Out Terminal

Ground Protective PE Out

Ground (Earth)

Motor Power U-phase 1U2 Out

from the drive
to the motor PE 1V2
1U2 1W2
Power V-phase 1V2 Out
from the drive
to the motor

Power W- 1W2 Out

phase from the
drive to the mo-
tor

92 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.2.2.3 24V Power Connector (J1)

Table 6-9: 460V Size 2 24V Power Connector (J1)

Signal Pin Terminal

Signal Type Description Label In/Out Terminal

Power 24 VDC input 1 +24V In Top

power
2 +24V 1 +24V
2 +24V
24V Logic Reserved for 3 Mains On Out Mains On
Output future use, do 3
not use ! 4 Shunt On
5 24 Com
24V Logic When this input 4 Shunt On In 6 24 Com
Input is active, the
shunt resistor
(if installed) be-
tween Ba+ and
Ba- is connect-
ed across the
DC bus.

Power 24 VDC input 5 24V Com In

common to the
drive. 6 24V Com

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 93
 460V 3-Phase MMC Smart Drive

6.2.2.4 Motor Brake Terminals (X101)

Table 6-10: 460V Size 2 Motor Brake Terminals (X101)

Signal Pin Terminal

Signal Type Description Label In/Out Terminal

Power 24 VDC brake in- 1 +24VBRK In

put power Top

Brake control Brake connections 2 Brake + Out 1 +24VBRK

2 Brake +
3 Brake - In 3 Brake -
4 24VCOM
Power 24 VDC common 4 24VCOM Out 5 N/C
(supply and mag-
net) 6 N/C

Not Used. 5 N/C Not

Used
6

Figure 6-5: Wiring Example for X101 Connector

Drive
Connector
4A
+24VBRK
+24V
BRAKE +
24V Power
Brake
Supply
BRAKE -
1N4004
24V
MOSFET
COM
+24VCOM

94 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.2.3 Size 3 460V Drive

Figure 6-6: Connectors on the Size 3 460V Drive

Line Power Terminals

24V Power
1W1 ZK+ Connector (J1)
1U1 Ba- Pin
PE 1V1 ZK- Ba+ PE 1 +24V
2 +24V
3 Mains On
4 Shunt On
5 24V Com
6 24V Com

Analog Interfaced Digital Interfaced

MMC-SD MMC-SD
Node Address
PiCPro Port (P1) Rotary Switches
PiCPro Port (P1)

Digital LInk
Not Used Connectors
(IN/OUT)

Feedback Feedback
Connector (F1) Connector (F1)

Feedback
Not Used Connector (F2)

User I/O User I/O

Connector (IO) Connector (IO)

*See NOTE on next page *See NOTE on next page

Motor Power Terminals

Motor Brake
Terminals (X101)
Pin (Located under cover)
1 +24VBRK
2 Brake+
3 Brake-
4 24VCOM
5 N/C
6 N/C
1U2 1W2
PE 1V2

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 95
 460V 3-Phase MMC Smart Drive

NOTE

The functionality and descriptions for the software control, motor

feedback and I/O connectors for the Size 1, Size 2, and Size 3 460V
MMC Smart Drives are the same as those used for the 230V MMC
Smart Drive. Refer to Chapter 5, 230V Single Phase MMC Smart Drive,
Section 5.2.1, PiCPro Communication Port, Section 5.2.4, Feedback
Connector (F1), Section 5.2.5, Feedback Connector (F2) (Digital Inter-
faced MMC-SD Only) and Section 5.2.6, User I/O Connector (IO).

6.2.3.1 AC Power Terminals

Table 6-11: 460V Size 3 AC Power Terminals

1U1 1W1 ZK+ Ba-

PE
PE 1V1 Ba+
ZK-

Signal Terminal
Signal Type Description Label In/Out

Ground Protective Ground PE Out

(Earth)

Power Three phase AC in- 1U1 In

put power in to
drive 1V1

1W1

DC Bus Power Direct DC bus con- ZK- Out

nection
ZK+

External Shunt Re- Ba+ Out

sistor used to dissi-
pate energy Ba-
returned to the
drive from motor

96 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

NOTE

The shunt resistor (if installed) across Ba+ and Ba- will be con-
nected across the DC bus when the DC bus reaches the "shunt
switch threshold" as shown in the specfication table; or when the
"Shunt On" input on the J1 connector is active.

NOTE

If a 460V drive is connected to 220V to run a 220V motor, enable

the "220V Shunt on 440V Drive" feature using PiCPro, connect
GPOUT3 on the USER I/O (IO) connector to the "Shunt On" in-
put on the J1 connector, and install the appropiate shunt resistor
across the Ba+ and Ba- terminals. The shunt resistor will be ap-
plied across the DC bus when the DC bus voltage rises above 415
volts, and will be removed when the DC bus voltage falls below
400 volts.

6.2.3.2 Motor Power Terminals

Table 6-12: 460V Size 3 Motor Power Terminals

Signal Terminal
Signal
Description Label In/Out Terminal
Type

Ground Protective PE Out

Ground (Earth)

Motor Power U-phase 1U2 Out

from the drive
to the motor

Power V-phase 1V2 Out

from the drive
to the motor

1U2 1W2
Power W- 1W2 Out
phase from the PE 1V2
drive to the
motor

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 97
 460V 3-Phase MMC Smart Drive

6.2.3.3 24V Power Connector (J1)

Table 6-13: 460V Size 3 24V Power Connector (J1)

Signal Pin Terminal

Signal Type Description Label In/Out Terminal

Power 24 VDC input 1 +24V In Top

power
2 +24V 1 +24V
2 +24V
24V Logic Reserved for 3 Mains On Out Mains On
Output future use, do 3
not use ! 4 Shunt On
5 24 Com
24V Logic When this input 4 Shunt On In 6 24 Com
Input is active, the
shunt resistor
(if installed) be-
tween Ba+ and
Ba- is connect-
ed across the
DC bus.

Power 24 VDC input 5 24V Com In

common to the
drive. 6 24V Com

98 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.2.3.4 Motor Brake Terminals (X101)

Table 6-14: 460V Size 3 Motor Brake Terminals (X101)

Signal Pin Terminal

Signal Type Description Label In/Out Terminal

Power 24 VDC brake in- 1 +24VBRK In

put power Top

Brake control Brake connections 2 Brake + Out 1 +24VBRK

2 Brake +
3 Brake - In 3 Brake -
4 24VCOM
Power 24 VDC common 4 24VCOM Out 5 N/C
(supply and mag-
net) 6 N/C

Not Used. 5 N/C Not

Used
6

Figure 6-7: Wiring Example for X101 Connector

Drive
Connector
4A
+24VBRK
+24V
BRAKE +
24V Power
Brake
Supply
BRAKE -
1N4004
24V
MOSFET
COM
+24VCOM

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 99
 460V 3-Phase MMC Smart Drive

6.3 Typical 460V Drive Connection Layout

Optional
Shunt Incoming AC
Resistor Power (Mains)
PE U V W

+24V M24V
RB
S1
4A L1
L2
Ba+
ZK+

1W1
Ba-

1U1
1V1
ZK-

PE
J1

MMC-SD-460

4A
X101-1
+24V
X101-2
X101-3
X101-4
X101-5
X101-6
A

F1/F2
1W2
1U2
1V2
PE

M
ENC
3
Brake Voltage

BRAKE

100 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.4 Specifications - 460V MMC Smart Drive

6.4.1 Common Data for Size 1/Size 2/Size 3 (All Models)

General Drive Data

Minimum wire size for input power 1.5mm2 (16 AWG) 75° C copper
wires

Maximum tightening torque for power 1.25Nm (11 in-lbs.)

wire terminals

Commutation 3 Phase Sinusoidal, Space Vector Modulated (SVM)

Current Regulator Digital PI 125 µsec update rate

Velocity Regulator Digital PID - 250 µsec update rate

General Operating Data

Operating Temperature Range o o o

7 C to 50 C (45 F to 122 F)
o

Storage Temperature Range o o o

-30 C to 70 C (-22 F to 158 F)
o

Humidity 5% to 95% non-condensing

Altitude 1500m (5000ft)

Derate 3% for each 300 m above 1500m

Vibration Limits (per IEC 68-2-6) 10-57Hz (constant amplitude .15mm)

Operating/Non-operating 57 - 2000Hz (acceleration 2g)

Shock (per IEC 68-2-27) 15g/11msec per axis

Non-operating

F1 and F2 Feedback Inputs

Input receiver type Maxim 3098 A quad B differential RS422 receiver

Encoder signals Differential quadrature

Input threshold ±200mV

Input termination 150Ω, provided internal

Maximum input voltage 5Vpp differential -10 to +13.2V common mode

Maximum input signal frequency 720KHz (2.88 M feedback unit count rate)

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 101
 460V 3-Phase MMC Smart Drive

General Purpose Inputs

Configuration • 8 optically isolated 24V DC inputs

• Active high
• 6 are current sourcing only (current flow into input)
• 2 are sink or source

Guaranteed On 15VDC

Guaranteed Off 5VDC

Time delay on 1ms max.

Time delay off 1ms max.

Input voltage Nominal 24VDC, maximum 30VDC

General Purpose Outputs

Configuration • 4 optically isolated 24VDC outputs

• Active high
• Current sourcing only (current into load)
• Short circuit and overload protected

Maximum current 50mA per output

Voltage range 24VDC +15%-10%

Time delay on for resistive loads 50µsec. max

Time delay off for resistive loads 50µsec. max

Leakage current in off state 0.5mA max

Command Input/Output

Command Input • Analog velocity or torque, 0 to + 10V

• 14 bit effective resolution

Digital Link In/Out Ports (Digital Interfaced MMC-SD only)

"In" port Sends and receives high speed data to and from connected MMC-
SD’s "Out" port.

"Out" port Sends and receives high speed data to and from connected MMC-
SD’s "In" port.

102 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

User I/O Connector Encoder Emulation Output

F1 Motor Feedback Type Input Limit Encoder Emulation Output

(A quad B Differential
Output)

Incremental Encoder 720KHz The motor encoder A/B/I inputs

2.88 M counts/sec. are electrically buffered and
retransmitted via the User I/O
connector.

High Resolution Encoder 100KHz The encoder SIN/COS signals

400K counts/sec. are electrically squared and
retransmitted as A/B. The index
mark "I" is synthesized by the
drive control DSP. Absolute
position information is not
available via the Encoder
Emulation Output.

Resolver 500RPS The field-installable resolver

2.00M counts/sec. interface module converts the
motor resolver to 1024 lines/
4096 counts per revolution of
A/B encoder output. The
module synthesizes the index
mark "I" once per revolution of
the resolver. Absolute position
information is not available via
the Encoder Emulation Output.

Conformity

CE Marked Conforms to Low Voltage Directive 73/23/EEC (amended

by 93/68/EEC) and EMC Directive 89/336/EEC (amended
by 92/31/EEC and 93/68/EEC).
Conformance is in accordance with the following
standards:
EN 50178 and EN61800-3 (Pending)

UL and C/UL Listed E233454 (Pending)

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 103
 460V 3-Phase MMC Smart Drive

6.4.2 Physical/Electrical Data for 460V Size 1 Drives

Model

MMC-SD-1.3-460 MMC-SD-2.4-460

Physical

Weight 10 lbs.

