12Lf Series User Manual

NOTE

This manual is the dedicated manual for 12Lf FORCE control version actuator which support force/speed control as well as position control. This manual is for the 12Lf Force control version user who has the model number which starts with “12Lf” with our For the users with 12Lf series who uses MODBUS RTU protocol, please refer separated “Force control/MODBUS RTU” manual and for the users who have the actuator which starts with D or L, please refer to the separate “Position control” actuator manual.

1. Before Use

1.1. Introduction

Thank you for purchasing mightyZAP mini Linear servo motors! Please peruse this manual before use to prevent any unexpected damage of product or serious injury of users.
mightyZAP mini Linear servo motors have been developed to provide reliable, high quality linear solution in compact space. mightyZAP mini Linear servo motors can be applied in various fields such as factory automation, medical devices, robotics, professional UAV and radio control hobby.

Features

• Position Control (Positional Accuracy 50~90um – see spec chart of each model)
• Stall Force Control based on Current feedback
• Speed Control by 1024 Resolution
• Bulit-in Drive circuit
• 4096 Step High Resolution
• High Performance Coreless Motor
• Minimized Mechanical Backlash (30um)
• Excellent Substitute for pneumatic cylinder which does not support position control
• Reasonable Cost

1.2. For Safety

warning

⚠ Please peruse safety instruction below to use mightyZAP safely. Please kindly note that abuse may invalidate your warranty.

1. Do NOT press the Rod when the servo is being operated. Motor may be damaged(burnt) if higher force than rated force is applied consistently.
2. Apply proper input voltage using power supply or correct battery. For instance, 7.0~12V for 12V input product(12Lf series). The motor may be burnt when higher voltage than 13V is applied to the actuator.
3. Lifespan of motor can be varied according to the load and duty cycle and etc. 1)       Use under rated force. For instance, rated force of 12Lf-20PT-27 is 20N(approx. 2kg). That is, lifespan of 12Lf-20PT-27 can be maximized when it is used less than 20N force condition. The lower load comparing to rated force, the longer lifespan of the motor. 2)      Use under 50% of Duty Cycle : If DC motor operates continuously without any interval (rest), motor will be overloaded and overload protection feature will cut off the power of servo motor. Therefore, user should consider “Duty cycle” which means the percentage of operating time against interval time. In other words, 50% duty cycle means that motor should rest 50% of time when motor operate during 50% of time to manage motor lifespan more efficiently. Use under 50% of duty cycle for optimized lifespan. The less duty cycle, the longer lifespan.
   3)      "Force Off" feature when servo motor is in standby mode may prolong the lifespan of servo motor. However, this feature can be used when there is no problem in your system even if rod position is changed due to external force because "force off" makes servo force is released. ( 1.5. Force Off )
4. Proper wiring : There is little chance of incorrect wiring when using wire harness with connector provided by our factory. However, if users use soldering or a third-party connector according to user’s desire, please pay attention to mis-wiring between the communication and power lines. Incorrect wiring results in fatal damage to the PC board or certain electrical components. Please refer to the wiring pin map on 4.1.Circuit Connection page on this manual to prevent incorrect wiring.
5. Position command within mechanical limit : There should be mechanical limit which servo rod can move when user install servo motor in their application. Make sure that positional command should be made within user’s mechanical limit. It is too common to mention, but we could see this mistake from time to time. If positional command is out of mechanical limit, servo will be overloaded at certain point of time and power will be cut off to protect the servo due to overload protection feature. (if overload protection is inactivated by user, motor will be not be protected.) Considering precise position control, make sure to re-check this matter when servo is applied.
   
6. It is strictly banned to use multiple qty actuators for single objective. Due to DC motor characteristic, each actuator’s speed can be slightly varied even if they are same model and goal position is same. (may cause overload to one of actuator)

7. Do not TWIST the rod with excessive force when tightening the rod end tip. If you apply excessive twisting force to the rod when tightening the rod and tip (while the body is fixed), it may cause damage to internal part (Engineering Plastic rod-insert). Follow below instruction to avoid damage.
instruction – M3 spanner 1) Fix the Rod-end with the included M3 spanner (⑤). This is to prevent the rod (①) from turning badly and damage while tightening the M3 nut (②). 2) According to preference, install the socket set screw (③) or rod end tip (④) to the proper positioning before hard tightening. 3) Adjust the angle of the rod end tip (④) to the desired angle. By using a long nose plier(or extra M3 spanner), fix the position by tightening the M3 nut (②) while rod end is fixed with M3 spanner(see above image.). This is “double nuts” concept which fixes mechanical position by friction.

8. Use properly "Overload protection" feature to protect the servo and your system from damage. Overload protection feature is activated from the factory, and for other protection setting, if necessary, set “Alarm shutdown” feature according to your system's condition.
9. Do NOT touch the servo case right after servo operation. It may hot.
10. Keep away from water, humidity, dust and oil.
11. It is designed for indoor purpose. Do not use in outdoor.
12. Keep out of reach of children. Keep hands off when servo motor operates to avoid unexpected injury.

1.3. For Storage

Do NOT store/use servo motor under below extreme condition. It may cause malfunction or damage of product.

• Direct light and High temperature more than 70 ˚C or Low temperature lower than minus 20˚C.
• Highly Humid space / Space having Vibrating condition / Space having Dust / Space causing Electrostatic

1.4. Constant Load / Overload Protection

Important Note : Constant load / Overload Protection Force Off Feature

Overload protection (Overload shutdown) feature is to prevent overload condition which greatly affect the service life and to motor burnout. Please read the following for proper protection and use it according to the conditions.

1.4.1. About mechanism of overload protection (overload shutdown) and terminology

• The overload protection mechanism of the 12Lf Force Control series uses a combination of current accumulation and operation time accumulation.
  • In case of continuous operation AT rated load, Shutdown occurs after about 30 sec as the accumulated current value.
  • In case of continuous operation UNDER rated load, Shutdown occurs after longer than 30 sec, but Shutdown will be made within max. 180 sec even at the lowest load.
  • In case of continuous operation ABOVE rated load, Shutdown occurs shorter than 30 seconds due to the high amount of current accumulation. For example, shutdown occurs within 2 seconds when the maximum current of 1.6A flows.
• Duty cycle is the ratio of the time which motor is actually driven against the time of motor rest.
• Duty cycle 50% means that 50% of the time should be restored if the motor runs 50% of the time.
• Motor operating time includes the time which the motor rotates/moves normally as well as the time which motor draws current by stuck condition without motor rotating.

