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1. 4 75 120 7mm CUSTOMER MTG 5 00 127 0mm d 0 75 19 1 CUSTOMER MTG 2 6 6410 Installation and Hardware Reference Manual Rev E Mounting Your installation should meet the following guidelines guidelines Vertical orientation for the unit Flat solid surface capable of supporting the approximate 1 0 lb weight 0 5 kg mass of the unit Free of excessive vibration or shock Minimum unobstructed space of 4 inches 10 cm above and below the unit Maximum ambient temperature of 50 C and maximum 6410 chassis temperature of 60 S 7 2 5 Connecting to the 6410 Introduction The three input output I O connectors are Ji Signal connector J2 Power connector J3 Motor connector These inputs and outputs are shown on the following page 6410 Installation and Hardware Reference Manual RevE 2 7 Connection diagram UNREGULATED POWER SUPPLY 24VdeTO75Vde MT EARTH GROUND J1 USER S STEP 4 CONTROL DIR 2 ELECTRONICS ENABLE ENABLED COLLECTOR 4 NOT USED 5 STEP G DIR 7 I ENIBLE g ENABLED EMITTER P SCIENTIFIC 6410 J2 DC MINUS DC PLUS EARTH GROUND J3 4 MOTOR PHASE A 5 2 MOTOR PHASE A 15 MOTOR PHASE B KN 4 MOTOR PHASE B 15 5 MOTOR GRO2. 7 Connecting input output cables 2 1 Unpacking and Inspecting Unpacking 1 Remove the 6410 from the shipping carton Make sure all procedure packing materials are removed from the unit 2 Check the items against the packing list A label located inside the chassis of the unit identifies the unit by model number serial number and date code Inspection Inspect the unit for any physical damage that may have been procedure sustained during shipment If you find damage either concealed or obvious contact your buyer to make a claim with the shipper Do this within 10 days of receipt of the unit Storing the unit After inspection store the controller in a clean dry place The storage temperature must be between 55 degrees C and 70 degrees C To prevent damage during storage replace the unit in the original shipping carton 6410 Installation and Hardware Reference Manual Rev E 2 1 2 2 Installing and Using the 6410 Unit Safely Your responsibility AN Safety guidelines As the user or person applying this unit you are responsible for determining the suitability of this product for any application you intend In no event will Pacific Scientific Company be responsible or liable for indirect or consequential damage resulting from the misuse of this product Note Read this manual completely to effectively and safely operate the 6410 unit Warning The circuits in the 6410 drive are a potential sourc
3. TLP 621 5 DR 7 jk Y ENABLE 3 YES TTL e 2 m ENABLE 8 Y COLLECTOR 4 TLP 621 r o 5 ENABLED sy EMITTER 9 DRIVER ENABLED 250 NS MIN 1US MIN WITH STEP MOTION OCCURS STEP FILTER ENABLED ELIE ONTHISEDGE SETUP TIME e 50USMN 9 DIRECTION INPUT DIRECTION DATA MUST BE STABLE OVER THIS INTERVAL 2 22 6410 Installation and Hardware Reference Manual Rev E Higher voltage Voltages up to 30 volts can be used for the opto power input to interface the 6410 drive However a resistor must be put in series with the command inputs as shown below Values for several common supply voltages are given in the following table If the drives have open collector outputs pull up resistors R3 should be added as shown A typical value of R3 is 2 7K c Opto Supply to 6410 R1 R2 amp 12 Vdc 1 Kohm 15K D 15 Vde 1 5 Kohm 22 30 Vdc 3 3 Kohms 6 8 K USER S J1 6410 CONTROL STEPPER ELECTRONICS DRIVE OPTO SUPPLY o Seng 2601 SR STEP 6 44 Y gt D R1 DR 2 TLP 621 el DIR 7 x YD R2 ENABLE 3 NH ENABLE 8 K YD R2 6410 Installation and Hardware Reference Manual Rev E 2 23 Mating The J1 signal interface connector is 9 contact female D connector connector The mating cable connector is an I
4. Packing list 2 1 Parallel connection 2 13 2 16 Phase A A 2 11 Phase B B 2 11 Power supply considerations C 1 Motor 2 17 C 1 Power up 3 1 6410 Installation amp Hardware Reference Manual Rev E Problems Solutions 4 2 Ramp time A 3 Rectifier diode selection C 5 Regeneration C 7 Regulated supply C 10 Repair procedure 4 4 Return procedure 4 4 S1 switch location 3 2 setting 3 2 digital electronic damping set up 3 4 idle current reduction setup 3 5 step size set up 3 3 Safety 2 2 D 4 Series connection 2 13 2 16 Shock hazard reduction 2 9 Short circuit protection circuitry 1 2 Signal interface J1 connector 2 23 high voltage 2 23 input output table 2 20 interface diagram 2 22 opto supply 2 23 requirements A 2 Specifications A 1 STEP input 2 20 Step rate A 3 Step size set up 3 3 benefits 3 3 definition 3 3 Step size 1 3 A 2 Storage 2 1 System components 1 4 diagram 1 5 2 8 Temperature operating 2 4 A 4 storage 2 1 A 4 Testing 3 7 connections 3 7 procedure 3 7 signals 3 8 Troubleshooting 4 1 Unpacking 2 1 Ventilation 2 7 Voltage motor supply 1 1 2 17 A 1 C 1 W Warranty 1 5 Weight 2 7 A 5 l 4 6410 Installation amp Hardware Reference Manual Rev E
5. 16 to 28 AWG wire requirements However use 16 AWG or heavier for motor phase excitations For the motor cable use cable with two twisted pairs twisted at about 3 to 4 turns per inch 1 to 1 5 turns per centimeter for the motor phase excitations and a fifth wire for the case ground As an option the cable may be shielded to reduce radiated noise A single shield can be used around both phase excitations and the ground wire or each phase excitation twisted pair can be individually shielded as in the Pacific Scientific cables Connect shields to pin 5 of the mating connector 6410 Installation and Hardware Reference Manual Rev E 11 Cabling diagram J 3 motor Motor Case Gnd Green an 7 mm B Yellow To M Fin Motor B Red 7 mm A Orange 7mm A Black 7 mm Note The colors in the diagram follow the Pacific Scientific stepper motor cable color code Procedure 1 Strip the wires to 0 27 in 7mm 2 M SOOO 2 Attach wires to connector as indicated in the diagram To Drive Note Make sure the screws on the PCD connector are tightened down firmly on the wiring Do not solder the tips of the cables before insertion into the Caution connector Solder can contract and cause a loose connection over time 2 12 6410 Installation and Hardware Reference Manual Rev E Flying Lead The figure below shows the connections required be
6. C using two M4 or 6 32 screws inserted through the mounting slots on the back of the unit Use a thermal pad or grease if surface is irregular The maximum temperature of the 6410 s back plate must be held below 60 C The graph of 6410 power dissipation vs current setting shown below may be used to design the cooling plate or direct measurements can be taken during normal operations and adjustments made to plate area or airflow over the plate if necessary Make sure that any difference between the ambient temperature during the measurement and worst case ambient temperature is accounted for The 6410 can also be mounted with its side against the cooling plate using 4 M4 or 6 32 screws if mounting depth is of greater concern than panel area The same thermal considerations apply as for back mounting 1 25 1 875 2 5 3 125 3 75 4 375 5 0 AMPS RMS 6410 Installation and Hardware Reference Manual Rev E Heatsink mounting Panel mounting 6410 Installation and Hardware Reference Manual Rev E 2 5 If a cooling plate is not provided the optional heatsink available from Pacific Scientific can be mounted to the side of the 6410 and the combined unit mounted to a panel using the slots on the back of the 6410 as described above bookcase mounting With a minimum unobstructed space of four inches above and below the unit and cooling accomplished solely through convection no fan the 6410 can be run at 5 Amps RMS maximum for ambient temp