Electrical Specifications

AC Input Specifications

Nominal Input Power 1.94kVA 3.33kVA

Input Voltage 200-460 VAC (nominal), Three Phase, 180-528 VAC

(absolute limits)

Input Frequency 47-63Hz

Nominal Input Current 2.44A RMS 4.18A RMS

Maximum Inrush 4.56A RMS 7.81A RMS

Current

Power Loss 34W 60W

AC Output Specifications

Continuous Output 3.0A 5.5A

Current (0-peak)

Continuous Output Power

Input = 230 VAC .65kW 1.2kW

Input = 460 VAC 1.3kW 2.4kW

Peak Output Current 6.0A 11.0A

(0-Peak)

Output Frequency 0-300Hz

DC Input Power Specifications (24VDC)

Input Voltage Range 24VDC +15% -10%

Typical Input Current 700mA

Typical Input Wattage 17W

Inrush Current 4A for 10ms

NOTE: AC Current is specified for nominal input voltage of 460 VAC. Currrent for
input voltages between 400 and 480 VAC equals approximately:
(current for 460 VAC) x 460/input voltage

104 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

Internal Holding Brake Driver

Maximum Current 0.5A

Energy Absorbtion Specifications

DC Bus Capacitance 110µF 240µF

(Internal)

Shunt Switch Threshold 780VDC

Joules available for energy absorption

230V motor w/ 3 joules 7 joules

230V line input

460V motor w/ 28 joules 60 joules

230V line input

460V motor w/ 10 joules 22 joules

460V line input

Exteranl Shunt

Maximum shunt resistor 5.9A (AC)

current

Minimum shunt resistor 130Ω

Maximum shunt resistor 4.5kW 5kW

power at minimum shunt
resistor

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 105
 460V 3-Phase MMC Smart Drive

6.4.3 Physical/Electrical Data for 460V Size 2 Drive

Model

MMC-SD-4.0-460 MMC-SD-6.0-460 MMC-SD-8.0-460

Physical

Weight 16 lbs.

Electrical Specifications

AC Input Specifications

Nominal Input Power 5.6kVA 8.6kVA 11.8kVA

Input Voltage 200-460 VAC (nominal), Three Phase, 180-528 VAC (absolute limits)

Input Frequency 47-63Hz

Nominal Input Current 7A RMS 10.8A RMS 14.8A RMS

Maximum Inrush 13.2A RMS 20.2A RMS 27.7A RMS

Current

Power Loss 102W 150W 204W

AC Output Specifications

Continuous Output 9.0A 13.5A 18.0A

Current (0-Peak)

Continuous Output Power

Input = 230 VAC 2.0kW 3.0kW 4.0kW

Input = 460 VAC 4.0kW 6.0kW 8.0kW

Peak Output Current 18.0A 27.0A 36.0A

(0-peak)

Output Frequency 0Hz to 300Hz

Internal Holding Brake Driver

Maximum Current 0.5A

NOTE: AC Current is specified for nominal input voltage of 460VAC. Currrent for
input voltages between 400 and 480VAC equals approximately:
(current for 460VAC) x 460/input voltage

106 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

DC Input Power Specifications (24VDC)

Input Voltage Range 24VDC +15% -10%

Typical Input Current 1050mA

Typical Input Wattage 25W

Inrush Current 4A for 10ms

Energy Absorbtion Specifications

DC Bus Capacitance 470µF 705µF

(Internal)

Shunt Switch 780VDC

Threshold

Joules available for energy absorption

230V motor w/ 13 joules 19 joules

230V line input

460V motor w/ 188 joules 177 joules

230V line input

460V motor w/ 44 joules 66 joules

460V line input

External Shunt

Maximum shunt 9A (AC) 9A (AC) 9A (AC)

resistor current

Minimum shunt 86Ω 60Ω 44Ω

resistor

Maximum shunt 7kW 10kW 14kW

resistor power at
minimum shunt
resistor

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 107
 460V 3-Phase MMC Smart Drive

6.4.4 Physical/Electrical Data for 460V Size 3 Drive

Model

MMC-SD-12.0-460 MMC-SD-16.0-460 MMC-SD-24.0-460

Physical

Weight 35 lbs.

Electrical Specifications

AC Input Specifications

Nominal Input Power 13.3kVA 16.8kVA 26.3 kVA

Input Voltage 200-460VAC (nominal), Three Phase, 180-528VAC (absolute limits)

Input Frequency 47-63Hz

Nominal Input Current 16.7A RMS 21.1A RMS 33.1A RMS

Maximum Inrush 32.2A RMS 39.2A RMS 61.8A RMS

Current

Power Loss 300W 390W 600W

AC Output Specifications

Continuous Output 27.5A 36.5A 55.0A

Current (0-Peak)

Continuous Output Power

Input = 230 VAC 6.0kW 8.0kW 12.0kW

Input = 460 VAC 12.0kW 16.0kW 24.0kW

Peak Output Current 55.0A 73.0A 110.0A

(0-peak)

Output Frequency 0Hz to 300Hz

Internal Holding Brake Driver

Maximum Current 0.5A

NOTE: AC Current is specified for nominal input voltage of 460 VAC. Currrent for
input voltages between 400 and 480 VAC equals approximately:
(current for 460 VAC) x 460/input voltage

108 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

DC Input Power Specifications (24VDC)

Input Voltage Range 24VDC +15% -10%

Typical Input Current 1050mA

Typical Input Wattage 25W

Inrush Current 4A for 10ms

Energy Absorbtion Specifications

DC Bus Capacitance 820µF 1230µF 1640µF

(Internal)

Shunt Switch 780VDC

Threshold

Joules available for energy absorption

230V motor w/ 22 joules 33 joules 45 joules

230V line input

460V motor w/ 206 joules 309 joules 412 joules

230V line input

460V motor w/ 76 joules 114 joules 152 joules

460V line input

External Shunt

Maximum shunt 36A (AC) 50A (AC)

resistor current

Minimum shunt 22Ω 16Ω

resistor

Maximum shunt 29kW 40kW

resistor power at
minimum shunt
resistor

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 109
 460V 3-Phase MMC Smart Drive

6.5 Dimensions for the 460V Drives

6.5.1 Size 1 460V Drive - Front View

110 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.5.2 Size 1 460V Drive - Side View

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 111
 460V 3-Phase MMC Smart Drive

6.5.3 Size 2 460V Drive - Front View

112 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.5.4 Size 2 460V Drive - Side View

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 113
 460V 3-Phase MMC Smart Drive

6.5.5 Size 3 460V Drive - Front View

114 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
460V 3-Phase MMC Smart Drive

6.5.6 Size 3 460V Drive - Side View

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 115
 Connections to External Devices

7 Cables and Connections to External Devices

7.1 I/O Cable Pin Assignments

Table 7-1: I/O Cable to Controller (Analog Interfaced MMC-SD only)
D-sub 26-Pin HD Male
Connector to MMC Smart
Drive D-sub 15-Pin HD Male Connector to
MMC Controller

18 6
9 26 11 1
Twisted Pair

9 pair 28 AWG 15
5
19 10
1
10

Jumper
Wire Color Pin Number SignalType Pin Number Connection Signal Type
Black 1 A 1 A
White/Black 2 A/ 2 A/
Red 3 B 3 B
White/Red 4 B/ 4 B/
Green 5 I 5 I
White/Green 6 I/ 10 I/
Orange 26 OUT4 6 DCIN+
White/Orange N/U N/U 7 DCIN-
Blue 14 CMD+ 8 DA+
White/Blue 15 CMD- 9 DA-
Yellow 17 IN1 13 DCOUT1
White/Yellow 18 IN2 14 DCOUT2
Brown N/U N/U N/U N/A
White/Brown N/U N/U 15 DCOSS
Violet N/U N/U N/U N/A
White/Violet N/U N/U N/U N/A
Gray 10 IO24V 11 24VDCOUT

White/Gray 16 IOCOM 12 COM

116 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Connections to External Devices

7.2 LSM and MSM Motors Cable Pin Assignments

Table 7-2: F1/F2 Motor Encoder Cable to LSM or MSM Motors
D-sub 15-Pin HD Male
Connector to MMC Smart
Connector to Motor
Drive

6 1 11
Twisted Pair 1 10
11 2 12
3 13 16 9
8 pair 28 AWG 17
1 pair 16 AWG 4 14 15 8
15 5 7
5 6

10

Pin Pin Jumper

Wire Color Number Signal Type Number SignalType
Connections
Yellow 1 A 1 A
White/Yellow 2 A/ 2 A/
Blue 3 B 3 B
White/Blue 4 B/ 4 B/
Black 5 I 5 I
White/Black 10 I/ 6 I/
Violet 12 S1 15 S1
White/Violet 13 S2 16 S2
Red 8 S3 17 S3
White/Red N/U N/A N/U N/A
Green 11 TEMPERATURE 13 TEMPERATURE+
White/Green N/U N/A 14 TEMPERATURE-
Orange N/U N/A N/U N/A
White/Orange N/U N/A N/U N/A
Brown 7 9 VDC 9 9 VDC
White/Brown N/U N/A N/U N/A
Gray 14 +5 VDC 10 +5 VDC

White/Gray 6 COM 11 COM

N/C 9 N/A 7 N/C

N/C 15 N/A 8 N/C
12 N/C

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 117
 Connections to External Devices

Table 7-3: Motor Power Connector to LSM or MSM Motors

Pin Number

+ V
C B

A U W
D 4
1 2
1
3

Size 1 Power Size 1.5.1 Power Size 1.5.2 Power

Wire Wire Signal Connector Connector Connector
Color Number Type (Kit No. (Kit No. (Kit No.
M.1302.0479) M.1302.1998) M.1302.2354)
Black (1) 1U2 Out 1 U
Black (2) 1V2 Out 3 V
Black (3) 1W2 Out 4 W
Green/
PE Ground 2
Yellow
Black (5) Brake+ Out A +
Black (6) Brake- Out B -

Table 7-4: Fan Motor Power Connector to LSM or MSM Motors

Pin Number

1 2

6 3

5 4

Wire Color Wire Number Signal Type Pin

Brown U Out 1
Black N Out 2
Green/Yellow PE Ground 3

118 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Connections to External Devices

7.3 XSM Motors Cable Pin Assignments

Table 7-5: F1/F2 Motor Encoder Cable to XSM Motors
D-sub 15-Pin HD Male
Connector to MMC Smart
Connector to Motor
Drive

A
6 B M
Twisted Pair 1 C N L
11 P
U
D V K
28 AWG R
T
16 AWG E S J
15 F H
5 G

10

Pin Pin Jumper

Wire Color Number Signal Type Number Connections SignalType
Black 1 A A A or SIN+
White/Black 2 A/ B A/ or SIN-
Red 3 B C B or COS+
White/Red 4 B/ D B/ COS-
Green 5 I E I or DATA+
White/Green 10 I/ F I/ or DATA-
Violet 14 +5V K +5V
White/Violet 6 COM L COM
Orange 7 +9V N +9V
White/Orange 11 TEMPERATURE R TEMPERATURE+
Blue N/U N/A S TEMPERATURE-
White/Blue 12 S1 T S1
Yellow 13 S2 U S2
White/Yellow 8 S3 V S3
Brown 9 TRAVEL LIMIT+ J +LIMIT
White/Brown 15 TRAVEL LIMIT- M -LIMIT
N/A N/A P COM
N/A N/A G N/C
N/A N/A H N/C

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 119
 Connections to External Devices

Table 7-6: Motor Power Cable to XSM Motors

A
D

B
C

Drive Lower Screw Terminal Connector End to Motor

Pin
Wire Color Terminal Signal Type Signal Type
Number
Brown U Out A Out
Black V Out B Out
Blue W Out C Out
Green/Yellow Ground D Ground

Motor Brake Cable Connector to LSM or

MSM Motors

A
B

D
C

Pin Number Signal Type

A B+
B (N/U) N/A
C B-
D (N/U) N/A

120 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Connections to External Devices

7.4 NSM Motors Cable Pin Assignments

Table 7-7: F1/F2 Motor Encoder Cable to NSM Motors
D-sub 15-Pin HD Male
Connector to MMC Smart
Connector to Motor
Drive

A
6 B M
Twisted Pair 1 C N L
11 P
U
D V K
28 AWG R
T
16 AWG E S J
15 F H
5 G

10

Pin Pin Jumper

Wire Color Number Signal Type Number Connections SignalType
Black 1 A A A
White/Black 2 A/ B A/
Red 3 B C B
White/Red 4 B/ D B/
Green 5 I E I
White/Green 10 I/ F I/
Gray 14 +5V J +5VDC
K +5VDC
White/Gray 6 COM L COM
M COM
S TEMPERATURE-
Blue 13 S2 U S2
White/Blue 12 S1 T S1
Brown 8 S3 V S3
White/Brown 11 TEMPERATURE+ R TEMPERATURE+
Orange N/U N/A N/U N/A
White/Orange N/U N/A N/U N/A
Violet N/U N/C G N/C
White/Violet 7 N/C H N/C
Yellow 9 N/C N N/C
White/Yellow 15 N/C P N/C