1.4.2. Overload shutdown Disable

The overload shutdown function protects the servo actuator under overload conditions. Depending on the application, there are applications that need to be operated under severe conditions, even if the overall mechanism protection is more important than the servo actuator, or even if the life of the servo actuator is shortened. For this case, shutdown function can be disabled through mightyZAP servo manager software so that shutdown does not work under overload situation. However, in the 12Lf force control series, the goal current can be set so that the motor can be protected by not exceeding the set maximum current even in an overload situation.

1.4.3. Recovery after overload shutdown

Since the communication line is still functioning after shutdown, it can be restored to the initial state by “Restart” command or by reconnecting power. Be sure to remove the cause of overload before restoration.

1.4.4. Exception and Cautions

• Caution 1) When the spring is installed between the application and the actuator, or it is installed in Z axis (the direction of gravity), it makes external force to the actuator. Under these conditions, the servo actuator operates slightly, but continuously to keep its position. If this condition persists, actuator may invoke Overload shutdown in some cases. To prevent this, use Force Off command while external power is applied.
• Caution 2) Each time overload shutdown is executed, it is not big but it damages the motor. Therefore, the cause of overload must be removed after the first overload shutdown so that shutdown does not occur frequently.

1.4.5. Overload Protection Function

Using Overload protection function, we can protect motor damage from overload condition.
Overload protection function is being activated from the factory. When it is activated, motor power will be cut off in case of overload condition to protect the servo actuator

The easiest way to set(activate/inactivate) Overload protection function is to connect servo with Servo Manager Software using IR-USB01 PC USB interface. Go to "Shutdown Alarm Setting” and simply click(activate) "Overload Error".

Another method to set Overload protection is to use a Command packet. You can send "Store data" command to the address(0X12) which is the address for Alarm Shutdown. Set bit 5 (see below) for Overload error from to "1"(Overload activation), then send "Store data" command to the servo motor. Servo force will be cut off under overload condition if the bit is set at "1".(1= Overload protection activation / 0=Inactivation)

Error	bit
NONE	7
NONE	6
NONE	4
NONE	3
NONE	2
NONE	1
Input Voltage Error	0

Refer to below example for"Store Data" command.

Command Packet

HEADER	ID	Size	Command	Factor #1 Address	Factor #2 Data	Checksum
0xFFFFFF	0x00	0x04	0xF3	0x12	0x20	0xD6

Caution - Use within Rated Load

For proper performance and better lifespan of mightyZAP, it is strongly requested to use it within the rated load range.

1.5. Force Off

Force Off Function

• After the servo actuator moves to the designated position, the operation stops unless there is an external force that causes the position value change. If the position value of the actuator is continuously changed due to vibration or external force, the actuator is operated continuously without rest to stick to the designated position value, which affects the lifespan of the motor.
• In this case, if the Force Off function is properly utilized, the motor power can be released to allow the motor to rest while maintaining its position with mechanical friction (Mechanical Self Lock function). Even when it is necessary to keep the position for a relatively long time after reaching a certain position, shutting off the power of the motor using the Force off parameter as an added safety function helps to manage the lifespan of the motor.
• Under force off condition, communication is still alive while motor power is off, so servo will move again when servo gets new position command without giving “Force ON” command.
• Force Off feature can be available for the actuator having “Mechanical self-lock” feature. Please see the chart below to see availability. (Below chart shows self-lock force of 27mm stroke mightyZAP only. Refer to the separate specification for 40/53/90mm stroke version’s Self lock force.)

Rated Load Spec	Mechanical Self-Lock
10-20N	NOT Available
27-100N	Available

For Force Off, send 0x00 as a "Store data" command to the address(0X80) which is the address for Force ON/OFF. (For Force ON, send 0x01)

Refer to below example for "Store Data" command.

Command Packet

HEADER	ID	Size	Command	Factor #1 Address	Factor #2 Data	Checksum
0xFFFFFF	0x00	0x04	0xF3	0x80	0x00	0x88

TIP

Under Force Off status, if user send "Goal Position" command, it is not necessary to send Force ON packet additionally because "Goal Position" command already includes "Force On" packet in it.

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2. Basic Information

2.1. Component

• #3 M3 nut can be used to fix the hinge and hinge base. Also, M3 nut should be used between rod-end nut and rod-end tip as a stopper as shown on the picture.

2.2. Specification

2.2.1. 12Lf Series Specifications

Rated Load	Stroke	Communication(RS-485)	Communication(TTL/PWM)	Rated Load/ Max Speed(No Load)	Stall Force at Current (1.6A/800mA/100mA)	Mechanical Self Lock (Z Axis Use)	Lead Screw / Gear Ratio / Gear Type
10N	40mm	12Lf-10F-40	12Lf-10PT-40	10N / 110mm/s	60N / 40N / 10N	No (Pay attention to application)	Lead Angle 20° / 10:1  / Engineering Plastic Gears
	53mm	12Lf-10F-53	12Lf-10PT-53
	90mm	12Lf-10F-90	12Lf-10PT-90
12N	27mm	12Lf-12F-27	12Lf-12PT-27	12N / 110mm/s	100N / 60N / 8N
17N	40mm	12Lf-17F-40	12Lf-17PT-40	17N / 80mm/s	100N / 60N / 8N		Lead Angle 15° / 10:1  / Engineering Plastic Gears
	53mm	12Lf-17F-53	12Lf-17PT-53
	90mm	12Lf-17F-90	12Lf-17PT-90
20N	27mm	12Lf-20F-27	12Lf-20PT-27	20N / 80mm/s	120N / 72N / 9.6N
27N	40mm	12Lf-27F-40	12Lf-27PT-40	27N / 28mm/s	160N / 96N / 12.8N	Yes (Applicable)	Lead Angle 5° / 10:1  / Engineering Plastic Gears
	53mm	12Lf-27F-53	12Lf-27PT-53
	90mm	12Lf-27F-90	12Lf-27PT-90
35N	27mm	12Lf-35F-27	12Lf-35PT-27	35N / 28mm/s	210N / 126N / 16.8N
42N	40mm	12Lf-42F-40	12Lf-42PT-40	42N / 15mm/s	240N / 144N / 19.2N		Lead Angle 5° / 20:1  / Metal Gear
	53mm	12Lf-42F-53	12Lf-42PT-53
55N	27mm	12Lf-55F-27	12Lf-55PT-27	55N / 15mm/s	300N / 180N / 24N
78N	40mm	12Lf-78F-40	12Lf-78PT-40	78N / 7.7mm/s	420N / 252N / 33.6N		Lead Angle 5° / 50:1  / Metal Gears
	53mm	12Lf-78F-53	12Lf-78PT-53
100N	27mm	12Lf-100F-27	12Lf-100PT-27	100N / 7.7mm/s	600N / 360N / 48N