7. WARRANTY PATENT OR COPYRIGHT INFRINGEMENT SHALL NOT EXCEED THE PRICE SPECIFIED OF THE PRODUCTS OR PROGRAMS GIVING RISE TO THE CLAIM AND IN NO EVENT SHALL PACIFIC SCIENTIFIC BE LIABLE UNDER THESE WARRANTIES OR OTHERWISE EVEN IF PACIFIC SCIENTIFIC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION DAMAGE OR LOSS RESULTING FROM INABILITY TO USE THE PRODUCTS OR PROGRAMS INCREASED OPERATING COSTS RESULTING FROM A LOSS OF THE PRODUCTS OR PROGRAMS LOSS OF ANTICIPATED PROFITS OR OTHER SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES WHETHER SIMILAR OR DISSIMILAR OF ANY NATURE ARISING OR RESULTING FROM THE PURCHASE INSTALLATION REMOVAL REPAIR OPERATION USE OR BREAKDOWN OF THE PRODUCTS OR PROGRAMS OR ANY OTHER CAUSE WHATSOEVER INCLUDING NEGLIGENCE The foregoing shall also apply to Products Programs or parts for the same which have been repaired or replaced pursuant to such warranty and within the period of time in accordance with Pacific Scientific s date of warranty No person including any agent distributor or representative of Pacific Scientific is authorized to make any representation or warranty on behalf of Pacific Scientific concerning any Products or Programs manufactured by Pacific Scientific except to refer purchasers to this warranty Table of Contents 1 Overview of the 6410 1 1 11 6410 Definition a 2 ddr vex Mt t aah ne edet de b
8. equals 1 414 times the secondary rms voltage For example a 40 Vrms secondary will develop 1 414 40 56 6 PIV across the rectifier diodes To allow for line variation and spiking allow at least a 50 safety factor in the diode rating Therefore the PIV rating of the rectifier diodes should be at least twice the rated secondary rms voltage Current Rating Since each diode conducts only on alternate cycles the average diode current will be half the supply s average DC current load on the supply When power is first applied there is a surge of current to charge the capacitor s which must be less than the diode s peak one cycle surge current Ipsm rating Typically diodes are chosen with an average current rating of at least twice the average current load of the supply It is often advisable to select diodes with an even greater average current rating because they have lower thermal resistance between junction and case and hence ease heat sinking requirements It is good design practice to limit the maximum junction temperature to 125 C Testing should be done to insure the power on surge current is within the diode s rating 6410 Installation amp Hardware Reference Manual Rev E C 5 C 1 3 Capacitor Selection Ripple current rating Example The table below gives the minimum bus capacitance value for a single 6410 as a function of the current setting and bus voltage These values give approximately 1096 peak to peak
9. 3 4 Dimensions 2 6 Diode selection C 5 DIRECTION input 2 20 4 3 A 2 Drive circuit A 1 current stepsize see S1 switch features 1 2 Earth ground safety 2 2 Enabling the drive 3 7 External capacitor 2 17 Fuse selection C 7 Getting help 3 8 Grounding D 5 Help getting 3 8 Holding torque and idle current reduction 4 3 Humidity A 4 ICR see Idle current reduction Idle current reduction 1 3 3 5 benefits 3 5 definition 3 5 Input Output connections diagram 2 8 Inputs 2 7 Inspecting 2 1 Installation 2 2 2 4 Interface high voltage 2 23 typical 2 21 J3 Motor 2 9 cable making your own 2 11 connector 2 11 diagram 2 12 PacSci cable 2 9 procedure 2 12 safety 2 2 table 2 11 J2 Power 2 17 cable 2 19 diagram 2 18 procedure 2 19 table 2 17 J1 Signal interface 2 19 connector 2 24 diagram 2 22 I O table 2 20 Line transformer selection C 2 Maintenance 4 1 Manual how to use 1 4 Microstepping 1 2 3 3 6410 Installation amp Hardware Reference Manual Rev E Motor 2 3 cable making your own 2 11 connector 2 11 Flying Lead 2 13 MS connectors 2 15 Power Max 2 16 Terminal Board 2 14 PacSci cable 2 9 selection 2 3 Mounting 2 4 CE D 4 dimensions 2 6 D 8 guidelines 2 7 Multi axis 2 3 Noise pickup reduction 2 9 Optically isolated connections A 2 safety 2 2 Opto supply table 2 23 Order information B 1 Overview general 1 1
10. 801931109 Q318VN3 sb 10 0 S gt dasn LON SOINOH1O313 tud OHLNOO dals suasn annoys HLYVA ef T oprszOLopa ve H3MOd qaivino3uNn 6410 Installation amp Hardware Reference Manual Rev E Mechanical Outline CLEARANCE FOR M4 4 30 109 2mm or 6 32 SCREW gt 4 1 10 27 9mm ox 1 50 38 1mm A e 4 75 120 7mm b CUSTOMER MTG 5 00 127 0mm e P ji nan Y 2 75 som 0 75 19 1mm CUSTOMER MTG OPTIONAL SIDE MTG D 8 6410 Installation amp Hardware Reference Manual RevE Address 4 4 B 2 Applications 1 4 Bipolar chopper drive 1 2 Cable CE D 5 J3 2 12 J2 2 19 Capacitor external 2 17 motor selection C 6 Chopper frequency 1 CE installation D 1 test set up D 3 Clamping circuit C 9 Cleaning unit 4 1 Components system 1 4 2 3 Connections motor 2 9 parallel 2 13 2 14 2 15 2 16 series 2 13 2 14 2 15 2 16 testing 3 7 Connectors A 5 J3 2 11 J1 2 23 6410 Installation amp Hardware Reference Manual RevE Index Current input 2 3 motor C 4 output 1 1 rating A 1 C 4 C 5 Damage 2 1 Date code 2 1 Declaration of Conformity D 2 Defective unit 4 4 Definition general drive 1 1 Digital electronic damping 1 2 3 4 benefits 3 4 definition
11. Power Supply 5 1 mA J1 9 e Note High 5 Vdc Low lt Vdc IMPORTANT NOTE If you suspect that the 6410 drive has been damaged DO NOT simply replace it with another and apply power Re check the power supply design and verify that it meets all requirements Improper supply design is the most common cause for damaged drives 4 2 6410 Installation and Hardware Reference Manual Rev E Corrective action table SYMPTOM CORRECTIVE ACTION Motor produces Ensure that the J6 5 6 jumper is out or if in that the enable input no torque Meter opto is driven with at least 3 mA read high Disconnect the motor cable and cycle the J2 power supply Off and On If the meter reads low check motor cable and motor for shorts across the windings or between the windings and the motor case Check that the J2 power supply voltage is gt 24 Volts and lt 75 Vdc If possible check with an oscilloscope to verify that this is true on a transient basis Motor produces Verify that DIP Switch S1 position 6 7 and 8 current select are no torque meter set correctly reads low Re check that the motor cable is wired correctly and properly plugged into the drive Motor produces Make sure that the STEP input is switching and meets specified torque but does electrical and timing requirements not turn Motor rotates in Check polarity of the DIRECTION input Also check that the the wrong DIRECTION input satisfi