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 121
 Connections to External Devices

Table 7-8: Motor Power Cable to NSM Motors

A
B E

C D

Drive Lower Screw Terminal Connector End to Motor

Wire Color Terminal Signal Type Pin Signal Type

Number
Brown U Out A Out
Black V Out B Out
Blue W Out C Out
Green/Yellow Ground D Ground
N/A N/C N/A E (N/C) N/A

Motor Brake Cable Connector to NSM

Motors

A C

Pin Number Signal Type

A B+
B B-
C (N/U) N/A

122 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Connections to External Devices

7.5 HSM and FSM Motors Cable Pin Assignments

Table 7-9: F1/F2 Motor Encoder Cable to HSM and FSM Motors
D-sub 15-Pin HD Male
Connector to MMC Smart
Connector to Motor
Drive

A
6 B M
Twisted Pair 1 C N L
11
D P T
K
28 AWG E R S
16 AWG J
15 F
H
5 G
10

Pin Pin Jumper

Wire Color Number Signal Type Number Connections SignalType
Black 1 A A A
White/Black 2 A/ B A/
Red 3 B C B
White/Red 4 B/ D B/
Green 5 I E I
White/Green 10 I/ F I/
Gray 14 +5V J +5VDC
K +5VDC
White/Gray 6 COM L COM
M COM
S TEMPERATURE-
Blue 13 S2 N S2
White/Blue 12 S1 T S1
Brown 8 S3 P S3
White/Brown 11 TEMPERATURE+ R TEMPERATURE+
Orange N/U N/A N/U N/A
White/Orange N/U N/A N/U N/A
Violet N/U N/C G N/C
White/Violet 7 N/C H N/C
Yellow 9 N/C N/U N/A
White/Yellow 15 N/C N/U N/A

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 123
 Connections to External Devices

Table 7-10: Motor Power Cable to HSM and FSM Motors

A D

B C

Drive Lower Screw Terminal Connector End to Motor

Pin
Wire Color Terminal Signal Type Signal Type
Number
Brown U Out A Out
Black V Out B Out
Blue W Out C Out
Green/Yellow Ground D Ground

Motor Brake Cable Connector to HSM

and FSM Motors

A B

Pin Number Signal Type

A B+
B B-

124 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Connections to External Devices

7.6 YSM Motors Cable Pin Assignments

Table 7-11: F1/F2 Motor Encoder Cable to YSM Motors
D-sub 15-Pin HD Male
Connector to MMC Smart
Connector to Motor
Drive

3 1
6
Twisted Pair 8 4
11 1
14 9
28 AWG 20 15
16 AWG 25 21
15
5 28 26
10

Pin Pin Jumper

Wire Color Number Signal Type Number Connections SignalType
Black 1 A 9 A
White/Black 2 A/ 10 A/
Red 3 B 11 B
White/Red 4 B/ 12 B/
Green 5 I 13 I
White/Green 10 I/ 14 I/
Gray 14 +5V 22 +5VDC
White/Gray 6 COM 23 COM
Blue 13 S2 17 S2
White/Blue 12 S1 15 S1
Brown 8 S3 19 S3
White/Brown 11 N/C 24 NO N/C
JUMPERED
7 N/C 1 PINS N/C
9 N/C 2 N/C
15 N/C 3 N/C
4 N/C
5 N/C
6 N/C
7 N/C
8 N/C
16 N/C
18 N/C
20 N/C
21 N/C
25-28 N/C

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 125
 Connections to External Devices

Table 7-12: Motor Power and Brake Cable to YSM Motors

3 2 1

6 5 4

9 8 7

Drive Lower Screw Terminal Connector End to Motor

Pin
Wire Color Terminal Signal Type Signal Type
Number
Brown U Out 1 Out
Black V Out 2 Out
Blue W Out 3 Out
N/A N/U N/A 4 (N/U) N/A
Green/Yellow Ground 5 Ground
N/A N/U N/A 6 (N/U) N/A
N/A N/U N/A 8 (N/U) N/A

Table 7-13: Motor Brake Cable Connector to

YSM Motors
Pin Number Signal Type
7 B+
9 B-

126 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Connections to External Devices

7.7 Connecting Shunt Modules

Use shielded, high temperature 75° C (167° F), 600V, 2.5-4.0 mm2 (12-14
AWG), 3.05 m (10 ft) maximum, copper wire. Follow one of the methods
given below to reduce the effects of EMI noise:
• Install wires using twisted pairs (two turns per foot minimum),
as shown in the figure above. Keep unshielded wires as short as
possible.
• Use shielded, twisted cable (ground shield at shunt and drive).
• Use shielded metal conduit (ground conduit at shunt and drive).
When two shunt modules are connected in parallel, the shunt capacity is
doubled.

WARNING

Do not connect more than two shunt

modules to an MMC Smart Drive.

7.7.1 Connecting the 230V MMC Smart Drive to 300 W

Shunt Module
Figure 7-1: Wiring 230V MMC Smart Drive to 300W Active Shunt Module

300W Active Shunt Module

Adjust
230V MMC Smart Drive Overtemp
DC Bus
Lower Terminal Strip Active

B+ DC Bus

B- L1
AC Line
L1 L2/N Detect

L2
Chassis

U
Warning:
Surfaces can be hot.
V Allow to cool before handling.

Warning:
W High voltage can exist 30
seconds after power down.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 127
 Connections to External Devices

7.7.2 Connecting the 460V MMC Smart Drive to G&L

Motion Control Shunt Modules
Figure 7-2: Wiring 460V MMC Smart Drive to 450 Watt, 130Ω Shunt Module / 700
Watt, 95Ω Shunt Module / 1400 Watt, 50Ω Shunt Module

Shunt Module

Using twisted pair wire, Connect Ba+ to + Terminal on

Shunt Module, Connect Ba- to - Terminal
on Shunt Module
Ba-
Ba+
ZK+
ZK-

460V MMC Smart Drive

Shunt/DC Bus Terminal Strip

128 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Connections to External Devices

Figure 7-3: Wiring 460V MMC Smart Drive to 2800 Watt, 25Ω Shunt Module /
3900 Watt, 18Ω Shunt Module

Shunt Module

Using twisted pair wire, Connect Ba+ to + Terminal on

Shunt Module, Connect Ba- to - Terminal
on Shunt Module
Ba-
Ba+
ZK+
ZK-

460V MMC Smart Drive

Shunt/DC Bus Terminal Strip

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 129
 Troubleshooting

8 Maintenance and Troubleshooting

8.1 Maintenance

WARNING

Disconnect input power before touching cables

or connections.
DC bus capacitors may retain hazardous voltages
after input power has been removed.
Before working on the drive, measure the DC
bus voltage to verify it has reached a safe level.
Failure to observe this precaution could result in
severe bodily injury or loss of life.

1. Remove superficial dust and dirt from the drive.

2. Check cable insulation and connections.
3. Clean exterior surfaces and airflow vents using an OSHA approved
nozzle that provides compressed air under low pressure of less than 20
kPa (30 psi).
4. Visually check for cable damage. Replace all damaged cables.
5. Inspect D-shell connectors for proper seating and signal continuity end-
to-end.
8.2 Diagnostics
8.2.1 Power-On Diagnostics
When the drive is powered up, it tests itself and reports the results
of the tests in the form of LED signals.
8.2.1.1 Power LED
If the Power (P) LED does not go on, or goes off during
operation of the system, check that 24 VDC power is
still connected to the drive.

130 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Troubleshooting

8.2.1.2 Diagnostic LEDs

The Status LED (D1) lights up briefly while diagnostic
tests are running and then goes off. If the Status LED
(D1) remains on, the drive has failed one of its
diagnostic tests. Follow these steps:
1. Turn off power to the drive system and to the
application.
2. Perform any necessary maintenance to the drive.
3. Check the I/O wiring and the devices the system is
connected to. There may be a short or other problem
other than the drive. Correct these problems.
4. Turn on power to check diagnostics again.

Power-On diagnostics are run only when the system is

powered up. If a drive fails during power-up, the Status
LED (D1) light remains on. If you suspect that a drive is
defective, cycle power to run diagnostics again.

8.2.2 Run-Time Diagnostics

While the MMC Smart Drive is running, other tests are performed
on a regular basis with their results also reported through the Status
LED (D1).
While the MMC Smart Drive is running, the Status LED (D1) will
flash a two digit code signal if there is an error. The errors are
described in Table 8-2: Drive Diagnostic LED Error Codes.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 131
 Troubleshooting

8.3 Troubleshooting
8.3.1 General Troubleshooting
Table 8-1: General Troubleshooting Symptoms, Causes, Remedies
Symptom Possible Cause Remedy

Power (P) indicator not ON No 24VDC input power. Verify 24 VDC power is applied to
the drive.

Internal power supply Contact your G&L Motion Control

malfunction. representative.

Motor jumps when first Motor wiring error. Check motor feedback and power
enabled wiring.
Incorrect motor chosen.
Verify the proper motor is selected.
Incorrect or faulty encoder
Replace the encoder with correct and/
or functional encoder.

I/O not working correctly I/O power supply disconnected. Verify connections and I/O power
source.

8.3.2 Troubleshooting Drive Diagnostic Error Codes

When an error is detected the Status LED (D1) located above the
PiCPro port on the face of the drive will flash a two-digit error
code. The LED will continue to flash until the error is eliminated.
For example, if there is a long pause-flash-pause-flash-flash-long
pause, the code is 12. The Diagnostic Error Codes are described in
Table 8-2: Drive Diagnostic LED Error Codes.

132 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Troubleshooting

Table 8-2:
Fault
Fault Possible Causes Possible Remedies
Code
11 Drive Memory Fault The drive’s non-volatile Upgrade firmware.
memory is not functioning Contact G&L Motion Control.
properly

12 Drive Bus Over Excessive regeneration of Change the deceleration or motion

Voltage Fault power. profile.
The motor may regenerate Check shunt connections and where
too much peak energy necessary, properly make connec-
through the drive’s power tons.
supply. A fault is generated Reduce the reflected inertia of your
to prevent overload. mechanical system.
Use a larger motor and/or drive.

Excessive AC input voltage. Verify input AC voltage is within

specifications. Adjust accordingly.

Output short circuit. Remove all power and motor con-

nections, and perform a continuity
check from the DC bus to the U, V,
and W motor outputs. If a continuity
exists, check for wire fibers be-
tween terminals, contact G&L Mo-
tion Control

Motor cabling wires shorted Disconnect motor power cables

together. from the drive. Test the cables for
short circuits. Replace cable if nec-
essary.

Internal motor winding short Disconnect motor power cables

circuit. from the motor. If the motor is diffi-
cult to turn by hand, it may need to
be replaced. Test winding resistance
to confrim short circuit.

230V motor used with a Set the drive for operation at 230V
460V drive and drive pow- and apply 230V power to the drive.
ered at 460V.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 133
 Troubleshooting

13 Drive PM1 Over Current feedback exceeds the Adjust the over current fault limit.
Current Fault drive over current fault limit.

Output short circuit. Remove all power and motor con-

nections, and perform a continuity
check from the DC bus to the U, V,
and W motor outputs. If a short ex-
ists, check for wire fibers between
terminals, contact G&L Motion
Control

Motor cabling wires shorted Disconnect motor power cables

together. from the drive. If faults stop, replace
cable.

Internal motor winding short Disconnect motor power cables

circuit. from the motor. If the motor is diffi-
cult to turn by hand, it may need to
be replaced.

14 Drive Over Power Drive current and voltage Verify ambient temperature is not
Fault output, in combination with too high.
the heatsink temperature in- Operate within the continuous pow-
dicate that the power output er rating.
required by the drive would Reduce acceleration rates.
damage the power section. Check for mechanical load prob-
lems and adjust as necessary.
Resize the application and apply
components accordingly.