2.2.2. 12Lf Series Common Specifications

Item			Value
Repeatability	27mm / 40mm		30μm (0.03mm)
	53mm		40μm (0.04mm)
	90mm		50μm (0.05mm)
Mechanical Backlash			0.03mm (30μm)
Rod Type			Metal Alloy Rod
Motor Type			Coreless Motor
Rated Voltage			12V
Motor Watt			3.5W
Recommended Duty Cycle	At Rated Load		Max 50%
	At Max Applicable Load		Max 20%
Current Accuracy			±15% at Over 50mA
Position Sensor			10KΩ linear Potentiometer
Input Voltage Range			7 ~ 13V
Current Consumption	Idle		20mA
	Rated		280mA
	Stall	Default	800mA
		MAX	1.6A
Audible Noise			50db at 1m
LED Indication			Two Errors Indications (Input voltage, Overload)
Pulse Signal / Pulse Range			PWM (PT version, R/C Hobby Signal) 900μs(Retracted)-1500μs(Center)-2100μs (Extended)
Data Communication / Protocol			RS-485 or TTL(PT version) / IR Robot open protocol
Ingress Protection			IP-54 (Dust & Water Tight)
Size / Weight	27mm		57.5(L)x29.9(W)x15(H)mm / 49~52g
	40mm		86.9(L)x36(W)x18(H)mm / 96~99g
	53mm		111.5(L)x36(W)x18(H)mm / 124~127g
	90mm		151.5(L)x36(W)x18(H)mm / 177g
Operating Temperature			-10℃ ~ 60℃
Wire Harness			TTL(PT version) :  Molex to Molex Type (Molex 50-37-5033, 3pins) / 200mm length, 0.08×60(22AWG) <br> or RS485(F version) : Molex to Molex Type (Molex 0510650400, 4pins) / 200mm length, 0.08×60(22AWG)

• Design and Specification can be changed without prior notice for further improvement.

3. Application

3.1. Factory Automation

• Better Replacement of Pneumatic Cylinder
• Real-Time Automatic Width Adjustment Conveyer
• Real-Time Automatic Product Alignment (Up/Down or Left/Right)
• Automatic Value Control (oil or water)
• Automatic Dispensing with Syringe
• Automatic Clamping System
• Fitting or Adjusting Distance
• Pick & Place
• In & out / Extension & retraction
• Open & Closing (On-Off )
• Change of Direction
• Hexapod/Tripod movement

3.2. Production & Test JIGs

• Hole Punching Jig
• Hole Inspection Jig
• Switch Inspection Jig
• Touch Panel Inspection Jig
• PC Board Testing Jig

3.3. Robotics

• Robot Joints
• Robot Grippers
• Linear Control Parts of Surgical Robot

3.4. UAV / Professional Drone

• Fixed wing (Aileron/Elevator/Throttle/Flap/Air Brake/ Rudder/ Throttle)
• Helicopter (Swash Plate Control/Rudder)
• Multicopter (Retract, Dropping Device)
• Linear control parts for Military products
• Pan/Tilt Camera control

3.5. Medical / Lab Equipment

• Linear position control for Medical Devices (HIFU, etc)
• Camera or Laser Focusing Control
• Laboratory Test Equipment

3.6. Education / Hobby

• 3D Printer
• Arduino or Raspberry Pie Control
• Maker's DIY Project

4. Servo Control

4.1. Circuit Connection

mightyZAP(12Lf-xx-xx) supports both data communication (Half Duplux TTL) as well as simple pulse(PWM) control. For the control under data communication, UART signal of main board should be converted into Half Duplex Type signal. TTL Conversion circuit will be as below.

4.1.1. TTL/PWM (3Pin Connector-Model 12Lfxx-xx-xx Series)

The direction of data signal for TxD and RxD of TTL level will be determined according to the level of direction_port as below. - The level of "direction_port" is LOW :Data signal will be inputted to RxD. - The level of "direction_port" is HIGH :TxD signal will be outputted as Data. ※ Both GNDs between actuator and controller should be connected as above diagram.

NOTE

• For PWM control, please connect PWM signal(3~5V) to the Data pin above. (GND,VDD are same as above)
• In case of using PWM communication, position control is possible, but feedback data such as the current position value cannot be received, and serial daisy chain connection is not supported since data communication is not supported.
• Feedback data reception and Daisy chain connection are possible by TTL or RS-485 communication.

4.1.2. RS-485(4Pin Connector - Model 12Lf-xx-xx Series)

Model 12Lfxx-xx-xx Series uses RS-485 communication. Pin map and Conversion circuit will be as below.

PIN NUMBER(COLOR)	PIN NAME	FUNCTION(RS485)
1(Yellow)	D-	RS485 –
2(White)	D+	RS485 +
3(Red)	VCC	Power +
4(Black)	GND	Power -

※ If the power is supplied from outside, you can connect to 485 D+, 485 D- only.

You can convert TX and RX mode by controlling “Direction_Port pin” in above circuit. - The level of "direction_port" is LOW : Data signal will be inputted to RxD. - The level of "direction_port" is HIGH : TxD signal will be outputted as Data ※ Both GNDs between actuator and controller should be connected as above diagram.