12. can be pumped up when the motor and load are decelerated by the drive In effect the motor becomes a generator converting mechanical energy stored in the spinning motor and load inertia into electrical energy If the mechanical energy is less than the losses in the drive and motor the supply voltage does not increase If the mechanical energy is greater than these losses the supply voltage will increase be pumped up The mechanical energy of a spinning inertia is given by E 3 87 10 J S where E kinetic energy joules J inertia in oz in sec S speed in rpm Final voltage If this energy is converted to electrical energy in the form of charge on the bus capacitor s the voltage will be Vies vola s EN where V is the final voltage after energy transferred to capacitor s Vo is the initial voltage C is the total capacitance in farads E is the initial kinetic energy in joules 6410 Installation amp Hardware Reference Manual Rev E C 7 Example If an unloaded E34 motor rotor inertia 035 oz in sec is rotating at 1500 rpm the stored energy is 3 87 10 035 15002 3 0 joules If all this energy is transferred to a 6800 mf capacitor initially charged to 70 volts the voltage on the capacitor after the transfer is equal to 76 volts Note This exceeds the volt maximum specification of the 6410 drive In practice most or all the kinetic energy is dissipated in the motor win
13. connector Mating connector PCD ELVP03100 T 5 Signal 9 contact female D connector Mating connector ITT Cannon DE 9P with ITT Cannon DE110963 Hood and D20419 Clamp Kit 9 a Motor PCD ELVH0510 connector Mating connector PCD o ELVP05100 6410 Installation and Hardware Reference Manual Rev E A 5 Appendix B Ordering Information c 2 L o Background This appendix lists 6410 part numbers and gives information on ordering 6410 part number table Pacific Scientific Part Order Comment Stepper Drive 6410 Connector Kit 106 641000 01 9 pin D connector 5 pin PCD 3 pin PCD Installation and MA6410 MA6410 Hardware Manual Motor Cable SPC xxx 6410 represents length in feet for example SPC 005 is a cable 5 feet long For lengths over 50 feet contact Pacific Scientific The connectors are MS on the motor end and PCD on the drive end to connect to Pacific Scientific motors 6410 Installation amp Hardware Reference Manual RevE B 1 How to order Contact Pacific Scientific to order these parts Call 815 226 3100 from 8am to 6pm Eastern Standard Time Write Pacific Scientific Customer Support 4301 Kishwaukee Street Rockford IL 61105 Fax 815 226 3048 B 2 6410 Installation amp Hardware Reference Manual RevE Appendix C Power Supply Considerations C 1 Bridge Capacitor Power Supply The figure below sho
14. described in the Declaration of Conformity on the following page Note The information contained in this appendix supplements the material in the MA6410 Customer This appendix supplied with all 6410 series drives provides Responsibility detailed information on installation This appendix must be closely followed if EMC compliance is to be maintained It covers details such as mechanical mounting safety earth connections and motor wiring The 6410 s input voltage is provided by a user supplied power supply System harmonics and conducted emissions are dependent on the system chosen Therefore the machine builder is responsible to properly filter the installation thereby preventing unwanted conducted line noise EN 61800 3 also puts the responsibility of filtering on the machine builder For additional information please see the Assessment of Compatability section in EN 61800 3 6410 Installation amp Hardware Reference Manual Rev E D 1 CE Declaration of Conformity Pacific Scientific Motion Technology Division 110 Fordham Road Wilmington MA 01887 USA This is to certify that Declares that the product s Designation STEPPER DRIVE Type 6410 6415 6420 comply with the following relevant regulations CE Guideline 89 336 EMC Directive Applied harmonized standards EN 61800 3 19956 Manufacturer s Contact Peter Deneault Compliance Engineer Issued By Pa
15. p SCIENTIFIC AUTOMATION TECHNOLOGY GROUP MOTION TECHNOLOGY DIVISION 110 Fordham Road Wilmington MA 01887 978 988 9800 Fax 978 988 9940 Part MA6410 List Price 25 U S October 1998 RevE MA6410 6410 Drive Installation amp Hardware Reference Manual This document is copyrighted by Pacific Scientific Company It is supplied to the user with the understanding that it will not be reproduced duplicated or disclosed in whole or in part without the express written permission of Pacific Scientific Company Copyright 1995 1996 1998 WARRANTY AND LIMITATION OF LIABILITY Includes software provided by Pacific Scientific Pacific Scientific warrants its motors and controllers Product s to the original purchaser the Customer and in the case of original equipment manufacturers or distributors to their original consumer the Customer to be free from defects in material and workmanship and to be made in accordance with Customer s specifications which have been accepted in writing by Pacific Scientific In no event however shall Pacific Scientific be liable or have any responsibility under such warranty if the Products have been improperly stored installed used or maintained or if customer has permitted any unauthorized modifications adjustments and or repairs to such Products Pacific Scientific s obligation hereunder is limited solely to repairing or replacing at its option at its facto
16. the Programs to conform to Pacific Scientific s specifications manual PACIFIC SCIENTIFIC DOES NOT SEPARATELY WARRANT THE RESULTS OF ANY SUCH CORRECTION OR WARRANT THAT ANY OR ALL FAILURES OR ERRORS WILL BE CORRECTED OR WARRANT THAT THE FUNCTIONS CONTAINED IN PACIFIC SCIENTIFIC S PROGRAMS WILL MEET CUSTOMER S REQUIREMENTS OR WILL OPERATE IN THE COMBINATIONS SELECTED BY CUSTOMER This warranty for Programs is contingent upon proper use of the Programs and shall not apply to defects or failure due to 1 accident neglect or misuse ii failure of Customer s equipment iii the use of software or hardware not provided by Pacific Scientific iv unusual stress caused by Customer s equipment or v any party other than Pacific Scientific who modifies adjusts repairs adds to deletes from or services the Programs This warranty for Programs is valid for a period of ninety 90 days from the date Pacific Scientific first delivers the Programs to Customer THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXCEPT AS TO TITLE WHETHER EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR ANY PARTICULAR PURPOSE AND ARE IN LIEU OF ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF PACIFIC SCIENTIFIC PACIFIC SCIENTIFIC S MAXIMUM LIABILITY WITH RESPECT TO THESE WARRANTIES ARISING FROM ANY CAUSE WHATSOEVER INCLUDING WITHOUT LIMITATION BREACH OF CONTRACT NEGLIGENCE STRICT LIABILITY TORT
17. 0 400 800 1000 1600 2000 3200 5000 6400 10000 12800 25000 25600 50000 51200 See circuit diagram Section 2 5 3 Optically Isolated Inputs Input Min Input Current Max Input Current Max Reverse Voltage Opto ON Input to J1 9 J1 1 J1 6 Step 5 5 mA 10 mA 5 volts J1 2 J1 7 Direction 3 0 mA 4 5 mA 5 volts J1 3 J1 7 Enable 3 0 mA 4 5 mA 5 volts Signal output characteristics J 1 4 J 1 9 Enabled See circuit diagram Section 2 5 3 Optically isolated NPN transistor with open collector and open emitter Maximum low level voltage while sinking 2 mA 0 5 volts 6410 Installation and Hardware Reference Manual Rev E Maximum step 2 MHz with step filter disabled rate 500 KHz with step filter enabled Step Direction The figure below show the required timing relationship between timing the requirements STEP and DIRECTION inputs 3 250 NS MIN 105 MIN WITH STEP _ NS _ j STEP FILTER ENABLED SETUP TIME E 50 US MIN Wo VLLL DIRECTION DATA MUST BE STABLE OVER THIS INTERVAL Minimum ramp 50 milliseconds This restriction only applies with mid band time for step rate stability control circuit enabled Accel Decel Drive state 1 generator transition delay relative to input step 2 6410 Installation and Hardware Reference Manual Rev E A 3 With mid band stability control cir