15 Motor Temperature Motor thermostat trips due to Operate within (not above) the con-
Fault high motor ambient tempera- tinuous torque rating for the ambi-
ture ent temperature (40°C maximum).
Lower ambient temperature, in-
crease motor cooling.
Check that motor is properly sized
for the application. If necessary, re-
size the motor.

Motor thermostat trips due to Reduce acceleration rates.

excessive current Increase time permitted for motion.
Use larger drive and motor.
Reduce duty cycle (ON/OFF) of
commanded motion.
Check tuning.

Motor thermostat trips due to

motor wiring error. Check motor wiring.

Motor thermostat trips due to Verify the proper motor has been
incorrect motor selection. selected.

16 Continuous Current Current exceeds the continu- Change motor and or drive to be
Fault ous motor current rating for compatible with load requirements.
an extended period of time. Check tuning.

17 Drive Heatsink Tem- Drive heatsink temperature Let the drive cool down and/or re-
perature Fault exceeds drive heatsink fault duce the load.
limit

134 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Troubleshooting

22 Drive F1 Feedback Error is detected in the motor Verify motor selection is correct.
Fault feedback Check to be sure the correct encoder
is attached.
Verify encoder wiring is correct.
Use shielded cables with twisted
pair wires.
Route the encoder feedback cable
away from potential noise sources.
Check ground connections.

23 Drive Ambient Drive ambient temperature Operate within (not above) the con-
Temp. Fault exceeds the drive ambient tinuous rating for the ambient tem-
temperature fault limit perature.
Lower ambient temperature, in-
crease cabinet cooling.

24 Motor Calculated Motor calculated temperature Check the machine for excessive
Temp. Fault exceeds the motor calculated loads. Motor may be undersized for
temperature fault limit. the application.

25 Drive Timing Fault Timing error is detected in Contact G&L Motion Control.
the execution of the control
algorithms performed by the
drive’s digital signal proces-
sor.

26 Drive Interface Fault Communication error is de- Contact G&L Motion Control.
tected in the transmission of
information between the
drive’s digital signal proces-
sor and the drive’s power
section.

27 User Set Fault PiCPro Set User Fault com- The PiCPro Set User Fault com-
mand selected. mand was selected or the Control
Panel mode was activated or deacti-
vated while the drive was enabled.

31 Drive F1 Communi- Communication error is de- Check encoder line and make sure
cation Fault tected in the transmission of the correct encoder is attached.
information between the Verify encoder wiring is correct.
drive and a high resolution or Use shielded cables with twisted
multi-turn absolute feedback pair wires.
device. Route the encoder feedback cable
away from potential noise sources.
Check ground connections.
Verify motor selection is correct.

Bad encoder. Replace motor and encoder.

32 Over Speed Fault User specified motor speed Check cables for noise.
has been exceeded. Check tuning.

33 Over Current Fault User-Specified average cur- Change to a less restrictive setting.
rent level has been exceeded. Reduce the load.

34 Drive Communica- Communication error occurs Do not disconnect the PiCPro cable
tion Fault while drive control is being while operating in Control Panel
performed using the PiCPro Mode.
Control Panel tools.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 135
 Troubleshooting

35 Drive Power Module The drive’s power section de- Verify AC power is applied to drive.
Fault tects a fault condition. Contact G&L Motion Control.

36 Drive Setup Data The configuration data has Re-download Drive Setup Data.
Fault been corrupted.

41 Drive Relay Fault The drive’s power section re- Check the drive system connce-
lay did not function properly tions. Adjust as necessary.
during power-up. Contact G&L Motion Control.

42 Drive PM2 Over Current feedback exceeds the Adjust the over current fault limit.
Current Fault drive over current fault limit.

Output short circuit. Remove all power and motor con-

nections, and perform a continuity
check from the DC bus to the U, V,
and W motor outputs. If a continuity
exists, check for wire fibers be-
tween terminals, contact G&L Mo-
tion Control.

Motor cabling wires shorted Disconnect motor power cables

together. from the drive. If faults stop, replace
cable.

Internal motor winding short Disconnect motor power cables

circuit. from the motor. If the motor is diffi-
cult to turn by hand, it may need to
be replaced.

43 Drive PM Over Drive power module temper- Check to be sure that the drive is be-
Temperature Fault ature exceeds the drive power ing operated within the continuous
module temperature fault power rating.
limit Check for adequate enclosure venti-
lation. Ensure cooling air flow is ad-
equate in space around the drive.
Check for clogged vents or defec-
tive fan.
Contact G&L Motion Control.

44 Motor Ground Fault Ground fault has occurred. Make sure motor ground connec-
tions are correct.
Replace defective motor ground
wires.
Check for internal motor winding
short circuits.

45 Drive AC Input Over Incoming AC voltage is too Verify input VAC is within specifi-
Voltage Fault high. caitons.

136 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Troubleshooting

46 Overtravel Plus Overtravel Plus Fault input is Overtravel Plus Fault status can be
Fault off and Drive Ignore Plus monitored using READ_SV vari-
Travel Limit is off. able 68 AND (16#400 0000). Fault
input write a 0 to WRITE_SV vari-
able 86. Use DRSETFLT to reset
fault indications. To override the
Overtravel Plus Fault input write a 1
to WRITE_SV variable 86, Ignore
Plus Travel Limit. To reactivate
checking of the Overtravel Plus in-
put write a 1 to WRITE_SV vari-
able 86, Ignore Plus Travel Limit.
To reactivate checking of the Over-
travel Plus Fault input write a 0 to
WRITE_SV variable 86.

47 Overtravel Minus This fault is set when the Overtravel Minus Fault status can
Fault Overtravel Minus Fault input be monitored using READ_SV
is off and Drive Ignore Minus variable 68 AND (16#800 0000).
Travel Limit is off. Use DRSETFLT to reset fault indi-
cations. To override the Overtravel
Minus Fault input write a 1 to
WRITE_SV variable 87, Ignore Mi-
nus Travel Limit. To reactivate
checking of the Overtravel Minus
Fault input write a 0 to WRITE_SV
variable 87.

51 Digital Link This fault is set when two Digital Link Communication Error
Communication consecutive corrupt Digital status can be monitored using
Error Link messasges are detected READ_SV variable 68 AND
or no Digital Link messages (16#1000 0000). This fault requires
are received within 250 mi- that the user servo setup function
croseconds. and DSTRTSRV be executed prior
to executing DRSETFLT to reset
the fault indication.

52 Invalid Switch This fault is set when the Invalid Switch Setting Fault status
Setting Fault drive address switch setting can be monitored using READ_SV
is set to 0 or greater than 64 variable 68 AND (16#2000 0000).
or its setting is changed while Use DRSETFLT to reset fault indi-
the Digital Link is operating cations.
in cyclic communications Note: Digital Link initialization
mode. must be performed before this fault
can be reset.

77 Drive Not Ready Power applied to an uninitial- Initialize andconfigure the drive us-
ized drive. ing PiCPro.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 137
 Troubleshooting

8.3.3 Troubleshooting Warning Error Codes

Table 8-3:
Error
Code Warning Possible Causes Possible Remedies

01 Drive Heatsink Temp. Drive heatsink temperature ex- TBD

Warning ceeds warning limit

02 Drive Ambient Temp. Acceptable ambient tempera- TBD

Warning ture limit has been exceeded
warning limit

03 Motor Temp. Warning Motor thermal device is a ther- • Reduce acceleration rates.
mistor and thermistor tempera- • Reduce duty cycle (ON/OFF) of
ture has exceeded acceptable commanded motion.
limit • Increase time permitted for
motion.
• Use larger drive and motor.
• Check tuning.

04 Motor Calculated Temp. Calculated motor temperature TBD

Warning has exceeded acceptable limit

138 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Optional Resolver

9 Resolver Interface Option Module

9.1 Theory of Operation

The Resolver Interface Option Module provides the interface between the
resolver and the drive’s DSP. It is a tracking system where the rotor is excited
with a sine wave. The outputs of the resolver are amplitude modulated by the
sine and cosine of the rotor shaft angle. The tracking converter converts the
sine and cosine amplitude ratio into a 12 bit number.
The module provides a 4 Vrms 5 kHz sine wave to excite the resolver rotor.
The resolver transformer ratio is .5:1 so the stator outputs are 2V RMS with
the shaft rotated to the angle of maximum coupling. The sine and cosine
rotor outputs are returned to the resolver module’s twin instrumentation
amplifier inputs to produce a high common mode noise rejection and a high
input impedance (220K Ω). The sine and cosine signals are then fed to a
resolver to digital converter chip that performs the tracking conversion. The
converter has both a serial output and an encoder emulator output. The serial
output is read when the drive is powered up to obtain the absolute
commutation angle for the motor. Thereafter, it is used as an encoder
emulator.
The module is able to detect a loss of feedback by monitoring the sine and
cosine signals. If both are near zero at the same time, a loss of feedback error
is generated.

9.2 Installing the Resolver Module

1. Remove the five screws at the corners of the face of the 230V drive or
loosen the 2 mounting screws on the face of the 460V drive.
2. Remove the shunt from the 24-pin DIP socket located on the MMC
Smart Drive board.
3. Position the Resolver Option Module so the standoffs align with the
mounting holes on the MMC Smart Drive board, and the header is
aligned with the socket.
4. Using even pressure, press the option module into place.
5. Verify that the module is fully seated into the socket and the locking
tabs on the standoffs are in the locked position.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 139
 Optional Resolver

Figure 9-1: Before Shunt Removed and Resolver Module Installed

Connector Side of Board

MMC Smart
Drive Board Resolver
Board
Shunt

Figure 9-2: Shunt Removed and Resolver Module Installed

Connector side of Board

230V MMC Smart

Drive Board

Resolver
Resolver 460V MMC Smart Module
Module Drive Board

View A View A

View A
24 PIn
Dip Socket
Resolver (Shunt Removed)
Slotted Tip
Module

MMC Smart Drive Board

Locking Tab

140 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Optional Resolver

9.3 Specifications
Resolver Interface Option Module
Characteristics Specifications
Function Resolver to encoder converter

Part Number M.1302.4523

Field Side Connector F1 Feedback Connector

Excitation Frequency 5 kHz

Output Voltage 4 VRMS

Current per Output Channel, max. 28 mARMS

Resolver Transformer Ratio 0.5:1.0

Resolver Resolution 4096 Feedback Units (FUs) per electrical revolution

Accuracy Over Temperature + 15 minutes

Range
Electrical Velocity, max. 500 RPS

Cable Length, max. 30 M

Power Powered from MMC Smart Drive

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 141
MMC Smart Drive Control

10 MMC Smart Drive Control

10.1 Introduction
This section contains information for the MMC Smart Drive Control (Digital
MMC-Dx). Block I/O information can be found in the Block I/O Modules
Manual. Software information can be found in the PiCPro Online Help, the
Function/Function Block Reference Guide, ASFB Manuals or on-line.

10.1.1 Overview
The MMC Smart Drive Control offers a complete solution to both
machine and motion control in a module that is installed into any
Digital Interfaced Smart Drive (MMC-SD-D). One MMC Smart
Drive Control can control from 1 to 16 drives as follows:
• Digital MMC-D1 (controls one MMC-SD-D)
• Digital MMC- D2 (controls two MMC-SD-D)
• Digital MMC- D4 (controls four MMC-SD-D)
• Digital MMC- D16 (controls 16 MMC-SD-D)
The PiCPro programming tool used with the PiC family of controls
is also used to program the MMC Smart Drive Control. The built-
in I/O [8 inputs (24 VDC) and 8 outputs (24 VDC)] can be
expanded using G&L Motion Control serially distributed block I/O
(not included on the Digital MMC-D1) .

142 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
MMC Smart Drive Control

10.1.2 Major Components

The MMC Smart Drive Control contains the CPU, a user serial
port, a Block I/O port, and a general I/O port consisting of 8 DC
inputs and 8 DC outputs.