4.2. Communication

mightyZAP and your main controller will communicate by exchanging data packet. The sorts of packet are Command packet (Main controller to mightyZAP) and Feedback packet(mightyZAP to your main controller)

4.2.1. Communication specification

• 2 Mode in One (Pulse / Data Mode Auto-Switching) mightyZAP 12Lf-xxPT-xx series will automatically recognize the input signal between data mode(TTL) and pulse mode(PWM).
• Data Mode (TTL/RS-485) Asynchronous Serial communication (8 bit, 1 Stop bit, None Parity)

Item	Spec
Structure	Half-duplex UART
Baud Rate	57600bps(default)
Data Size	8bit
Parity	non-parity
Stop Bit	One bit

CAUTION

• mightyZAP uses half duplex communication, and need to put proper delay time to prevent communication error.
• Recommendable delay time is 5msec for data write, 10msec for data read.
• Otherwise, there can be communication collision and motor failure.
• Above delay time is not minimum, but proper delay time for safety.

• PWM Pulse Mode PM(Pulse Position Modulation) Compatible [ Radio-Control Servo Pulse Mode] (900us(Retracted)~1500 us(Center)~2100 us(Fully Extended). Under PWM mode, position command available without feedback data.

  ※ Short stroke : Retract stroke / Long stroke : Extend stroke

NOTE

• Since PWM control is vulnerable to noise, it is highly recommended to control with a saturation-type PWM signal (continuous PWM) rather than a single PWM signal, so that it does not break at a specific frequency. Recommended frequency is 50Hz(20ms).
• In case of using PWM communication, position control is possible, but feedback data such as the present position value cannot be received, and serial daisy chain connection is not supported since data communication is not supported. Feedback data reception and Daisy chain connection are possible by TTL or RS-485 communication.
• Alternatively, PWM control is possible in the following way. Frequency 50Hz / Duty rate 4.5% ~ 10.5%. (Control by 0.05% unit)

4.2.2. Data specification

Data range is basically determined as below in both Data and Pulse modes.

Rod Stroke	Data Mode	Pulse Mode
Short (Retracting) Stroke	0	900us
Half Stroke	2047	1500us
Long (Extending) Stroke	4095	2100us

TIP

For 27mm stroke mightyAP, long stroke limit is set at 27mm, but user is able to extend the long stroke to max.30mm. Data value for 27mm stroke is 3686. (for better mechanical stability against lateral load, 27mm is recommended.)

4.2.3. Daisy-Chain Connection

After receiving Command Packet at multiple qty of mightyZAPs, the servo whose ID is N will be operated only. (Only N ID servo will send Feedback packet and execute Command.)

CAUTION - Unique ID

• Each mightyZAP servo must have an individual ID to prevent interference between same IDs. Therefore, you need to set individual IDs for each servo in the network node.
• User may assign 253 different IDs and connect 253pcs servos in serial via TTL protocol. For RS-485 protocol, 253 IDs can be assigned, but available serial connection is up to 32pcs servo motors due to RS-485 node regulation.
• As factory default ID is 0, so please assign different, individual IDs for each actuator from ID0~253 for daisy chain connection.

4.3. Data Map

4.3.1. IR Protocol

Memory using data (Non-volatile)

• Data to be saved in non-volatile memory which maintains data even after power OFF/ON.
• All data will be reset to default value when Factory Reset command is executed.

Address	Name	Description	Access	Default
0 (0x00)	Model Number(L)	Lower byte of Model number	R
1 (0x01)	Model Number(H)	High byte of Model number	R
2 (0x02)	Version of Firmware	Firmware version info	R	-
3 (0x03)	ID	Servo ID	RW	0 (0x00)
4 (0x04)	Baud Rate	Communication Speed	RW	32 (0x20)
6 (0x06)	Short Stroke Limit(L)	Lower byte of Short Stroke Limit	RW	0 (0x00)
7 (0x07)	Short Stroke Limit(H)	High byte of Short Stroke Limit	RW	0 (0x00)
8 (0x08)	Long Stroke Limit(L)	Lower byte of Long Stroke Limit	RW	102 (0x66)
9 (0x09)	Long Stroke Limit(H)	High byte of Long Stroke Limit	RW	14 (0x0E)
10 (00x0A)	Protocol Type	Comm. Protocol (MODBUS RTU or  IR Open)	RW	0x01 (IRPROTOCOL)
12 (0x0C)	the Lowest Limit Voltage	Lowest Voltage Limit	R	Each SPEC
13 (0x0D)	the Highest Limit Voltage	Highest Limit Voltage	R	Each SPEC
14 (0x0E)	Motor Operating Rate(L)	Lower byte of Motor Operating Rate	RW	255 (0xFF)
15 (0x0F)	Motor Operating Rate (H)	High byte of Motor Operating Rate	RW	3 (0x03)
16 (0x10)	Feedback Return Mode	Feedback Return Mode	RW	1 (0x01)
17 (0x11)	Alarm LED	Alarm LED Function	RW	33 (0x21)
18 (0x12)	Alarm Shutdown	Alarm Shutdown Function	RW	33(0x21)
19 (0x13)	Start Compliance Margin	Start Compliance Margin	RW	Each SPEC
20 (0x14)	End Compliance Margin	End Compliance Margin	RW	Each SPEC
21 (0x15)	Speed Limit(L)	Lower byte of average motor speed limit	RW	255(0xFF)
22 (0x16)	Speed Limit(H)	High byte of average motor speed limit	RW	3(0x03)
24 (0x18)	Calibration Short Stroke (L)	Lower byte of Calibration Short Stroke	R	0 (0x00)
25 (0x19)	Calibration Short Stroke (H)	High byte of Calibration Short Stroke	R	0 (0x00)
26 (0x1A)	Calibration Long Stroke (L)	Lower byte of Calibration Long Stroke	R	255 (0xFF)
27 (0x1B)	Calibration Long Stroke (H)	High byte of Calibration Long Stroke	R	15 (0x0F)
33 (0x21)	Acceleration Ratio	Moving Acceleration Ratio	RW	Each SPEC
34 (0x22)	Deceleration Ratio	Moving Deceleration Ratio	RW	Each SPEC
35 (0x23)	Current I Gain	Current Integral Gain	RW	Each SPEC
36 (0x24)	Current P Gain	Current Proportional Gain	RW	Each SPEC
37 (0x25)	Speed D Gain	Derivative Gain	RW	Each SPEC
38 (0x26)	Speed I Gain	Integral Gain	RW	Each SPEC
39 (0x27)	Speed P Gain	Proportional Gain	RW	Each SPEC
46 (0x2E)	Min Position Calibration	Min Position Value Trim	RW	Each SPEC
47 (0x2F)	Max Position Calibration	Max Position Value Trim	RW	Each SPEC
52 (0x34)	Current Limit (L)	Lower Byte of Current Limit	RW	32 (0x20)
53 (0x35)	Current Limit (H)	High Byte of Current Limit	RW	3 (0x03)

Parameter Using Data (Volatile)

• All data to be reset to default value whenever power is On.