18. 0 350 45 5 Vac 500 46 8 Vac The average current load of the 6410 is a function of the motor used as well as motor speed and torque To optimize the power supply design the supply current can be measured using a DC current meter when the motor is producing the highest shaft power If it is difficult to make this measurement assume the maximum average load current equals the selected phase current Thus if the DIP switch is set for 5 Amps RMS assume the maximum average power supply current is 5 amps The average transformer secondary current equals the sum of the average currents for all 6410s powered by the supply Because the transformer supplies pulses of current to charge the bus capacitor s on the other side of the diode bridge the rms current is higher than the average current The transformer should have a rated secondary rms current of at least 1 8 times the average current The transformer used to supply three 6410 drive modules each set for 5 Amps rms should have a rated secondary rms current of 1 8 5 5 5 27 amps or greater Note Jt is generally not advisable to significantly oversize the transformer because this will increase rectifier surge current during turn on as well as capacitor ripple current 6410 Installation amp Hardware Reference Manual Rev E C 1 2 Rectifier Diode Selection Voltage rating For the bridge rectifier configuration shown the peak inverse voltage PIV
19. C CARD EDGE HUM 1 SIDE VIEW 123 4 5 6 7 8 FACTORY DEFAULT POSITIONS SHOWN STEP SIZE SW1 POSITION MOTOR SW1 POSITION DEC CURRENT 2 CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED OPEN CLOSED OPEN CLOSED CLOSED OPEN OPEN OPEN CLOSED CLOSED OPEN CLOSED OPEN OPEN OPEN CLOSED OPEN OPEN OPEN IDLE T SW1 IDLE CURRENT JUMPER POSITION 5 REDUCTION DISABLED 0 1 SEC DELAY 0 05 SEC DELAY 1 0 SEC DELAY 3 2 6410 Installation and Hardware Reference Manual Rev E 3 1 1 Step Size Definition The step size sets the amount of rotation per input step Fifteen step sizes are available using Jumper J6 position 3 4 and DIP switch S1 positions 1 3 as shown For all Pacific Scientific stepper motors and all 1 8 step motors step size can be converted to steps per rotation using the following table Decimal Binary Full 200 Half 400 Half 400 1 4 800 1 5 1 000 1 8 1 600 1 10 2 000 1 16 3 200 o 1 25 5 000 1 32 6 400 1 50 10 000 1 64 12 800 1 125 25 000 1 128 25 600 2 1 250 50 000 1 256 51 200 Benefits Selecting a microstep size of 1 4 or smaller results in higher resolution smoother low speed operation ability to operate in low speed resonance regions 6410 Installation and Hardware Reference Manual Rev E 3 1 2 Digital Electronic Damping Control Definition Benefit Mid speed instability and the resulting lo
20. MAX BUSS MDA 10 FUSE TWISTED 2 8 2 1 ACIN 127 3 d J1 GROUND BUSS MDA 10 FUSE TWISTED 2p 2 1 3 e J1 e TO OTHER AXES MULTIPLE AXES Cable Use 16 AWG for the power supply cable Use cable twisted at requirements about 3 to 4 turns per inch 1 to 1 5 turns per centimeter 2 18 6410 Installation and Hardware Reference Manual Rev E Cable diagram J 2 power cable Green Earth Ground White DC 3 S 7 Black DC 1 Strip the wires 0 27 inch 7mm 2 Attach the wires to the connector as indicated in the diagram Note Make sure the screws on the PCD connector are tightened down firmly on the wiring A Caution 7 Do not solder the tips of the cables going into the PCD Cow eX connector This can result in a loose connection 2 5 3 J1 Signal Interface Connection Introduction The J1 signal interface accepts step direction and enable signals from an indexer or other source and outputs an enabled signal which indicates the 6410 is applying current to the motor windings 6410 Installation and Hardware Reference Manual Rev E J1 signal table Note All inputs and outputs are optically isolated Input Output Pin Explanation STEP J1 1 Input used to command motor rotation See figure at the end of t
21. S USER S STEP 4 6410 EARTH GROUND CONTROL 5 ELECTRONICS ENABLE J3 ENABLED COLLECTOR 4 D 1 uoron puase a 5 INTERFACE MOTOR PHASE A amp STEP 6 2 ROWED 7 MOTOR PHASE B N ENABLE g 4 MOIORPHASEB 8 ENABLED EMITTER TWO PHASE CHASSIS 5 MOTOR GROUND STEPPER MOTOR SYSTEM MOTOR EARTH MS CONNECTOR GROUND Note Your installation may vary from this configuration 1 3 How to Use this Manual This manual contains information and procedures to install setup and troubleshoot the 6410 stepper motor drive The most effective way to use this manual is to follow the installation and power up instructions contained in Chapter 2 and Chapter 3 6410 Installation amp Hardware Reference Manual Rev E 1 5 1 4 Warranty The Pacific Scientific 6410 drives have a two year warranty against defects in material and assembly Products that have been modified by the customer physically mishandled or otherwise abused through miswiring incorrect switch settings and so on are exempt from the warranty plan 6410 Installation amp Hardware Reference Manual RevE 2 Installing the 6410 In this chapter This chapter explains how to install the 6410 stepper motor drive Topics covered are Unpacking and inspecting the 6410 Installing and using the 6410 unit safely Selecting other system components Mounting the 6410 in your installation S
22. TT Cannon DE 9P with ITT Cannon DE110963 Hood and D20419 Clamp Kit 2 24 6410 Installation and Hardware Reference Manual Rev E 3 Powering Up the 6410 Drive In this chapter This chapter explains how to power up the 6410 drive after installation Topics covered are Setting up functions using switch S1 and Jumper J6 Testing the installation This section is intended to familiarize the 6410 user with the hardware adjustments and settings required to power up and operate the 6410 drive 3 1 Setting Switch S1 amp J umper J 6 Introduction DIP switch S1 and Jumper J6 set the following Step size Motor current level Q D E gt Digital electronic damping ON OFF 41 current reduction Enable sense Step filter response time 6410 Installation and Hardware Reference Manual Rev E 3 1 Location of 51 ENABLE SENSE JUMPER DEC JUMPER SEE SW1 TABLE BELOW NS IN OPTO ON TO ENABLE IN SELECT DECIMAL STEP SIZES OUT OPTO OFF TO ENABLE OUT SELECT BINARY STEP SIZES FACTORY DEFAULTS 5 0 AMPS RMS IDLE T JUMPER STEP BW JUMPER STEPSIZE 1 25 SELECT IDLE CURRENT IN 500 KHz MAX STEP RATE 500 KHz MAX STEP RATE REDUCTION TIME OUT 2 MHz MAX STEP RATE IDLE CURRENT REDUCTION SEE TABLE BELOW ENABLED 0 1 SEC JUMPERS 1 2 3 4 amp 7 8 ay DIGITAL ELECTRONIC INSTALLED AT FACTORY DAMPING CONTROL ENABLED DRIVER ENABLED UNLESS ENABLE OPTO DRIVEN P
23. The polarity of the enable input can be changed using Jumper J6 position 5 6 With the jumper removed factory default the drive is enabled when the enable input is not driven and disabled when driven current flows in enable opto This allows the 6410 to be used with no connection to the enable input With the J6 5 6 jumper installed the enable input must be driven current in opto for the 6410 power stage to be enabled 3 1 6 Step Bandwidth Adjustment A digital filter can be enabled which reduces susceptibility to noise on the step input at the expense of a lower limit on maximum step frequency With Jumper J6 positions 1 2 installed factory default the filter is enabled and step pulses must have a minimum width of one microsecond Pulses less than 0 5 microseconds in width will be rejected With the filter disabled Jumper J6 position 1 2 removed step pulses must be a minimum of 0 25 microseconds wide Therefore the maximum step frequency is 500 KHz with the filter enabled and 2 MHz with the filter disabled 3 6 6410 Installation and Hardware Reference Manual Rev E lt 3 2 Testing the Installation Background The following procedure verifies that the 6410 is installed properly and that it was not damaged during shipment Procedure After installing the 6410 as described in Chapter 2 test your installation as follows Warning Perform this initial power up with the motor shaft disconnected from the load Improper wiring