Figure 1: The MMC Smart Drive Control

Diagnostic LED (D2) Scan LED (S)

(Yellow) (Green)

Block I/O Port (C1)*

(9-Pin Standard D-Shell)

User Serial Port (C3)

(15-Pin High Density D-Shell)
Ethernet Link LED*
(Green) Ethernet Activity LED*
(Green)

Ethernet Communications Port (C4)*

(RJ-45 8-Pin)

General I/O Port (C5)

(26-Pin High Density D-Shell)

* The Block I/O Port connector (C1), Ethernet Communications Port connector (C4), Ethernet
Link LED, and Ethernet Activity LED are present on the Digital MMC-D1 Control, but are
not functional.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 143
MMC Smart Drive Control

10.2 Installing the MMC Smart Drive Control

10.2.1 Installing the MMC Smart Drive Control into a

Digital Interfaced 230V MMC-SD Drive
1. Remove the three screws from the right side of the cover and
one screw from the top and bottom of the drive near the front.
Remove the cover.
2. Place the cover removed in step 1 on a flat surface, with the
blue plastic faceplate down, and the large side cover to the left
pointing up.
3. Remove the two screws that hold the .6" by 8" blue filler plate
to the back of the faceplate and remove the plate.
4. Locate the 4 screws that secure the top-most printed circuit
board into the drive. Remove one of the screws and the asso-
ciated lockwasher, and install one of the four threaded stand-
offs that were included with the MMC Smart Drive Control
(do not use the lockwasher). Repeat this process for the other
3 screws, one at a time.
5. Place the MMC Smart Drive Control into the drive, with the
connectors facing towards the front of the unit. Align the 20-
pin connector on the MMC Smart Drive Control with the 20-
pin connector on the drive. Press the MMC Smart Drive Con-
trol onto the drive until the 20-pin connector is completely
seated and the MMC Smart Drive Control is seated against the
threaded standoffs installed in step 4.
6. Fasten the MMC Smart Drive Control onto the threaded
standoffs using the lockwashers and screws removed in step 4.
7. Replace the cover using the 4 screws removed in step 1.

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10.2.2 Installing the MMC Smart Drive Control into a

Digital Interfaced 460V MMC-SD Drive
1. Turn the two locking screws on the front of the drive
clockwise ¼ turn and pull the drive control board unit out of
the drive.
2. Place the drive control board unit removed in step 1 on a flat
surface, with the blue plastic faceplate down, and the drive
control board to the left.
3. Remove the two screws that hold the .6" by 8" blue filler plate
and remove the plate.
4. Place the drive control board unit on a flat surface so that the
control board is facing up, and the blue plastic faceplate is
facing away from you.
5. Locate the 4 screws that secure the top-most printed circuit
board into the drive. Remove one of the screws and the asso-
ciated lockwasher, and install one of the four threaded stand-
offs that were included with the MMC Smart Drive Control
(do not use the lockwasher). Repeat this process for the other
3 screws, one at a time.
6. Place the control board unit on a flat surface, with the blue
plastic faceplate down, and the drive control board to the left.
7. Loosen (but do not remove….about 2 turns) the 5 screws that
hold the drive control board mounting plate to the front cover
plate.
8. Place the MMC Smart Drive Control into the drive, inserting
the connectors on the MMC Smart Drive Control through the
front plate.
9. Align the 20-pin connector on the MMC Smart Drive Control
with the 20-pin connector on the drive. Press the MMC Smart
Drive Control onto the drive until the 20-pin connector is
completely seated and the MMC Smart Drive Control is
seated against the threaded standoffs installed in step 5.
10. Tighten the 5 screws loosened in step 7
11. Fasten the MMC Smart Drive Control onto the threaded
standoffs using the lockwashers and screws removed in step 5.
12. Replace the control board unit back into the drive, and turn
the locking screws ¼ turn counter-clockwise to secure the unit
in place.

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10.3 System Wiring Guidelines

The MMC Smart Drive Control relies on electrical signals to report
what is going on in the application and to send commands to it. In
addition, signals are constantly being exchanged within the system.
The MMC Smart Drive Control is designed for use in industrial
environments, but some guidelines should be followed.

Figure 2: Recommended EMC Compliant Connections

COMMUNICATIONS

MMC
Smart
Drive
Control
DC INPUT/OUTPUT

Power
Connector
COM
24V

Capacitor

AC INPUT +
POWER DC POWER SUPPLY
GND

SINGLE-POINT GROUND

SINGLE-POINT GROUND

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Inside a control cabinet, connect the shields of shielded cables. The two
different methods of terminating shields are used to accommodate two
different immunity requirements. Immunity required inside an enclosure is
considered lower because cables are typically less than three meters in length
and/or can be separated from each other and from noise sources.
Immunity required external to an enclosure is considered higher because the
user may have less control over the noise environment. Low level signal
cables that can be external to an enclosure are tested at a 2 KV level for
electrical fast transients (EFTs). Low level signals that can be less than three
meters in length or can be separated from noise sources are tested at a 1 KV
level. Under the stated conditions, there will be no disturbance of digital I/O,
encoder, or encoder operation. For analog signals, there may be momentary
disturbances but there will be self-recovery when the noise subsides.
Do not operate transmitters, arc welding equipment, or other high noise
radiators within one meter of an enclosure that has the door open. Continue
to equip inductive devices, if they are in series with a mechanical contact or
switch, with arc suppression circuits. These devices include contactors,
solenoids and motors. Shield all cables that carry heavy current near the
system, using continuous foil wrap or conduit grounded at both ends. Such
cables include power leads for high-frequency welders and for pulse-width-
modulated motor drives.

WARNING

Use care when wiring I/O devices to the MMC Smart Drive Control
and when plugging in cables. Wiring the wrong device to the connec-
tor or plugging a connector into the wrong location could cause inter-
mittent or incorrect machine operation.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 147
MMC Smart Drive Control

10.4 Starting an Operation

Good procedure suggests that the system should be tested each time a new
application is powered up. The Diagnostic LED (D2) on the MMC Smart
Drive Control should be off indicating that the diagnostic tests were passed.
Turn off the main disconnect switch and plug the DC connector into the
power connector on the MMC-SD. Turn on input power. The D2 LED turns
on and then turns off when the MMC Smart Drive Control passes its
diagnostic tests.

10.4.1 Connecting the MMC to the Application

1. Turn off the main disconnect switch in the control cabinet. If
some devices are not powered from the control cabinet, turn
them off also.
2. Connect the connectors according to your diagrams.
3. Turn on power to the system. The PWR light on the MMC-SD
goes on and stays on.
The D2 light goes on, then goes off in turn.
The SCAN (S) light goes on.
The application starts to work under control of the system.
4. If an application program is not in system memory, use the
download command in the PiCPro software to place it there.

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10.4.2 Basic Setup and Maintenance Procedures

Table 1 below summarizes how to proceed when performing certain
maintenance and/or setup functions.
Table 1: Troubleshooting Summary
In order to:

Turn off the entire application. Turn off main disconnect (which should
also turn off all external power supplies to
the application); unplug the DC power to
the MMC-SD.

Wire the I/O to the application. Turn off main disconnect (which should
also turn off all external power supplies to
the application); unplug the DC power to
the MMC-SD.

Change the battery. Turn off main disconnect (which should

also turn off all external power supplies to
the application); unplug the DC power to
the MMC-SD.

Connect/disconnect the MMC with the Turn off main disconnect (which should
computer workstation through the also turn off all external power supplies to
PiCPro port. the application); unplug the DC power to
the MMC-SD.

Connect/disconnect the MMC with an Turn off main disconnect (which should
operator interface through the User port. also turn off all external power supplies to
the application); unplug the DC power to
the MMC-SD.
Download an application program into Make sure power is on (check the P LED)
the memory. on the MMC-SD.

Stop the scan. From the workstation - use the Stop Scan
commands in the PiCPro software.

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MMC Smart Drive Control

10.4.3 Start-up Diagnostics

When the system is powered up, it tests itself and reports the results
in the form of LED signals.

10.4.3.1 Power LED

If the Power LED (P) on MMC-SD does not go on, or
goes off during operation of the system, check that
power is still connected to the MMC-SD. If the power
LED on the MMC-SD is on, turn off the main
disconnect switch and replace the MMC Smart Drive
Control.

10.4.3.2 Scan LED

If the SCAN (S) LED does not go on:
1. Check that the power (P) light is ON.
2. Check that the diagnostic (D2) light is OFF.

10.4.3.3 MMC Start-Up Diagnostic LEDs

The LED D2 light on the MMC Smart Drive Control
lights up briefly while its diagnostic tests are running
and then goes off. If D2 remains on, the MMC Smart
Drive Control has failed one of its tests. Follow these
steps:
1. Turn off power to the system and to
the application.
2. If the I/O wiring is connected, remove the
connector.
3. Remove the defective MMC Smart Drive
Control from the drive.
4. Replace with a new MMC Smart Drive Control.
Connect the I/O wiring.
5. Turn on power to check diagnostics again.

NOTE

Diagnostics are run only when the system is powered up.

It is possible that a failure might occur during operation.
If so, D2 remains off. If you suspect that a module might
be defective, cycle power to run diagnostics again.

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10.4.4 MMC Run-Time Diagnostics

While the MMC Smart Drive Control is running, other tests are
performed on a regular basis with their results also reported by D2.
While the MMC Smart Drive Control is running, the D2 will flash a
three digit code signal if there is an error. For example, if there is a
long pause-flash-pause-flash-flash-pause-flash-flash-flash-long
pause, the code is 123.

Code Error Description

123 Scan too long A ladder scan loss has occurred because the CPU
takes more than 200 ms to scan the application
program.
Whenever the scan light is out, the discrete outputs go
to the OFF state and the analog outputs are zeroed.

124 Excessive overhead The system overhead update time is excessive.

125 Insufficient memory There is insufficient memory on the CPU to run the
current program.

126 No hardware bit memory There is no bit memory installed on the CPU and the
program requires it.
127 No software bit memory There is no bit memory capability via software and
the program requires it.

222 Driver error No driver support on the CPU for the I/O module.
Update your system EPROMs.

22_ Master rack error The I/O modules in the master rack do not match
what was declared in the hardware master declaration
table. The number of flashes in the third digit (_)
identifies the slot number that is in error.
232 Communications error A failure has occurred in remote I/O communications.

3_ _ Expansion rack error The I/O modules in the block I/O modules do not match
what was declared in the expansion hardware declaration
table.
For block I/O modules:
The number of flashes in the second and third digits
indicates the block I/O module (01 through 77). The
second digit will flash a 1 - 7, 10 for 0. The third digit will
flash a 1 - 9, 10 for 0.
For example, if the second digit flashes 3 times and the
third digit flashes 10 times, the module is 30.

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MMC Smart Drive Control

10.5 MMC Connections to External Devices for

Machine Control
G&L Motion Control provides many optional accessories that simplify
wiring the MMC Smart Drive Control to external devices.
These accessories include cables to connect MMC-SD drives together and
breakout boxes that provide screw-terminal connections to the MMC Smart
Drive Control. Contact G&L Motion Control for further information.

10.5.1 PiCPro Port (P1)

The provides serial communication for the PiCPro programming
interface. PiCPro Port (P1) is physically located on the MMC-SD
faceplate. Refer to Chapter 5 for information on the PiCPro (P1)
Port.

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10.5.2 Block I/O Port (C1)

Note: The Block I/O Port (C1) is not included on the Digital
MMC-D1.
The Block I/O Port (C1) is a 9-pin female "D" connector and
provides:
• Up to 77 expansion block I/O units
• 4-wire communication interface
• Up to 200 feet between block I/O units

Table 2: Pinout for Block I/O Port (C1)

Pin Description In/Out

1 NC
2 NC
3 Block I/O Transmit Data + Out
4 Block I/O Transmit Data - Out
5 Block I/O Receive Data + In
6 Block I/O Receive Data - In
7 Shield (see Note below)
8 NC
9 NC

NOTE

Pin 7 of the Block I/O Port (C1) connector is connected to the connec-
tor shell within the MMC Smart Drive Control. Therefore, the shield
may be connected to either pin 7 or the connector shell.