Address	Name	Description	Access	Default
128 (0x80)	Force ON/OFF	Force On/ Off	RW	1 (0x01)**
129 (0x81)	LED	LED On/Off	RW	0 (0x00)
134 (0x86)	Goal Position(L)	Low byte of Goal position value	RW	-
135 (0x87)	Goal Position(H)	High byte of Goal position value	RW	-
136 (0x88)	Goal Speed(L)	Low byte of Goal speed value	RW	Speed Limit
137 (0x89)	Goal Speed(H)	High byte of Goal speed value	RW	Speed Limit
138 (0x8a)	Goal Current(L)	Low byte of Goal curent value	RW	Current Limit
139 (0x8b)	Goal Current(H)”	High byte of Goal curent value	RW	Current Limit
140 (0x8C)	Present Position(L)	Low byte of present position value	R	-
141 (0x8D)	Present Position(H)	High byte of present position value	R	-
142 (0x8e)	Present Current (L)	Low byte of present Current	R	-
143 (0x8f)	Present Current (H)	High byte of present Current	R	-
144 (0x90)	Present Motor Operating Rate (L)	Low byte of present motor operating value	R	-
145 (0x91)	Present Motor Operating Rate (H)	High byte of present motor operating value	R	-
146 (0x92)	Present Voltage	Current voltage	R	-
150 (0x96)	Moving	Moving status	R	0 (0x00)

4.3.2 MODBUS RTU

• 산업 표준화 프로토콜인 Modbus RTU Protocol 을 사용한 제어 Data Map 입니다.
• 해당 모델은 Readd Single Register(0x03)와 Write Holding Register(0x06)만 사용 가능합니다.
• Reset명령 수행 시 모든 데이터는 Default값으로 설정되게 됩니다.

Memory using data (Non-volatile)

• Multi write function is not supported.
• All data will be reset to default value when Reset command is executed.

Address	addr	Name	Access	Default	MIN	MAX
40001	0x0000	Model Number	R	-
40002	0x0001	Version of Firmware	R	-
40003	0x0002	ID	RW	1	1	247
40004	0x0003	Baud Rate	RW	32(0x20)	16	128
40005	0x0004	Protocol Type (MODBUS RTU / IRROBOT)	RW	0	0	1
40006	0x0005	Short Stroke Limit	RW	0(0x0000)	0	4095
40007	0x0006	Long Stroke Limit	RW	Individual Spec	0	4095
40008	0x0007	Lowest Limit Voltage	R	70	-	-
40009	0x0008	Highest Limit Voltage	R	130	-	-
40010	0x0009	Alarm LED	RW	33	-	-
40011	0x000a	Alarm Shutdown	RW	33	-	-
40012	0x000b	Start Compliance Margin	RW	7	0	255
40013	0x000c	End Compliance Margin	RW	2	0	255
40014	0x000d	Speed Limit	RW	1023	0	1023
40015	0x000e	Current Limit	RW	800	0	1600
40016	0x000f	Calibration Short Stroke	R	Individual Spec	0	4095
40017	0x0010	Calibration Long Stroke	R	Individual Spec	0	4095
40018	0x0011	Acceleration Ratio	RW	Individual Spec	0	255
40019	0x0012	Deceleration Ratio	RW	Individual Spec	0	255
40020	0x0013	Current I Gain	RW	Individual Spec	0	255
40021	0x0014	Current P Gain	RW	Individual Spec	0	255
40022	0x0015	Speed D Gain	RW	Individual Spec	0	255
40023	0x0016	Speed I Gain	RW	Individual Spec	0	255
40024	0x0017	Speed P Gain	RW	Individual Spec	0	255
40025	0x0018	Min Stroke Position	RW	Individual Spec	0	255
40026	0x0019	Max Stroke Position	RW	Individual Spec	0	255

Parameter Using Data (Volatile)

• All data to be reset to default value whenever power is On.

Address	addr	Name	Access	Default	MIN	MAX
40051	0x0032	Force ON/OFF	RW	1	0	1
40052	0x0033	LED	RW	0	0	255
40053	0x0034	Goal Position	RW	-	0	4095
40054	0x0035	Goal Speed	RW	Speed Limit	0	1023
40055	0x0036	Goal Current	RW	Current Limit	0	1600
40056	0x0037	Present Position	R	-	0	4095
40057	0x0038	Present Current	R	-	0	1600
40058	0x0039	Present Motor Operating Rate	R	-	0	2048
40059	0x003a	Present Voltage	R	-	0	255
40060	0x003b	Moving	R	-	0	1
40061	0x003c	Hardware Error State	R	0	0	255

4.4. Data Description

WARNING

non-volatile memory area. If you change the data, communication may stop for a short time during saving process. Therefore, please be careful of frequent value changes during operation.

4.4.1. Model Number

The model number of MightyZAP "Read" only to discriminate & recognize concerned model

4.4.2. Version of Firmware

Check if current firmware is the latest version.

4.4.3. ID

ID to discriminate each servo. Different IDs should be assigned in Daisy-Chain system.

	Range	Broadcast	default
IR Protocol	0 ~ 253	254	0
Modbus RTU	1~247	0	1

4.4.4. Baudrate

• Determining communication speed. Default value is 57600bps
• Servo system MUST be rebooted to apply changed baud rate to the actuator.

Value	Baud Rate(bps)
16 (0x10)	115200
32 (0x20)	57600
48(0x30)	38400
64 (0x40)	19200
128 (0x80)	9600

NOTE

In old Firmware version 1.5 or lower, Baudrate 38400bps is not provided.