24. UND SYSTEM MOTOR MS CONNECTOR TWO PHASE STEPPER MOTOR 6410 Installation and Hardware Reference Manual Rev E Wiring is application specific N Noise pickup reduction Shock hazard reduction Wiring sizes wiring practices and grounding shielding techniques described in the following section represent common wiring practices and should prove satisfactory in the majority of applications Caution Non standard applications local electrical codes special operating conditions and system configuration wiring needs take precedence over the information included here Therefore you may need to wire the drive differently then described here Use shielded and twisted cabling for the signal and power cables as described below This precaution reduces electrical noise Refer to section 2 2 for safety information that must be followed to reduce shock hazard 2 5 1 J 3 Motor Connections Introduction Pacific Scientific cable 6410 Installation and Hardware Reference Manual Rev E 2 9 The J3 motor cable connects the controller to the motor windings and motor case J3 utilizes a plug in screw terminal type connector to simplify assembly and allow quick connect and disconnect Pacific Scientific makes cables that connect directly from J3 to our system motors To order the cable from Pacific Scientific use the order number SPC xxx 6410 where is the length in feet one foot increme
25. b 1 1 1 2 Other System 1 4 1 3 How to Use this Manual 1 5 14 Waanty ooo Ren qno er amp Badge Dw Seg 1 5 2 Installing the 6410 2 1 2 1 Unpacking and Inspecting 2 1 2 2 Installing and Using 410 2 2 2 3 Selecting Other System Components 2 3 2 4 Mounting the 6410 Unit 2 4 2 5Connectingtothe6410 eA 2 7 2 5 1 J3 Motor 2 9 2 5 2 J2 Power Connector i s soo p Res 2 17 2 5 3 J1 Signal Interface Connector 2 20 3 Powering Up the 6410 Drive 3 1 3 1 Setting Switch S1 amp Jumper J6 llle 3 1 3 11 Step Size 2s esu omo uoo RR e E 3 3 3 12 Digital Electronic Damping Control 3 4 3 1 3 Idle Current 3 5 3 1 4 Setting Motor Current 3 6 3 1 5 Enable Sense Control SU 3 6 3 1 6 Step Bandwidth Adjustment _ 3 6 3 2 Testing the Installation ees 3 7 4 Maintaining Troubleshooting 4 1 4 1 Maintaining the 6410 Drive 0 0 4 1 4 2 Troubleshooting the 6410 Drive 4 1 6410 Installation amp Hardware Reference Manual RevE Appendix A Specifications A 1 Appendix B Ordering Information B 1 Appendix C Power Supply Considerations C 1 A
26. cific Scientific Motion Technology Division President William T Fejes Place Date Wilmington MA USA 10 29 98 Legally bindi 3 en Signature xs Z Mea D 2 6410 Installation amp Hardware Reference Manual RevE CE Test Set Up The 6420 was determined to be the noisiest configuration for the 64xx family Therefore it was used for all EMC testing Motor EE N32 HCHJ LNK NS 00 All mounting surfaces are free of paint Metal Plate Motor Cable SPC 020 6410 All other cables are in accordance with Chapter 2 of this manual All D Sub connectors have metallic hoods Wire to Earth Ground Rail 24 75 VDC AWG 3 0 or larger Power Supply S To AK 1 To Earth Ground rail 6410 Installation amp Hardware Reference Manual Rev E D 3 Safety Drive mounting Cable Routing In addition to the safety guidelines given in Section 2 2 observe the following Electronic drives contain electrostatic sensitive devices which can be damaged when handled improperly Qualified personnel must follow ESD protection measures For example wear grounded heel and wrist straps when contacting drive Follow IEC 536 2 and IEC 1140 for installation protection against electric shock Installation shall be performed in accordance with local electric codes local accident prevention rules and EN 61800 3 All covers shall be closed during operation Braided cable shields shou
27. close to the 6410 drive but it can be located near the power supply and connected to the 6410 with a twisted pair no longer than 3 feet in length The capacitor should have a 20KHz ripple current rating of at least the 6410 s current setting and a voltage rating of 1 3 times the nominal bus voltage A second precaution involves regenerated power see section C 1 5 Regulated supplies are usually not designed to absorb power This might cause their output voltage to rise during regeneration and lead to power supply and or 6410 damage The same considerations and solutions described in section C 1 5 apply 6410 Installation amp Hardware Reference Manual Rev E 6410 s powered by regulated supply shown The figure below illustrates powering the 6410 from a regulated supply where both an external capacitor and regenerated power dump circuit are required The recommended fusing is also REGULATED POWER SUPPLY EARTH SAFETY GROUND J2 3 2 1 6420 J2 3 FUSE EEDER RESISTOR nae TWISTED 2 BUS T MDA10 54K 75 VOLT 2W MAX OUF E NAP 6420 3 FEET MAX 6410 Installation amp Hardware Reference Manual Rev E Appendix D CE Installation Guide Introduction The information contained in this appendix applies to the 6410 ONLY The 6410 is designed for use within machines that require compliance with European Safety and EMC Directives The standards that the 6410 complies with are
28. connection is made within the 6410 between J2 1 and J2 3 Earth Ground J2 3 Connected to 6410 Case and J3 5 Motor Ground Connections between the 6410 and power supply are shown in the diagram on the following page A simple non regulated supply is used for this example DC and DC should be run from the power supply s capacitor to the 6410 as a twisted pair no longer than 3 feet in length shielding with the shield connected to earth ground can reduce noise emissions A Buss MDA 10 A slow blow fuse or equivalent should be included in the power supply between the rectifier and capacitor as shown IMPORTANT NOTE It is extremely important that the supply voltage never exceed 75 volts even on a transient basis This is one of the most common causes of drive failures Wiring inductance between the 6410 power input and the external capacitor is significant because a PWM chopper drive requires pulse currents Therefore it is extremely important that the two be connected by a twisted pair no longer than three feet in length S 7 Connection diagram pies 3 FEET MAX MDA 10 3 TWISTED 5 1 AC IN 3 e J1 EARTH AROUND SINGLE AXIS 3 FEET
29. cuit enabled at pulse frequencies less than 500 full steps sec delay is less than 500 usec At frequencies greater than 500 full steps sec delay is less than 270 of the input pulse period With mid band stability control circuit disabled delay is less than 10 usec at all step frequencies 7 G 5 o Environmental Operating Full rated current 0 to 50 C ambient air with or without cover Temperature provided chassis properly mounted so as not to exceed 60 C Storage 55 C to 70 C temperature Maximum chassis temperature Humidity Range Convection Cooling With optional heat sink Without heat sink 60 C Note For optimal thermal performance mount the 6410 chassis back or side to a cooling plate or heatsink Use a thermal pad or grease if surface is irregular A fan or idle current reduction may be employed to keep chassis below 60 C 10 to 90 non condensing 6410 not mounted on cooling plate Full rating 5 A at 25 C Ambient 2 5 A max at 45 C Ambient 2 5 A max at 25 C Ambient 1 25 A max at 45 Ambient See Figure on the following page for plot of drive power dissipation vs output current 6410 Installation and Hardware Reference Manual Rev E Figure 1 30 WATTS 25 20 0 625 1 25 1 875 2 5 3 125 3 75 4 375 5 0 AMPS RMS Mechanical Dimensions Refer to Section 2 4 Weight 1 0 Ib nominal Connectors Power Supply PCD ELVHO0310
