MOOG M3000 ® Control system and MSC servo controller

Cable fault monitoring: Continuously monitor the analog current output and digital sensor interfaces (A, B, Z signals), and indicate open or short circuit faults through dedicated front-end LEDs.

Power management and data retention

The internal power supply of MSC is divided into L1+/M1, which supplies power to internal electronic devices, and L2+/M2, which supplies power to digital I/O peripheral circuits. The module integrates a low voltage detection function (with a threshold of approximately 16V). When the main power supply (L1+/M1) fails, the module uses internal energy storage capacitors to orderly switch the running state (RUN) to the data save (SAVE) state, securely save the RETAIN variable, Boot item, and error message to the Flash EEPROM, and then enter the idle (IDLE) or off (OFF) state. This mechanism ensures that critical data is not lost during power outages and does not require battery maintenance.

License Key: Carrier of Function and Identity

A physical license key must be inserted into the<LK>slot on the MSC front-end to enable it to run. It not only contains runtime licenses, but also stores key identity information such as CANopen node IDs and IP addresses. This means that when replacing MSC hardware, only the license key needs to be transferred and the configuration can be migrated. Different colored keys (such as gray "control" key, green "motion" key) unlock different levels of function libraries, such as the basic PLCopen motion control function requiring a green key.

Safety, installation, and wiring: the cornerstone of ensuring reliable operation

The manual extensively emphasizes safety regulations, which are a prerequisite for the proper use of industrial equipment.

Core Security Warning

Qualification requirements: Only trained and qualified professionals are allowed to operate.

Power safety: A 24V DC power supply that meets SELV standards must be used. Special Warning: For some early models of MSC (D136E001-001), their digital I/O power terminals L2+/M2 do not have reverse polarity protection, and reversing them will cause permanent damage. Other models and L1+/M1 terminals are protected.

Power on and maintenance: Any installation, wiring, disassembly, or maintenance work must be carried out with the system completely powered off, including the power supply of all external devices.

Anti backflow: When connecting sensors, it is necessary to ensure that the sensor and the connected I/O group use the same power supply that cannot be disconnected separately. Otherwise, when the module power is turned off while the sensor power is still on, reverse power supply from the sensor to the module may occur, resulting in uncontrollable states or damage.

Mechanical installation and grounding

All rail modules are installed on standard DIN TH 35-7.5 rails and need to be mounted on vertical metal backplates.

Proper grounding is crucial: DIN rails must be connected to protective grounding (PE) through low impedance, large cross-section wires. The module achieves conductive connection with the guide rail by locking it on the guide rail, thereby obtaining signal ground. This forms the basis for effective electromagnetic compatibility (EMC) shielding and is key to meeting CE marking requirements.

Key points of network cabling

CAN bus: Shielded twisted pair cables with an impedance of 120 Ω must be used. Both ends of the network (and only both ends) need to be connected to a 120 Ω terminal resistor. The cable length needs to match the baud rate (e.g. up to 25 meters at 1 Mbps). Star wiring should be avoided and a linear bus structure should be used, with branch lines as short as possible.

E-Bus group: physically spliced through Q connectors on the side of the module. There can only be one master station (MSC or RDIO) within a group, and a maximum of 7 (for MSC) or 6 (for RDIO) slave stations can be connected. Modules must be closely adjacent without gaps.

Programming, Configuration, and Communication

Project development process

Engineers complete hardware configuration (adding MSC, Q module, etc., setting I/O parameters), write IEC 61131 application programs, compile, and then download to MSC via Ethernet or serial cable in the MACS development environment on PC. Applications can be stored in RAM for temporary execution, or saved as "Boot projects" written to Flash for self booting upon power up.

E-Bus communication mechanism

E-Bus communication is periodically initiated by the MSC master station. The update rate depends on the product of the shortest task cycle in the MACS task configuration and a module parameter called Updating Rate, which must be less than 50ms, otherwise the QDIO/QAIO module will disable its output due to timeout. For QAIO 16/4 modules, due to their analog conversion characteristics, the E-Bus clock frequency must be set to 5 MHz. In each E-Bus cycle, all digital I/O data is updated, but analog I/O data is time-division multiplexed, with only one channel updated per cycle. Therefore, the overall update rate of analog values decreases as the number of channels used increases.

System Integration and Diagnosis