4.4.5. Stroke Limit (0~4095)

Stroke limit between Short Stroke (A) and Long Stroke (C) which is the max/min. value of Goal Position. If the Goal Position value is smaller than the Short Stroke Limit value or greater than the Long Stroke Limit value, Goal Position value is replaced with the Stroke Limit value.

(Range : 0 ~ 4095 )

4.4.6. Protocol type (Default : IR Protocol)

Select the communication protocol method.

Value	Protocol	Description
0 (0x00)	MODBUS RTU	Industrial RS485 Standard Communication Protocol ※Refer to the separate MODBUS Protocol user manual
1(0x01)	IR Protocol	IRROBOT Open Protocol

WARNING

In old Firmware version 1.5 or lower, only IR Protocol is provided. (MODBUS available from V2.0 or higher)

4.4.7. The Highest / Lowest Limit Voltage

Max/Min. value of input voltage (unit : 0.1V) According to input voltage, speed and force of actuator can be varied. For detailed info, please refer to the data sheet of each model.

Input Volt	Default Value
Lowest Voltage	7.0 [V]
Highest Voltage	13 [V]

• If higher voltage than 13V supplied, input voltage error will be triggered and motor power will be shutdown.

4.4.8. Motor Operating Rate (0~1023 / Default : 1023)

It represents the maximum operating rate of the motor and the maximum PWM value supplied to the motor. If it is set to less than 400, the motor may not operate. Please note that changing the Motor Operating Rate also changes the speed and stall force.

4.4.9. Feedback Return Mode

Feedback packet return mode after receipt of Command Packet

Mode	Feedback Packet Return or NOT
0	Do NOT sending Feedback packet for all Commands. (Except for Echo command)
1	Sending Feedback packet only for Load Data Command.
2	Sending Feedback packet for all Commands.

Note

Under Broadcast ID(0xFE) mode, feedback packet will NOT be sent regardless values of Feedback Return Mode.

4.4.10. Alarm LED (Default : 33)

If concerned bit is set as "1" when error occurs, error LED indication will be activated. (1 : activate, 0: deactivate)

Error	bit	LED Indicate
Overload Error	5	Red Blink
Input Voltage Error	0	Red Steadily ON

In case of Input Voltage Error, the alarm is immediately cleared when the error is resolved. In case of Overload Error, the alarm is not cleared even after overload condition is resolved, but can be cleared by rebooting the power or restarting the system.

4.4.11. Alarm Shutdown (Default : 33)

Force will be OFF if concerned bit is set as "1" when error occurs. (1 : activate, 0: deactivate)

Error	bit
Overload Error	5
Input Voltage Error	0

In case of Lowest Input Voltage Error, the motor will NOT be shut-down(force off). In case of Highest Input voltage Error and Overload Error, the motor will be shut-down)force off) and shut-down status will be cleared by rebooting the power or restarting the system.

TIP

Overload error / Input voltage error shutdown feature is activated from the factory. These can be disabled by user using mightyZAP manager software according to their wish, but please consider carefully to protect the motor

4.4.12. Compliance Margin

Start Compliance Margin(Long/Short)(Recommended margin value : 7)

• Minimum margin value for the servo actuator to start position movement.
• For example, if the compliance margin is 7 and the current position value is 400, motor start will be made when positional value between 407(400+7) and 393(400-7) is set.
• Likewise, when the positional change occurs by more than +/-7(out of 393~407) from the present position value due to physical external pressure or electrical noise, the motor starts to run to compensate position.
• For this reason, the larger this value means more stable operation without jittering even in the environment where the external pressure, electrical noise, or the clearance increases, but the sensitivity to drive to the desired position may be reduced. In other words, generally, increasing this value increases durability, and reducing it increases precision.
• This value must be equal to or greater than the "End compliance margin value" described below. Setting it to a lower value may cause an error.

End Compliance Margin (Recommended margin value : 4)

• Minimum margin value for the servo actuator to complete position movement.
• For example, if actuator is instructed to move to a position value of 400, and assuming that it cannot physically stop at a position value of 400 exactly due to software & mechanical clearance, acceleration, etc. of the servo, End compliance margin will be a criteria to judge if the positional command has been performed properly. If this value is set to 4 and the position command value is set to 400, actuator judges that positional movement has been made properly when it reaches within 396~404 range and then stop movement.
• If this value is increased for stable operation, you should not increase it beyond the "Start Compliance Margin” value which is described above, and if this value is decreased too much to increase the accuracy, it may bring adverse effect such as jitter.
• The smaller the End Compliance Margin, the more sensitive and better the positioning accuracy. However, if it is reduced below a certain value, the effect becomes insignificant.
• If the End Compliance Margin is increased, the operation becomes cleaner and more stable when the target position is reached. Especially, the faster the product, the better the effect. However, if it is too large, conversely, the precision may deteriorate.

4.4.13. Current Limit (0~1600 / Default : 800)

• It is the maximum current limit value of the motor (0~1600). In other words, the stall force is adjusted by controlling the stall current limit. (Stall force : maximum power of the motor.)
• The control value is set from 0 to 1600, and the control value of 1600 represents the maximum stall current - 1600mA. (Error range :+/-15%)
• The default set value is 800 (mA) from the factory to prevent unnecessary use of the maximum stall current in case of emergency, but guarantees the maximum speed at the rated load.
• As the Current Limit is set closer to the stall force, the maximum force that the motor can produce in an overload situation increases, but it may cause a shortening of motor lifespan.
• The Current Limit is a non-volatile parameter stored in memory. Thus, it is highly recommended to set the “Current Limit” value only at the initial setting. For frequent current changes during operation, please use the “Goal Current” command, which is a volatile parameter.
• When the non-volatile “Current Limit” value is changed, note that the volatile parameter “Goal Current” is also changed when power is reapplied.
• Actuator operation may be irregular or may not move in the low current setting (less than 200mA) depending on the deviation of internal mechanical resistance of each product.
• For the difference in stall force value according to the current setting, refer to the related graph in the data sheet.

Warning

non-volatile memory area. If you change the data, communication may stop for a short time during saving process. Therefore, please use volatile parameter “Goal Current” for frequent value changes during operation.