30. dings or in the drive power circuitry so that voltage pump up is often not a problem However in systems running at high speeds and having large load inertia the voltage might be pumped up significantly and circuitry must be added to insure that the 75 volt limit is never exceeded Note Regeneration effects should be considered in the presence of high line conditions To find out if regenerative energy is a problem run the system while monitoring the supply voltage with a storage oscilloscope Alternatively a simple peak detector made form a diode and a capacitor can be attached to the bus and the peak voltage measured using a digital voltmeter Start the system with slow deceleration rates and monitor the motor power supply to see if the voltage rises during deceleration Slowly increase the deceleration rate shorten the deceleration time while monitoring the voltage If regeneration causes the supply voltage to exceed 75 Vdc peak a clamping circuit is required Note Be sure to consider the effect of high line voltage when evaluating this test 6410 Installation amp Hardware Reference Manual RevE C lamping If a clamp is required a power zener diode can be used as shown Circuit in the figure The maximum zener clamp voltage must not exceed 75 volts Caution If a clamp is required the transformer secondary voltage must be re checked to insure that the minimum clamp voltage is not exceeded under high line and low load co
31. e of severe electrical shock Follow the safety guidelines to avoid shock To avoid possible personal injury whenever you are working with the 6410 unit Do not operate the drive without the motor case tied to earth ground Note This is normally done by connecting the motor s case to J3 5 of the 6410 and connecting J2 3 of the 6410 to earth ground Do not make any connections to the internal circuitry The input and output signals are the only safe connection points Always remove power before making or removing connections from the unit Be careful of the J3 motor terminals when disconnected from the motor With the motor disconnected and power applied to the drive these terminals have high voltage present even with the motor disconnected Do not use the ENABLE input as a safety shutdown Always remove power to the drive for a safety shutdown 6410 Installation and Hardware Reference Manual Rev E OEE T 2 2 3 Selecting Other System Components Selecting an The 6410 drive requires STEP and DIRECTION inputs Select an indexer indexer that provides as a minimum these commands A compatible indexer will provide the capability to drive the input circuits shown in Section 2 5 3 For most applications that operate at speeds above 300 rpm an indexer that can ramp the step frequency is required Selecting a The 6410 is designed for use with Pacific Scientific s line of motor hybrid stepper motors or most o
32. eratures of 25 C or less and 2 5 Amps RMS maximum for ambient temperatures of 45 C or less Using a fan to blow air past the heatsink will increase the allowable current significantly It is always required that the 6410 s chassis temperature not exceed 60 C It is best to confirm this by direct measurement with a temperature probe during system operation Any difference between the ambient temperature during the measurement and the worst case should be added to the measured chassis temperature The resulting sum must be under 60 C If the 6410 is mounted to a panel with no cooling plate and no heat sink a minimum unobstructed space of four inches above and below and one inch between the side plate and any other object must be provided If cooling is accomplished solely through convection air flow no fan the unit can be run at 2 5 Amps RMS maximum if the ambient temperature is 25 C or less and 1 25 Amps RMS maximum if the ambient temperature is 45 C or less Again use of a fan to blow air past the side plate of the 6410 will increase the allowable current The same considerations given above for the optional heatsink apply S 7 Mounting When mounting the 6410 please refer to the dimensions below dimensions 4 30 109 2mm CLEARANCE FOR M4 6 32 SCREW r 1 10 27 9mm 1 YU COMP S NOT SHOWN 2 75 69 9mm OPTIONAL SIDE MT CLEARANCE FOR M4 or 6 32 SCREW fro 1 50 38 1mm
33. erence Manual RevE User adjustments using DIP switch 51 using plug on jumpers Motor current sets the motor phase current to 5 0 4 375 3 75 3 125 2 5 1 875 1 25 or 0 625 A rms Step size sets the amount of shaft rotation per step with the decimal jumper installed The settings are full half 1 5 1 10 1 25 1 50 1 125 and 1 250 steps per micro step This corresponds to 200 400 1000 2000 5000 10 000 25 000 and 50 000 micro steps per revolution with a standard 1 8 motor With the decimal jumper removed the settings are 1 2 1 4 1 8 1 16 1 32 1 64 1 128 and 1 256 steps per micro step This corresponds to 400 800 1600 3200 6400 12 800 25 600 and 51 200 micro steps per revolution Digital Electronic Damping control enables this patented feature which eliminates loss of torque and possible motor stalling conditions when operating at mid range speeds This instability is a phenomenon of the electronic magnetic and mechanical characteristics of a stepping motor system The compensation circuit damps mid range oscillations by advancing or delaying switching of the output current relative to the incoming pulse train Idle current reduction ICR enables or disables idle current reduction which reduces motor winding current by 50 of its rated value during motor dwell periods ICR begins 0 1 second after the last input step pulse occurs This delay can also be set to 0 05 seconds or 1 second u
34. es the specified electrical and timing direction requirements Reverse the A and A motor phases Motor does not Check that the step size setting of the drive is the same as the step reach expected size setting of the indexer position o a c m Verify that the motor does not stall If it does 1 Re check sizing calculations Be sure that the power supply voltage is high enough for the required torque vs speed curve 2 Use a finer step size to avoid low speed resonance problems 3 Enable Mid Band Instability Compensation S1 position 4 OFF Check that the STEP and DIRECTION Inputs satisfy all electrical and timing requirements 6410 Installation and Hardware Reference Manual Rev E 4 3 If the drive is defective Return procedure 1 If you cannot correct drive problem or if it is defective return it to Pacific Scientific for repair or replacement Call Pacific Scientific at 815 226 3100 from 8am to 6pm Eastern Standard Time to get a Returned Materials Authorization Number RMA Note Do not attempt to return the 6410 or any other equipment without a valid RMA Returns received without a valid RMA will not be accepted and will be returned to the sender 2 Pack the drive in its original shipping carton Pacific 3 Scientific is not responsible or liable for damage resulting from improper packaging or shipment Ship the drive to Pacific Scie