10.5.3 User Port (C3)

The User Port (C3) is a 15-pin male high density "D" connector,
used to communicate with a touch-screen, a hand-held controller, or
other serial interface device. The User Port (C3) provides:
• RS232/RS485 communication
• Baud rates to 115.2 K
• Multidrop capability

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MMC Smart Drive Control

Table 3: Pinout for User Port (C3)

Pin Description In/Out Pin Description In/.Out

1 NC N/A 9 RS232 Receive Data In

2 NC N/A 10 RS232 Transmit Data Out
3 NC N/A 11 NC
4 RS232 Data Terminal Ready Out 12 RS485 Receive Data + In
(3.3V)
5 RS232 Request to Send Out 13 RS485 Receive Data - In
6 NC N/A 14 RS485 Transmit Data + Out
7 RS232 Clear to Send In 15 RS485 Transmit Data - Out
8 Signal Ground In/Out

10.5.4 Ethernet Port (C4)

NOTE: The Ethernet Port (C4) is not included on the Digital
MMC-D1.
The Ethernet Port (C4) consists of an 8-pin RJ45 connector and
LEDs that provide:
• IEEE 802.3/802.3u-100Base-TX/10Base T, half duplex
connectivity
• A green "Link" LED. This LED will be on if there is either
a 100Base-T or 10Base-T Link.
• A green "Activity" LED. This LED will be on whenever a
send or receive packet has occurred.

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MMC Smart Drive Control

Communication using the Ethernet Port can be between the MMC

Smart Drive Control and a PC, User Interface, or other Ethernet
device or network.

Table 4: Pinout for Ethernet Port (C4)

Pin Description In/Out

1 Transmit Data + (TD+) Out

2 Transmit Data - (TD-) Out
3 Receive Data + (RD+) In
6 Receive Data - (RD-) In
4,5,7,8 Termination Resistors In
(See Note 1, below)
Shell Chassis Ground In

Note 1: Pins 4, 5, 7, and 8 are tied to termination resistors on the

MMC Smart Drive Control. Standard Ethernet cables contain 8
wires. The MMC Smart Drive Control only uses 4 of these wires as
shown. Connecting the 4 unused wires to the MMC Smart Drive
Control pins 4, 5, 7, and 8, (as will be done in a standard Ethernet
cable) reduces noise that can be induced from the unused wires to
the Transmit and Receive wires.
Typically, a "straight-through" cable should be used when
connecting the MMC Smart Drive Control to another Ethernet
device. Refer to Figure 11.4 on page 162 for cables available from
G&L Motion Control.

10.5.5 General I/O Port (C5)

The General I/O Port (C5) is a 26-pin male high density "D"
connector and includes:
• 8-24 VDC sourcing inputs (Input 1 can trigger an interrupt
on the rising or falling edge)
• +24 VDC and 24 V Common
• 8-24 VDC outputs
• Source only
• 250 mA output capacity
• Short circuit protection

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MMC Smart Drive Control

Table 5: Pinout for General I/O Port (C5)

Pin Description In/Out Pin Description In/Out

1 DCOUT1 Out 16 IO24C In/Out

2 DCOUT2 Out 17 IO24C In/Out
3 DCOUT3 Out 18 IO24C In/Out
4 DCOUT4 Out 19 DCIN1 In
5 DCOUT5 Out 20 DCIN2 In
6 DCOUT6 Out 21 DCIN3 In
7 DCOUT7 Out 22 DCIN4 In
8 DCOUT8 Out 23 DCIN5 In
9 24VDC OUT In 24 DCIN6 In
POWER
10 IO24V In/Out 25 DCIN7 In
11 IO24V In/Out 26 DCIN8 In
12 IO24V In/Out
13 IO24V In/Out
14 IO24C In/Out
15 IO24C In/Out

NOTES:
• Pin 9 is 24VDC into the MMC Smart Drive Control to power the
8 outputs
• Pins 10-13 are only connected to each other within the MMC
Smart Drive Control. If used, tie one pin to 24VDC, and the other
to one side of input devices.
• Pins 14-18 are connected together within the MMC Smart Drive
Control. Connect pin 14 to 24V common. This provides the
return path for the 24VDC inputs. and allows pin 15-18 to be con-
nected to one side of ouput devices if desired.

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There are 8 DC outputs on the General I/O Port (C5). These outputs
get their power from Pin 9 of the MMC Smart Drive Control as
shown in Figure 3.

Figure 3: General Outputs for General I/O Port (C5) Connected to Loads

MMC Smart Drive Control

GENERAL
CONNECTOR DC
LOAD OUTPUT PINS
14

1
15

2
16

3
17
4
18
DCOUT5
5
DCOUT6
6
DCOUT7
7
DCOUT8
8
DCOUT9
9

_
+
DC Power Supply To
Common SPG

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MMC Smart Drive Control

There are 8 general inputs on the General I/O Port (C5) . The inputs
are configured as sourcing as shown in Figure 4.

Figure 4: Source General Input Configuration for General I/O Port (C5)

MMC Smart Drive Control

GENERAL
CONNECTOR DC
INPUT PINS
I/O 24C
14
+24V
10

11
DCIN1
19
12
DCIN2 SOURCE
20
13
DCIN3
21
DCIN4
22
DCIN5
23
DCIN6
24
DCIN7
25
DCIN8
26

+
_
DC Power Supply

To
SPG

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MMC Smart Drive Control

10.6 Specifications
General
Characteristic MMC Specifications

Number of servo axes available

at six update rates*

Part App RAM User 8 4 2 1 .5 .25

Model No. Speed Mem Mem Mem ms ms ms ms ms ms

Digital M.1302 Std. 384K 256K 64K 1 1 1 1 1 1

MMC-D1 .8230

Digital M.1302 Std. 384K 256K 64K 2 2 2 2 2 1

MMC-D2 .8231

Digital M.1302 Std. 384K 256K 64K 4 4 4 4 2 1

MMC-D4 .8232

Digital M.1302 X1.5 384K 256K 64K 16 16 8-16 4-8 2-4 1-2
MMC-D16 .8233

* Using features such as servo tasks, S-curve, RATIO_RL, M_LINCIR, M_SCRVLC, PLS, and CAM_OUT
places a heavier burden on available CPU time. Consult G&L Motion Control for assistance if you want to
exceed the number of axes in this chart.

CPU 32 bit RISC processor with numeric coprocessor

Battery 3V Coin Cell, BR2032 lithium battery
CAUTION for Lithium Batteries
Danger of explosion if battery is incorrectly replaced. Replace only with the same or
equivalent type recommended by the manufacturer. Dispose of used batterries according to
the manufacturer’s instructions.
Flash Disk 2 Megabytes

Memory 1 Megabyte max.

PiCPro Port (to workstation) RS232 serial port, secured protocol

Software selectable baud rate to 115.2K
User Port (to serial interface RS232/RS485 serial port
device) Supports RTS/CTS hardware handshaking
Software selectable baud rate to 115.2K

Ethernet Port (to Ethernet IEEE 802.3/802.3u-100Base-TX/10Base T Half duplex

Device)

Input voltage from MMC-SD 20 VDC to 30 VDC

Drive

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MMC Smart Drive Control

Input power from MMC-SD 250 mA

Drive

Time-of-day clock Access via PiCPro 10.2 and above or your application
program
Clock tolerance At 25°C (77°F),±1 second per day
Over temperature, voltage and aging variation,
+2/-12 seconds per day
General DC Inputs

Configuration Sourcing only. Operates with IEC Type 1 inputs (per

IEC 1131-2)

Input voltage Nominal 24 VDC, maximum 30 VDC

Guaranteed on voltage 15 VDC

Guaranteed off voltage 5 VDC

Turn on/off time 1 ms

General DC Outputs

Number of outputs 8 outputs

Input voltage Nominal 24 VDC, 30 VDC maximum

Configuration Eight solid-state switches.

Protection of logic circuits Optical isolation between the logic and field side,
transient suppression on the 24V external supply
Maximum current .25 A per output

Voltage range 24 VDC nominal, 5 to 30 VDC

Switch characteristics Solid-state switches

Time delay on for resistive loads 50 µsec max

Time delay off for resistive loads 50 µsec max

Leakage current in off state 0.5 mA max

Switch voltage, maximum ON 1 VDC max

Short circuit protection for each 15 A (max) pulses for about 130 µsec every 100 msec
group until short is removed

Scan loss response Outputs turn off

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 Part Numbers

11 Part Numbers

11.1 Drives
DESCRIPTION MODEL NUMBER PART NUMBER
230V MMC Smart Drive
2.5A Cont. / 7.5A Max./ .5kW MMC-SD-0.5-230 M.1302.5090
MMC-SD-0.5-230-D M.1302.8130
5A Cont. / 15A Max./ 1kW MMC-SD- 1.0-230 M.1302.5091
MMC-SD-1.0-230-D M.1302.8131
10A Cont. / 30A Max / 2kW MMC-SD-2.0-230 M.1302.5092
MMC-SD-2.0-230-D M.1302.8132
460V MMC Smart Drive
3.0A Cont. / 6.0A Max. / 1.3 kW MMC-SD-1.3-460 M.1302.5093
MMC-SD-1.3-460-D M.1302.8133
5.5A Cont. / 11.0A Max. / 2.4 kW MMC-SD-2.4-460 M.1302.5094
MMC-SD-2.4-460-D M.1302.8134
9.0A Cont. / 18.0A Max. / 4.0 kW MMC-SD-4.0-460 M.1302.5095
MMC-SD-4.0-460-D M.1302.8135
13.5A Cont. / 27.0A Max. / 6.0 kW MMC-SD-6.0-460 M.1302.5096
MMC-SD-6.0-460-D M.1302.8136
18.0A Cont. / 36.0A Max. / 8.0 kW MMC-SD-8.0-460 M.1302.5097
MMC-SD-8.0-460-D M.1302.8137
27.5A Cont. / 55.0A Max. / 12.0 kW MMC-SD-12.0-460 M.1302.5098
MMC-SD-12.0-460-D M.1302.8138
36.5A Cont. / 73.0A Max. / 16.0 kW MMC-SD-16.0-460 M.1302.5099
MMC-SD-16.0-460-D M.1302.8139
55.0A Cont. / 110.0A Max. / 24.0 kW MMC-SD-24.0-460 M.1302.5100
MMC-SD-24.0-460-D M.1302.8140

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Part Numbers

11.2 Option Modules

11.2.1 Resolver Interface Option Module

Module Model Number Part Number

Resolver Interface Option Module M.1302.4523

11.2.2 MMC Smart Drive Control

MMC Smart Drive Control Model Number Part Number

1 Axis Controller Digital MMC-D1 M.1302.5101
2 Axis Controller Digital MMC-D2 M.1302.5102
4 Axis Controller Digital MMC-D4 M.1302.5103
16 Axis Controller Digital MMC-D16 M.1302.5104

11.3 Direct Connect Cables

11.3.1 Drive Programming Cable

Description Drive Connector Part Number

PiCPro Port to PC Connector (Analog) M.1302.8250
P1
PiCPro Port to PC Connector (Digital) M.1302.8284

11.3.2 Standalone MMC to MMC Smart Drive I/O Cable

Description Drive Connector Part Number

MMC A’n’ to MMC Smart Drive I/O 0.5M M.1302.5990
MMC A’n’ to MMC Smart Drive I/O 1.0M M.1302.5991
IO
MMC A’n’ to MMC Smart Drive I/O 1.5M M.1302.5992
MMC A’n’ to MMC Smart Drive I/O 3.0M M.1302.5993