4.4.14. Speed Limit (0~1023 / Default : 1023)

• Average moving speed limit value of the motor (0~1023). When it is 0, the starting power is OFF, and when it is 1023, the maximum speed is achieved.
• Changing the Speed Limit does not affect the Force.
• However, if the speed limit is set too low, the response of the motor may be delayed or it may not be able to move.
• When the Speed Limit value is changed, the Goal Speed is also changed.

4.4.15. Calibration Stroke

• Calibration Short Stroke : Short Stroke calibration value, Short Stroke Calibration value which is set at the factory will be saved.
• Calibration Long Stroke : Long Stroke calibration value, Long Stroke Calibration value which is set at the factory will be saved.

4.4.16. Acceleration / Deceleration (0~255 / Default : Individual Spec)

• Indicates the acceleration/deceleration rate of the motor.
• Acceleration: The acceleration value when the motor starts moving. If the value is high, the motor accelerates rapidly. Conversely, if the value is low, smooth acceleration, but if it is too low, the motor may not move.
• Deceleration: The deceleration value when the motor reaches the position. If the value is high, it decelerates rapidly and may stop outside the goal position with a bounding phenomenon occurs that moves from the deviating position to the goal position. In this case, normal braking may not be achieved. If the deceleration is too low, the actuator becomes too slow and the time to reach the goal position may be delayed.

TIP

When correcting Acceleration / Deceleration, test after applying a small change value.

4.4.17. Current PI (0~255 / Default : Individual Spec)

• PI value for motor current control.
• If you apply a larger PI value than the set value, it may operate harshly against the error with the Goal Current.
• If you apply a smaller PI value than the set value, it may operate smoothly against the error with the Goal Current, but the error with the Goal Current value may appear large.

WARNING

Please test by applying from small change values.

4.4.18.Speed PID (0~255 / Default : Individual Spec)

• PID value for speed control of motor.
• If a PID value larger than the set value is applied, the motor may vibrate without being able to stop at the set position value due to overshoot or over-response state due to rough operation against the error between the goal speed and the current speed
• If a PI value smaller than the set value is applied, it operates smoothly in the error between the goal speed and the current speed, but the error between the goal speed value may appear large.

WARNING

Test from applying a small change value.

4.4.19. Min/Max Position Calibration (0~255 / Default : Individual Spec)

• Min Position: The position of the minimum stroke when the Goal Position value is ‘0’.
• Max Position: The maximum stroke position when the Goal Position value is ‘4095’.
• Unlike the Stroke Limit command, the range of the Goal Position value [0~4095] is not limited and the length of the actual used stroke is changed.
• Min/Max Position value of each actuator has a mechanical tolerance of ±0.5mm. So,

Parameter	Goal Position Range	Remark
Stroke Limit	Short Stroke Limit ~ Long Stroke Limit	No limit on the available stroke range, only limit G/P input range (0~4095)
Position Calibration	0 ~ 4095(Full range)	Input range (0~4095) is not limited, but the available stroke range may vary.

For example, if the Min Position Calibration value at Min Position 3.8mm of 12Lf-20F-27 is 5, increasing the Min Position Calibration value increases the Min Position value and the entire stroke range will be reduced as the Min Position increases.

4.4.20. Force ON/OFF (Default : 1 / Force ON)

• Setting for Force On and OFF ( 0 : OFF, 1 : ON)

value	Description
0	Cut off power to the motor and Force is OFF.
1	Power to be supplied to the motor and Force is ON.

TIP

migtyZAP keeps its position due to mechanical design even after motor power is off. For instance, mightyZAP having more than 27N rated load, rod sticks to its position firmly when motor power is off. So, in case servo motor needs to keep certain position (if mechanical frictional force is able to keep its position under power off condition against your load), apply FORCE OFF parameter. In this case, communication line is still alive and only motor power can be off which helps longer lifespan of the servo. Upon new positional command, servo will be FORCE on and do its next movement.

4.4.21. LED

• Control LED when there is no Error indication.

bit	Description
0	LED Disable ( All LEDs will be Off when it is 1)
1	RED LED Control
2	GREEN LED Control

4.4.22. Goal Position (0~4095)

• Goal position value which is desired position value to move. The goal position value will be affected by both short/long stroke limit. (i.e. move only to the stroke limit position even if the position command is out of the stroke limit range) .
• For the 27mm stroke product, the goal position value at 27mm is 3686 due to the long stroke limit setting. It can be extended to 30mm (4095) if desired.

4.4.23. Goal Speed (0~1023 / Default : 1023)

• Goal speed is the average moving speed value of motor (0 ~ 1023) and it is volatile memory parameter.
• When the servo motor power is applied or the Restart command is applied, the value of Speed Limit, which is a non-volatile parameter, is copied to Goal Speed.
• It reacts faster than the Speed Limit command and can be used to change the speed in real time during operation.
• When it is 0, the maneuverability is OFF and when it is 1023, it gives the maximum speed.
• Changing the Goal Speed does not affect the force.
• However, if the GoalSpeed setting is too low, the motor response may be slowed down or it may not be able to move.

4.4.23. Goal Current (0~1600 / Default : 800)

• It is the maximum current limit value of the motor (0~1600). In other words, the stall force is adjusted by controlling the stall current limit. (Stall force : maximum power of the motor.)
• Goal Current is functionally same as Current Limit which is a non-volatile parameter, but for frequent current setting changes during operation, use the Goal Current command, a volatile parameter for faster response and preventing communication failure.
• The control value is set from 0 to 1600, and the control value of 1600 represents the maximum stall current - 1600mA. (Error range :+/-15%)
• The default set value is 800 (mA) from the factory to prevent unnecessary use of the maximum stall current in case of emergency, but guarantees the maximum speed at the rated load.
• As the Goal Current is set closer to the stall force current, the maximum force that the motor can produce in an overload situation increases, but it may cause a shortening of motor lifespan.
• When the non-volatile “Current Limit” value is changed, note that the volatile parameter “Goal Current” is also changed when power is reapplied.
• Actuator operation may be irregular or may not move in the low current setting (less than 200mA) depending on the deviation of internal mechanical resistance of each product. So, please set the current to higher than 200mA for proper performance.
• For the difference in stall force value according to the current setting, refer to the related graph in the data sheet.