35. he peak bus voltage increases to 1 414 1 1 40 1 5 60 7 volts at rated transformer loading Load regulation must also be accounted for when selecting the transformer Transformers are designed to produce their specified secondary voltage when loaded by their rated current For currents less than rated the secondary voltage will increase Signal Transformer gives the following load regulation data for its line of rectifier transformers VA Rating Load Regulation 1 100 10 100 350 8 gt 500 5 or less This means that the secondary voltage of a 100 VA transformer will increase 10 over the specified voltage if the load current is reduced from rated current to zero Since the stepper drive s might sometimes be disabled the full regulation effect as well as maximum line voltage should be considered when selecting the transformer 1 The VA product is obtained by multiplying the specified secondary voltage Volts rms by the rated secondary current Amps rms For example a 24 Vac transformer with a rated secondary current of 1 Amp has a VA of 24 6410 Installation amp Hardware Reference Manual RevE C 3 Current Rating Example Based upon these considerations the table below gives the highest allowable rated secondary voltage when using a line with 10 voltage tolerance Transformer VA Maximum Rated Rating Secondary Voltage 1 100 44 7 Vac 10
36. he table for circuit and timing information DIR J1 2 Input that determines the direction of motor rotation If standard motor wiring is followed the motor will turn clockwise if the opto current is zero The sense of the DIR input can be reversed by reversing the connection of either but not both motor phase connectors i e switching A amp A OR B amp B Refer to the figure at the end of the table for timing and circuit information ENABLE J1 3 Input used to enable or disable the 6410 s power stage With the J6 5 6 jumper out factory default the power stage is enabled if the opto current is zero and disabled if the opto is driven Inserting the jumper reverses this functionality See figure at the end of the table for circuit information There is a delay of approximately 500 us after enabling the drive and the power stage becoming active Enabled Collector J1 4 Output Collector of transistor that is on when the 6410 s power stage is active See figure at the end of the table for circuit information J1 5 Not used STEP J1 6 Input used to command motor rotation See figure at the end of the table for circuit and timing information 6410 Installation and Hardware Reference Manual Rev E Table contd Input Output Pin Explanation DIR J1 7 Input that determines the direction of motor rotation If standard motor wiring
37. is followed the motor will turn clockwise if the opto current is zero The sense of the DIR input can be reversed by reversing the connection of either but not both motor phase connectors i e switching A amp A OR B amp B Refer to the figure at the end of the table for timing and circuit information ENABLE Input used to enable or disable the 6410 s power stage With the J6 5 6 jumper out factory default the power stage is enabled if the opto current is zero and disabled if the opto is driven Inserting the jumper reverses this functionality See figure at the end of the table for circuit information There is a delay of approximately 500 us after enabling the drive and the power stage becoming active Enabled Emitter Output Emitter of transistor that is on when the 6410 s power stage is active See figure at the end of the table for timing and circuit information Typical interface 6410 Installation and Hardware Reference Manual Rev E 2 21 The figure on the following page shows a typical interface between the user s electronics and the 6410 The TTL gates should have totem pole outputs and be capable of sinking at least 10 0 mA at 0 4 volts S 7 Interface diagram USER S 6410 CONTROL STEPPER ELECTRONICS DRIVE 45Vde o T I TLP 2601 a gene ls gt STEP 6 464 DIR 2
38. ld be connected to protective earth ground Mount the drive to a conductive surface of the machine chassis to ensure a good high frequency ground If the chassis is painted or coated with another nonconductive coating remove the coating from the mounting location prior to mounting the drive To avoid the risk of crosstalk motor and command I O cables should be kept away from sensitive signal cables such as telephone and intercommunication lines 6410 Installation amp Hardware Reference Manual RevE Cable shielding The following information is not required for CE compliance of a and grounding single axis installation When planning a multi axis installation or if extra high frequency noise reduction is required Pacific Scientific suggests e In addition to the cable requirements given in this manual the motor and signal interface cables should have a braided shield which can be grounded to reduce high frequency disturbances e The motor cable shield must be grounded near the drive with a suitable high frequency ground Such a ground connection is made by removing the cable s outer insulation to expose the braided shield then clamping the exposed braid to a conductive surface of the machine chassis If the chassis is painted or coated with another nonconductive coating remove the coating from the clamping location prior to clamping the shield It is important that the clamp chosen be conductive and provide a full 360 degree con
39. me can be set to 0 05 seconds 0 1 seconds or 1 0 second Current to both motor windings is reduced by one half The ICR function can be enabled disabled and the time delay between the last step command and current reduction can be set to 50 ms 0 1 seconds or 1 0 second using DIP switch S1 position 5 and Jumper J6 position 7 8 With the jumper installed factory default ICR is disabled when DIP Switch S1 position 5 is in the closed position and enabled with a delay of 0 1 second current is reduced by 5096 when no step command is received for 0 1 second when the switch is open With the jumper removed ICR is enabled and the delay can be set to 0 05 second or 1 0 second by placing DIP Switch S1 position 5 in the closed or open position respectively Note When ICR is active both the holding torque generated by the motor and the motor stiffness around the holding position are reduced by approximately 50 Q gt D x gt Benefits The ICR function Reduces motor and drive heating during stand by operation 6410 Installation and Hardware Reference Manual Rev E 3 5 3 1 4 Setting Motor Current Motor current can be set using DIP Switch S1 positions 6 7 and 8 as shown Current should be compatible with motor current ratings Note Power dissipation in the 6410 drive increases as the output current is increased so that more cooling is required at high motor currents 3 1 5 Enable Sense Control