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 Part Numbers

11.4 Digital Link and Networking Cables

MMC-SD
Drive Control
Description Connector Connector Part Number
CAT5e Patch Cord 0.3M M.1302.8285
CAT5e Patch Cord 0.6M M.1302.8286
CAT5e Patch Cord 1.0M M.1302.8287
CAT5e Patch Cord 2.0M M.1302.8288
CAT5e Patch Cord 3.0M IN, OUT C4 M.1302.8289
CAT5e Patch Cord 5.0M M.1302.8300
CAT5e Patch Cord 10M M.1302.8301
CAT5e Patch Cord 15M M.1302.8302
CAT5e Patch Cord 30M M.1302.8303

11.5 Connector Kits

Description Part Number
CONN-FBK-17POS-16-28AWG M.1302.0510
CONN-PWR-BRK-8POS-16AWG M.1302.0479
CONN-PWR-BRK-8POS-12-14AWG M.1302.1998
CONN-PWR-BRK-8POS-8-10AWG M.1302.2354
CONN-PWR-FAN-6POS-16AWG M.1302.6219
CONN-X100-X101 M.1302.7099
CONN-4TERM-MAINS M.1302.7158
CONN-4TERM-MOTOR M.1302.7159

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Part Numbers

11.6 Breakout Boards/Flying Leads Cables and Kits

11.6.1 Mounted Breakout Boards

Description Drive Connector Part Number

BKOUT BD, F1/F2 MMC-SD DR MT F1, F2 M.1302.6970
BKOUT BD, I/O MMC-SD DR MT IO M.1302.6971
MMC Block I/O Breakout Board C1 Contact
G&L Motion Con-
MMC Block I/O Breakout Board C3 trol

11.6.2 Panel Mounted Breakout Boards

MMC-SD
Drive Control
Description Connector Connector Part Number
BKOUT BD, F1/F2 MMC-SD PNL MT F1, F2 M.1302.6972
BKOUT BD, I/O MMC-SD PNL MT IO M.1302.6973
BKOUT BD, DIG I/O MMC I/O PNL MT C5 M.1302.8253

11.6.3 Breakout Board Kits

Description Drive Connector Part Number

KIT, BKOUT BD, F1/F2 MMC-SD 1.0M M.1302.7005
KIT, BKOUT BD, F1/F2 MMC-SD 3.0M M.1302.7006
F1, F2
KIT, BKOUT BD, F1/F2 MMC-SD 9.0M M.1302.7007
KIT, BKOUT BD, F1/F2 MMC-SD 15.0M M.1302.7008
KIT, BKOUT BD, I/O MMC-SD 1.0M M.1302.7009
KIT, BKOUT BD, I/O MMC-SD 3.0M IO M.1302.7030
KIT, BKOUT BD, I/O MMC-SD 9.0M M.1302.7031

163 MMC Smart Drive Hardware Manual G & L Motion Control Inc.
 Part Numbers

11.6.4 Breakout Board Cables

MMC-SD
Drive Control
Description Connector Connector Part Number
CABLE, BKOUT BD, F1/F2 MMC-SD 1.0M M.1302.6976
CABLE, BKOUT BD, F1/F2 MMC-SD 3.0M M.1302.6977
CABLE, BKOUT BD, F1/F2 MMC-SD 9.0M F1, F2 M.1302.6979
CABLE, BKOUT BD, F1/F2 MMC-SD
M.1302.6980
15.0M
CABLE, BKOUT BD, I/O MMC-SD 1.0M M.1302.6982
CABLE, BKOUT BD, I/O MMC-SD 3.0M IO M.1302.6984
CABLE, BKOUT BD, I/O MMC-SD 9.0M M.1302.6985
CABLE, BKOUT BD, DIG-MMC I/O 1.0M M.1302.8254
CABLE, BKOUT BD, DIG-MMC I/O 3.0M C5 M.1302.8255
CABLE, BKOUT BD, DIG-MMC I/O 9.0M M.1302.8256
CABLE, MMC User Serial Port to Breakout
Board, 1 Foot
CABLE, MMC User Serial Port to Breakout
Board, 2 Foot C3

CABLE, MMC User Serial Port to Breakout

Board, 3 Foot Contact G&L
CABLE, MMC Block I/O Port to Breakout Motion Control
Board, 1 Foot
CABLE, MMC Block I/O Port to Breakout
Board, 2 Foot C1

CABLE, MMC Block I/O Port to Breakout

Board, 3 Foot

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 164
Part Numbers

11.6.5 User I/O Flying Lead Cables

MMC-SD
Drive Control
Description Connector Connector Part Number
CABLE, USER I/O, MMC-SD 1.0M M.1302.7032
CABLE, USER I/O, MMC-SD 3.0M M.1302.7034
CABLE, USER I/O MMC-SD 9.0M IO M.1302.7035
CABLE, USER I/O, MMC-SD 15.0M M.1302.7036
CABLE, USER I/O, MMC-SD 30.0M M.1302.7037
CABLE, DIG-MMC I/O, 1.0M M.1302.8257
CABLE, DIG-MMC I/O, 3.0M M.1302.8258
CABLE, DIG-MMC I/O, 9.0M C5 M.1302.8259
CABLE, DIG-MMC I/O, 15.0M M.1302.8290
CABLE, DIG-MMC I/O, 30.0M M.1302.8291
CABLE, MMC User Serial Port to Flying
Lead C3
Contact
CABLE, MMC Block I/O Port to Flying G&L Motion Control
C1
Lead

165 MMC Smart Drive Hardware Manual G & L Motion Control Inc.
 Part Numbers

11.7 Motor Cables (LSM/MSM Motors)

ENC-L&M-001M-MCS-DCA-28-NA
Type of Cable
ENC = Encoder Feedback
PWR = Power Wire Size/Twisted Pair
FAN = Fan (e.g. 28 = 28 AWG Twisted Pair)
For Motor Type Drive Connector, Angle
LSM or MSM DCA = 45 Angle
000 = Wire Leads
Cable Length in Meters
(e.g. 1M = 1 Meter) Motor Connector Straight

11.7.1 Feedback Cables (LSM/MSM Motors)

Feedback Cable Part Number

Static Type
ENC-L&M-001M-MCS-DCA-28-NA M.1302.0944
ENC-L&M-003M-MCS-DCA-28-NA M.1302.0945
ENC-L&M-009M-MCS-DCA-28-NA M.1302.0946
ENC-L&M-015M-MCS-DCA-28-NA M.1302.0947
ENC-L&M-030M-MCS-DCA-28-NA M.1302.0948
Flexing Type
ENC-L&M-001M-MCS-DCA-28-AA M.1302.5834
ENC-L&M-003M-MCS-DCA-28-AA M.1302.5835
ENC-L&M-009M-MCS-DCA-28-AA M.1302.5836
ENC-L&M-015M-MCS-DCA-28-AA M.1302.5837
ENC-L&M-030M-MCS-DCA-28-NA M.1302.5838

11.7.2 Power Cables for Blower Fan (LSM/MSM Motors)

Power Cable Part Number

FAN-L&M-001M-MCS-000-16 M.1302.6310
FAN-L&M-003M-MCS-000-16 M.1302.6311
FAN-L&M-009M-MCS-000-16 M.13026312
FAN-L&M-015M-MCS-000-16 M.1302.6313
FAN-L&M-030M-MCS-000-16 M.1302.6314

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 166
Part Numbers

11.7.3 Motor Power Cables (LSM/MSM Motors)

Power Cable (Flexing Type) Part Number

PWR-L&M-001M-MCS-000-16-6H M.1302.1114
PWR-L&M-003M-MCS-000-16-6H M.1302.1115
PWR-L&M-009M-MCS-000-16-6H M.1302.1116
PWR-L&M-015M-MCS-000-16-6H M.1302.1117
PWR-L&M-030M-MCS-000-16-6H M.1302.1118
PWR-L&M-001M-MCS-000-14-6H M.1302.1119
PWR-L&M-003M-MCS-000-14-6H M.1302.1130
PWR-L&M-009M-MCS-000-14-6H M.1302.1131
PWR-L&M-015M-MCS-000-14-6H M.1302.1132
PWR-L&M-030M-MCS-000-14-6H M.1302.1133
PWR-L&M-001M-MCS-000-12-6H M.1302.1134
PWR-L&M-003M-MCS-000-12-6H M.1302.1135
PWR-L&M-009M-MCS-000-12-6H M.1302.1136
PWR-L&M-015M-MCS-000-12-6H M.1302.1137
PWR-L&M-030M-MCS-000-12-6H M.1302.1139
PWR-L&M-001M-MCS-000-10-6H M.1302.1140
PWR-L&M-003M-MCS-000-10-6H M.1302.1142
PWR-L&M-009M-MCS-000-10-6H M.1302.1143
PWR-L&M-015M-MCS-000-10-6H M.1302.1144
PWR-L&M-030M-MCS-000-10-6H M.1302.1145
PWR-L&M-001M-MCS-000-08-6H M.1302.1146
PWR-L&M-003M-MCS-000-08-6H M.1302.1147
PWR-L&M-009M-MCS-000-08-6H M.1302.1148
PWR-L&M-015M-MCS-000-08-6H M.1302.1149
PWR-L&M-030M-MCS-000-08-6H M.1302.1150

167 MMC Smart Drive Hardware Manual G & L Motion Control Inc.
 Part Numbers

11.8 Optional External Devices

11.8.1 AC Line Filters

For Drive Model AC Line Filter Description Line Filter Part No.
MMC-SD-0.5-230
6A, 250V, Single phase M.1015.6922
MMC-SD-1.0-230
MMC-SD-2.0-230 10A, 250V, Single phase, M.1015.6917
MMC-SD-1.3-460
7A, 480V, Three phase M.1302.5241
MMC-SD-2.4-460
MMC-SD- 4.0-460
MMC-SD-6.0-460 16A, 480V, Three phase M.1302.5244
MMC-SD- 8.0-460
MMC-SD-12.0-460
30A, 480V, Three phase M.1302.5245
MMC-SD-16.0-460
MMC-SD-24.0-460 42A, 480V, Three phase M.1302.5246
To be determined 56A, 480V, Three phase M.1302.5247
To be determined 75A, 480V, Three phase M.1302.5248

11.8.2 AC Line Reactors

Required
Line Power
Drive Model Reactor Loss Inductance Weight Part
(Amps) (Watts) (mH) (Pounds) Number

MMC-SD-12.0- 25 52 1.2 14 M.1302.7373

460*

MMC-SD-16.0- 35 54 0.8 16 M.1302.7374

460*

MMC-SD-24.0- 45 62 0.7 28 M.1302.7375

460*

*Add -D suffix for digital drive.

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 168
Part Numbers

11.8.3 External Shunt Resistor Kits

Part
For Drive Shunt Resistor Module Number
MMC-SD-0.5-230 100Ω, 300W, 600V, Dynamic M.1015.7046
MMC-SD-1.0-230
MMC-SD-2.0-230
MMC-SD-1.3-460 130Ω, 450W Cont. Power, 5.4kW Peak M.1302.7048
MMC-SD-2.4-460 Power, 820V, 240 sec. Time Constant,
121 mm x 93 mm x 605 mm
MMC-SD-4.0-460 95Ω, 700W Cont. Power, 8kW Peak Power, M.1302.7049
820V, 250 sec. Time Constant,
121 mm x 93 mm x 705 mm
MMC-SD-6.0-460 50Ω, 1400W Cont. Power, 17kW Peak Power, M.1302.7060
MMC-SD-8.0-460 850V, 250 sec. Time Constant,
130 mm x 182 mm x 710 mm
MMC-SD-12.0-460 25Ω, 2800 W Cont. Power, 32kW Peak Power, M.1302.7061
MMC-SD-16.0-460 850V, 60 sec. Time Constant,
71 mm x 430 mm x 550 mm
MMC-SD-24.0-460 18Ω, 3900W Cont. Power, 70kW Peak Power, M.1302.7063
850V, 70 sec. Time Constant,
180 mm x 445 mm x 490 mm

11.9 Software
Description Part Number
PiCPro Professional Edition M.1300.7213
PiCPro MMC Limited Edition M.1300.7214
PiCPro Monitor Edition M.1300.7215

169 MMC Smart Drive Hardware Manual G & L Motion Control Inc.
Declarations of Conformity

12 Declarations of Conformity

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 170
 Declarations of Conformity

171 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Declarations of Conformity

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 172
 Declarations of Conformity

173 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Declarations of Conformity

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual 174
 Appendix A - DC Bus Sharing

Appendix A - 460V MMC Smart Drive DC Bus Sharing

A.1 Introduction
This section discusses DC bus sharing among 2 or more 460V Smart Drives.
DC bus sharing accomplishes 4 things:
• It pools the capacitance of all of the drives.
• It lowers electricity cost.
• It allows multiple dries to share one shunt resistor.
• It allows the shunt energy to be shared among multiple shunt resistors.
Pooling the capacitance increases the Joule energy absorption capability to the sum
of the drives connected (See Table A-2). This lowers energy cost slightly because
energy that can be absorbed is not wasted in the shunt resistors. In some
applications, this can eliminate the need for a shunt resistor altogether.
Many applications will have one drive motoring while the other is regenerating.
This energy is transferred from one drive to the other through the DC bus rather
than being dissipated in a shunt. This saves energy cost.
If it is desired to share one shunt resistor instead of using one per drive, the energy
flows through the DC bus to the drive controlling the shunt resistor. Its internal
circuitry will turn the shunt on when the bus voltage reaches an upper limit.
If it is desired to distribute the shunt load among multiple drives, each having a
smaller resistor, then it is important to interconnect the "Shunt On" signals for
all drives sharing the DC bus. This ensures that all of the shunt resistors will
properly share the load. If this connection is not made, it is likely that only one
shunt resistor will dissipate all of the shunt power, overheating it.