4.4.24. Goal Current (0~1600 / Default : 800)

• The maximum current limit value of the motor (0~1600). In other words, the stall force is adjusted by controlling the stall current limit. (Stall force : maximum power of the motor.)
• Goal Current is functionally same as Current Limit which is a non-volatile parameter, but for frequent current setting changes during operation, use the Goal Current command, a volatile parameter for faster response and preventing communication failure.
• The control value is set from 0 to 1600, and the control value of 1600 represents the maximum stall current - 1600mA. (Error range :+/-15%)
• The default set value is 800 (mA) from the factory to prevent unnecessary use of the maximum stall current in case of emergency, but guarantees the maximum speed at the rated load.
• As the Goal Current is set closer to the stall force current, the maximum force that the motor can produce in an overload situation increases, but it may cause a shortening of motor lifespan.
• When the non-volatile “Current Limit” value is changed, note that the volatile parameter “Goal Current” is also changed when power is reapplied.
• Actuator operation may be irregular or may not move in the low current setting (less than 200mA) depending on the deviation of internal mechanical resistance of each product. So please set the current to higher than 200mA for proper performance
• For the difference in stall force value according to the current setting, refer to the related graph in the data sheet

4.4.25. Present Position [0~4095]

• Current Position value.
• Range is between 0~4095, and even after the motor is stopped, the minute position change within the margin value can be made, and this is a normal operation.

4.4.26. Present Motor Operating Rate [0~2047]

• Current Motor operating rate value. It can be affected by Goal current, Goal speed, Acceleration/ Deceleration adjustment.
• To be shown in the range of 0~2047
• Value 0 indicates the motor is stopped.
• Between1~1023: Motor operating rate on short stoke direction (retract direction).
• Between 1024~2047: Motor operating rate on long stoke direction (extend direction).

4.4.27. Present Current [0~1600]

• Present motor Current value.
• To be displayed in the range of 0 ~ 1600.
• The value includes the error(+/-15%) of the actual current value. Please use it just for reference.

4.4.28. Present Voltage

• Current input voltage. The unit is 0.1V
• For instance, 74 means 7.4V, 120 means 12V

4.4.29. Moving

• Moving status

Value	Description
0	Goal Position command execution is completed. (Motor stop)
1	Goal Position command execution is under operation. (Motor moving)

5. Optional Accessories

5.1. Metal Bracket (IR-MB02/IR-MB03/IR-MB04)

• IR-MB02
  
• IR-MB03
  
• IR-MB04
  IR-MB02 is the LATERAL mounting bracket for 27mm stroke lineup only and MB04 is the VERTICAL bracket for 27mm stroke mightyZAP. For 41~90mm stroke lineup, they can be mounted via built-in mounting holes on the case. Or, if you wish more flexible mounting, you can use IR-MB03 for 40~90mm stroke versions. The drawing is open at our website, so you may make this bracket at their end.

5.2. PC USB Interface (IR-USB02)

USB Interface between mightyZAP and user’s PC. Through PC software, mightyZAP manager, user is able to control below.

• Parameter and Memory setting
• Motion test
• Voltage, temperature, present position, force monitoring
• System initialization and Firmware update

5.3. End-Bearing (IR-EB01)

Mount mightyZAP on applications using this end bearings for most optimal installation. Put it on the rod end(M3) and on the end of servo case(M2.5). Two end bearings (M3 & M2.5) to be packed in a set.

5.4. EZ Controller (IR-CT01)

• mightyZAP controller/tester for customers who do not have their own controller
• Arduino based simple operation
• Built-in basic control program, User programmable (Arduino example provided)
• Built-in position setting dials, position command button switches and position command slide
• Controllable through external switch or voltage level signal
• 6 x I/O pins for analog/digital sensor connection
• External communication terminal for Bluetooth or Zigbee communication

5.5. Raspberry Pi HAT (IR-STS02)

IR-STS02 is a Raspberry Pi HAT(Hardware Attached on Top) which is compatible with Raspberry Pi B3 or Raspberry Pi Zero. With TTL/RS-485/PWM communication interface, power connector and GPIO pins, user is able to control mightyZAP on Raspberry Pie. API and Library can be downloaded from our web.

5.6. Extension Wire (IR-EW01~10)

Optional extension wires for applications which need longer wire harness.

• IR-EW01 :Extension wire - 3pin TTL 1000mm
• IR-EW02 :Extension wire - 3pin TTL 2000mm
• IR-EW03 :Extension wire - 4pin RS-485 2000mm
• IR-EW04 :Extension wire - 4pin RS-485 4000mm
• IR-EW08 :Extension wire - 3pin TTL 500mm
• IR-EW09 :Extension wire - 4pin RS-485 500mm
• IR-EW10 :Extension wire - 4pin RS-485 1000mm Above extension wires are NOT shielded wires. For the customer’s application having considerable electrical noise, please use shielded wires. Make shielded wires and we are selling optional Molex connector housings and terminals for it.

5.7. Rod End Tips (IR-GT01)

The IR-GT01 Rod-End Grip tip is an accessory that prevents physical damage to the application object by attaching a grip tip with a soft pad onto the rod-end of mightyZAP. For example, by attaching a rubber/silicone pad to the flat grip tip, it can be used to push or touch an object that is easy to be scratched or damaged, or to hold or lift an object using the frictional force of the silicone.

For more information for all available accessories, please visit our website – www.mightyzap.com

6. Warranty Service

6.1. Warranty & Service

The warranty period of mightyZAP is 1 year from the date of purchasing the goods. Please prepare some evidence showing the date of purchase and contact your product supplier or IR Robot. Warranty service will not cover the malfunctions of product which are derived from customer's abuse, mistake, or carelessness (including normal wearing of gear train, tear of wire harness and motor burnt-out). Please kindly note that all service should be processed by designated engineers and voluntary disassembly or maintenance may void warranty.

IR Robot Customer Service Team : Tel : +82- 070-7600-9466 Address : (ZIP 14502) 1303, Bucheon Techno Park 401, Pyeongcheon-Ro 655, Wonmi-Gu, Gyeonggi-Do, Korea. E-mail : cs@irrobot.com

Thank you.