A.2 DC Bus Sharing with AC Power to All Drives

When sharing DC power among several drives with AC power supplying all of the
drives (See Figure A-1), all drives must be the same size (for example, all drives
must be MMC-SD-4.0-460). When two drives are connected to a shared DC bus in
this manner, the combined energy absorption of all drives is available.
3% line reactors are required for all sizes using this configuration to ensure
rectifier balance. However, shunt resistors are optional (see below). Refer to
Chapter 4 in this manual for information related to fusing, line reactors and shunts.
Refer to Chapter 6 for connector information.
When more than one shunt is used with the MMC Smart Drives, it is important to
tie the "Shunt On" circuits together so that all shunts get turned on at the same
time. For example, in Figure A-1, if the shunt connected to Drive 1 turns on, the

A1-1 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Appendix A - DC Bus Sharing

"Shunt On" signal will turn on the shunt for Drive 2. The second shunt resistor is
optional as long as the "Shunt On" signal is connected as shown. The "Shunt On"
signal acts as both an input and an output for each Drive.

Figure A-1: DC Bus Sharing with AC Input Power to All Drives

Incoming
AC Power AC Power to
(Mains) Next Drive
if Applicable

Circuit Protection Devices Circuit Protection Devices

(Supply Circuit Disconnect, (Supply Circuit Disconnect,
SCPD, Line Filter etc..) SCPD, Line Filter etc..)

Line Reactor Line Reactor

(for balancing) (for balancing)

Bus +
DC Bus to
Next Drive
Bus - if Applicable

Fuses

Bus + Bus - Bus + Bus -

DRIVE 1 DRIVE 2
"Shunt On" Signal

Shunt Shunt
Resistor Resistor

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual A1-2
 Appendix A - DC Bus Sharing

A.3 DC Bus Sharing with AC Power to One Drive

When sharing DC power among several drives with AC power supplying just one
of the drives (See Figure A-2), all drives need not be the same size (for example,
one drive may be a MMC-SD-8.0-460, and another drive may be a MMC-SD-1.3-
460). When two or more drives are connected to a shared DC bus in this manner,
there are two limits that must be considered:
• The drives not powered by AC must not consume more power than the
"Bus power available for linking to other drives" as listed in Table A-1.
• The total power consumed by all drives cannot exceed the greater of
"Bus power available for linking to other drives" and the kW rating of
the AC powered drive as listed in Table A-1.
For example, assume that the AC powered drive is a MMC-SD-24.0-460 and
consumes 14kW, and supplies DC power to two more drives that consume 4kW
each (8kW total). From Table A-1, the total DC power available to the non-AC
powered drives is 10kW, meeting the first criteria. The total power consumed is
22kW, and since the AC powered drive is a 24kW drive, meets the second criteria.
The continuous current available from the drive would be reduced by the same
percentage as the kW. In the example given, the available kW was reduced from 24
to 16kW. Therefore 16/24 = 67%. The drive’s continuous current is reduced by 1/3
from 45 Amps to 30 Amps.
If peak current is to be used at the same time on more than one drive, the total peak
current used by all drives must not exceed that of the main drive. If both the main
and auxiliary drives will accelerate at the same time, the peak current used by
auxiliary drives is subtracted from the available peak current of the main drive.
Connection of a shunt to the main drive is optional depending on the results found
in sizing the system. The system will have the combined DC Bus capacitance of all
drives connected.
Table A-2 on page 5 shows the MMC Smart Drive bus capacitance and energy
absorption capability.

Table A-1: kW Ratings for Powered Drive

Drive MMC-SD-xx-460 1.3kW 2.4kW 4.0kW 6.0kW 8.0kW 12.0kW 16.0kW 24.0kW
Bus power available 2.0kW 2.0 kW 5.0kW 5.0kW 5.0kW 10.0kW 10.0kW 10.0kW
for linking to other
drives
Continuous Current 3 5.5 9 13.5 18 27.5 36.5 55
(Amps)
Peak Current (Amps) 6 11 18 27 36 55 73 110

A1-3 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
Appendix A - DC Bus Sharing

Figure A-2: Two or more drives with AC input power to one drive
Incoming
AC Power
(Mains)

Circuit Protection Devices

(Supply Circuit Disconnect,
SCPD, Line Filter etc..)

Line Reactor
(size 3 only)

Bus +
DC Bus to
Next Drive
Bus - if Applicable

Fuses*

Bus + Bus - Bus + Bus -

DRIVE 1 DRIVE 2
(Main) (Auxiliary)

*Fuses should be sized to the Auxiliary Drive’s DC

bus rating, and must be able to interrupt 700V DC.
Shunt
Resistor

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual A1-4
 Appendix A - DC Bus Sharing

Table A-2: Drive Bus Capacitance and Energy Absorption Capability

MMC Energy Energy Energy

Smart Drive Absorption at Absorption at Absorption at
Bus Capaci- 230V Line Input and 230V Line Input and 460V Line Input and
tance 230V Motor 460V Motor 460V Motor
Drive* (µFarad) (Joules) (Joules) (Joules)

460V Size 1

MMC-SD-1.3-460 110 3 28 10

MMC-SD-2.4-460 240 7 60 22

460V Size 2

MMC-SD-4.0-460 470 13 118 44

MMC-SD-6.0-460 470 13 118 44

MMC-SD-8.0-460 705 19 177 66

460V Size 3

MMC-SD-12.0-460 820 22 206 76

MMC-SD-16.0-460 1230 33 309 114

MMC-SD-24.0-460 1640 45 412 152

230 V

MMC-SD-0.5-460 1410 38

MMC-SD-1.0-460 1880 51

MMC-SD-2.0-460 1880 51

* add suffix (-D) to model number for Digital Drive

A1-5 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
INDEX size 1 460V drive 85
size 2 460V drive 90
A size 3 460V drive 95
contents of the manual 9
Altitude 75, 101
control cabinet
application
requirements 24
wiring 29, 146
D
B
device protection 40
battery
diagnostic
disposal 159
error codes 132
type 159
LED 150
block I/O
run-time 151
port
troubleshooting 150
pinout 153
Diagnostics 150
bonding
diagnostics
mounting 22
power on 130
C run-time 131
cables runtime 131
pin assignments dimensions
HSM and FSM motors 123 230V drive 80
I/O 116 460V drive 110
LSM and MSM motors 117 cabinet clearance 20
NSM motors 121 line filters 57
XSM motors 119 motor cable 36
YSM motors 125 shunts 49
CE distribution
filter requirements 27 power 32
conformity download hex 148
european directives 19 E
UL and cUL standards 19
electrical service & maintenance safety 15
Conformity, Declarations of 170
EMI (ElectroMagnetic Interference)
connections
bonding 22
general outputs 157
environment requirements
general purpose inputs 158
system 39
MMC CPU module 152
error codes
connector
diagnostic 132
block I/O 153
ethernet
ethernet 154
port
general I/O 155
pinout 154
user port 153
connectors F
230V 24VDC IN/Brake 73 faults
230V F1 feedback 65 diagnostic 132
230V F2 feedback 68 features of the MMC Smart Drive 8
230V motor 74

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual IND-1
filter, AC power 27 line filters
flash memory 159 block diagram for 3-phase 53
fuse sizing 39 CE compliance 53
fuses connection diagram for 3-phase 54
NFPA 79 Table 7.2.10.1 40 part numbers 55
NFPA 79 Table 7.2.10.4 40 technical data
230V 55
G
460V 56
general I/O line reactors 168
port pinout 155
M
general inputs
sinking/sourcing 158 maintenance 130
general outputs manual cleaning procedure 17
connections 157 MMC
general purpose inputs connecting to an application 148
connections 158 CPU
grounding module connections 152
CE single phase 230V drive system 27 overview 142
multiple drives 29 ports 143
protective earth 12 power 33
system 25 Servo Control Unit 143
specifications 159
H
mounting 24
handling the MMC Smart Drive 18 bonding 22
heat
N
controlling 21
hex noise
download 148 see bonding 22
Humidity 75, 101 O
I operation
inspection safety 14
safety 14 startup 148
installation 19 overview
installing 18 MMC 142
isolation transformers P
230V formula 46
460V formula 46 part numbers
breakout boards, cables and kits 163
L connector kits 162
LEDs drive connect cables 161
230V single phase drive 59 drives 160
460V analog 3-Phase drive 84 LSM and MSM feedback cables 166
diagnostic 150 optional external devices 168
error codes 132 PiCPro
power 150 port pinout 152
scan 150 pinout

IND-2 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.
 block I/O port 153 dimensions 49
ethernet port 154 signs
general I/O port 155 safety 12
PiCPro port 152 single point ground (SPG)
user port 153 checklist 26
power software
AC input requirements 39 required 9
distribution in MMC 32 specifications
LED 150 230V MMC Smart Drive 75
power requirements 460V analog drive 101
system 39 Altitude 75, 101
procedure Humidity 75, 101
manual cleaning 17 MMC 159
protective earth optional resolver module 141
grounding 12 Shock 75, 101
Storage Temperature 75, 101
R
Vibration 75, 101
Requirements storage
Transformer 39 before installation 18
Wire Size 39 Temperature 75, 101
resolver storing the drive 18
installing 139, 140 switch
resolver module main disconnect
installing 139 wiring modules 149
theory of operation 139 system
run-time diagnostics 151 environment requirements 39
S power requirements 39
system mounting requirements
safety fuse sizing 39
after shutdown 14 ventilation 19
cleaning 17
electrical service & maintenance 15 T
inspection 14 technical support contacts 10
operating safely 14 Transformer
operation 14 Size 39
signs 12 troubleshoooting
system 11 general 132
warning labels 13 troubleshooting 149
scan fault error codes 133
LED 150 hardware wiring 131
shields 30
U
Shock 75, 101
short circuit protection 41 Unpacking 18
shunts user port
choosing 47 pinout 153

G & L Motion Control Inc. MMC Smart Drive and Digital MMC Control Hardware Manual IND-3
V connecting shunt modules 127
connections for 3-phase line filter 54
ventilation 19
connectors on 230V drive 60
Vibration 75, 101
EMC compliant 29, 146
W interface cables 35
warning label preparing motor connection wires 36
danger, warning, caution 13 routing high/low voltage cables 35
hazard 13 terminating 230V motor power cable 37
Wire Size 39 terminating 460V power cable 38
wiring user I/O connector 72
application 29, 146

IND-4 MMC Smart Drive and Digital MMC Control Hardware Manual G & L Motion Control Inc.