40. n producing high back EMF rejection with low chopping ripple current Benefits include reduced heat dissipation low electric noise and improved current control during motor breaking Microstepping switch selectable full 1 2 1 5 1 10 1 25 1 50 1 125 and 1 250 step capability with decimal jumper installed and 1 2 1 4 1 8 1 16 1 32 1 64 1 128 and 1 256 with decimal jumper removed Digital Electronic Damping patented circuit eliminates torque and or motor stalling through mid speed region that is inherent in all open loop stepper applications Short circuit protection circuitry disables the drive if a short circuit occurs on the motor outputs The drive must be power cycled to clear fault MOSFET power devices allows chopper frequency of approximately 20 kHz eliminating acoustical noise often associated with choppers Optically isolated signal interface connection optical isolation is provided on the step direction and enable inputs in addition to the enabled output The use of optical isolation increases the options available for system grounding The source commanding the step and direction lines is not tied directly to the motor power supply ground allowing the system ground point for these signals to be made external to the unit UL Recognized 508C Type R File Number E 137798 This also complies with CSA Standard for Process Control Equipment C22 2 No 142 M1987 6410 Installation amp Hardware Ref
41. nditions when there is no regeneration Otherwise the zener might overheat and fail To determine the required diode power rating start with a 5W device and monitor the zener current with a current probe Power in watts is the average current in amps times the zener voltage Estimate the average current from the oscilloscope trace and compute the power Select a zener rated slightly higher than the measured power If the average power is too high to be conveniently dissipated in a zener diode the active voltage clamp circuit shown below can be used instead Power is dissipated in the 250 30W resistor if the Motor Power Supply voltage exceeds 75 volts Active clamp circuit MOTOR POWER SUPPLY A 12 22 AA 1K IRF633 6410 Installation amp Hardware Reference Manual Rev E C 9 C 2 Powering the 6410 from a Regulated Supply C 10 Certain precautions should be taken when powering the 6410 drive from a regulated power supply The 6410 s bipolar chopper output stage draws current from the DC supply in the form of pulses with fast rise and fall times This may be a problem for some regulated supplies designed to drive loads having relatively constant or slowly varying current drain If a regulated supply is used and problems are encountered a 470uf capacitor should be placed across the DC and DC lines between the power supply and 6410 Ideally this capacitor is located
42. nection 40mm 15mm Wrap the end of the shielding in wire and solder it Shielding T eL Motor connector max 40 cm Motor Clamp Note Ground shield to machine X Z chassis with a metal clamp providing a cable 360 degree termination cable Machine Chassis 6410 Installation amp Hardware Reference Manual Rev E D 5 The signal interface cable shield should be grounded to the drive through the 9 pin D sub connector s conductive hood If the cable connector does not provide a 360 degree ground connection to the shield the signal interface cable should be grounded in accordance with the instructions given in the previous paragraph for the motor cable For additional information please contact the factory to request e Application Note 106 Reducing Motor Drive Line Noise e Application Note 107 Reducing Motor Drive Radiated Emissions 6410 Installation amp Hardware Reference Manual RevE Connection Diagram YOLOW Y3dd3LS 3SVHd OML YOLOANNOO SIN YOLOW WALSAS eT ANNOYS SOLON ASVHd YOLOW 9 dsVHd YOLOW V ASVHd YOLOW V ASVHd YOLOW s er ANNOYS HitiV3 smd 29 er 9 SISSVHO 3OVJ3U3 LNI qa1v1osi ATIVOLLdO 0199 zs WALLIN G318VN3 aNnOu9 IE 318VN3 Adans H3MOd 4315
43. ntific Motion Technology Division 110 Fordham Road Wilmington MA 01887 Attn Repair Department RMA Note Do not ship Pacific Scientific motors to the above address The correct address for motors is Pacific Scientific Motor Products Division 4301 Kishwaukee Street Rockford IL 61105 Attn Stepper Repair Department RMA Shipment of your drive or motor to Pacific Scientific constitutes authorization to repair the unit Refer to Pacific Scientific s repair policy for standard repair charges Your repaired unit will be shipped via UPS Ground delivery If another means of shipping is desired please specify this at the time of receiving an RMA 6410 Installation and Hardware Reference Manual Rev E Appendix A Specifications Electrical Input power 24 75 Vdc 5 0 Amps supply Rated drive Setting current motor phase current 5A SA 0 25A 4 375 4 375 0 2A 3 75 3 75 0 2 A 3 125 3 125 0 15 A 2 5 2 5 0 15 A 1 875 1 875 0 125 1 25 1 25 0 125 0 625 0 625 0 1 A Drive circuit Chopper frequency Two phase bipolar chopper current regulated 20 KHz nominal 6410 Installation and Hardware Reference Manual Rev E A 1 7 G 5 o Step size Signal input requirements Switch settable Full 1 2 1 2 1 4 1 5 1 8 1 10 1 16 1 25 1 32 1 50 1 64 1 125 1 128 1 250 1 256 Steps motor revolution 1 8 stepper motor 200 40
44. nts up to 50 feet For example SPC 050 is a cable 50 feet long S 7 Pacific Scientific If you are using Pacific Scientific motor cable with the mating cabling diagram connectors already attached install as follows JACKET A 1 A BLK A MOTOR A 2 ORG B PHASES B 3 It C Lj CASEGND 5 5 Pin PCD SPC XXX 6410 5 Pin MS Connector 6410 MOTOR Note All wires are 16 AWG 2 10 6410 Installation and Hardware Reference Manual Rev E Making your own To make your own motor cable follow the guidelines given below cable for wiring to the J3 mating connector Depending on your motor configuration refer to the appropriate diagram at the end of this section to determine the motor connections required J connection table s Output Pin Explanation I7 c Motor Phase A J3 1 Motor Phase A excitation Twisted Motor Phase J3 2 Fay Motor Phase B J3 3 Motor Phase B excitation Twisted Motor Phase J3 4 Pair Drive Case J3 5 Connected to the motor case ground Earth Ground Mating The J3 motor connector on the 6410 mates to a 5 pin PCD screw connector cable connector The mating cable connector is type ELVP05100 Cable The mating connector terminals will accept
45. or undiscovered shipping damage could result in undesired motor motion Be prepared to remove power if excessive motion occurs Connections test 1 Check all wiring and mounting to verify correct installation 2 With the power Off check that S1 is set as follows factory default settings l 2 3 4 5 7 8 Q gt D x gt ZO These settings reflect the following Step size of 1 25 Digital electronic damping enabled Idle current reduction enabled 5 Arms motor current Warning If the motor is rated at less than 5 A rms winding current set positions 6 7 amp 8 accordingly 6410 Installation and Hardware Reference Manual Rev E 3 7 Procedure contd Warning N Make sure power is removed before proceeding 3 Check that Jumper J6 is set as follows a 9 o dux eS Neel que 8 These settings reflect the following Idle Current Reduction Enabled 0 1 second delay 6410 enabled without enable input driven Decimal step size selected Step input filter enabled 4 Switch On power Signals test 1 Verify that the motor has holding torque by attempting to rotate the motor shaft The energized motor shaft is either immovable or is resistant to rotation 2 Input a step command and verify that the motor moves 3 Reverse the pola
46. ppendix D CE Installation D 1 Index Rev E 6410 Installation amp Hardware Reference Manual 1 Overview of the 6410 In this chapter This chapter introduces the 6410 stepper drive Topics covered are 6410 definition Other system components System diagram How to use this manual Warranty information 1 1 6410 Definition Overview The Pacific Scientific 6410 converts step and direction inputs into motor winding currents to control a two phase stepper motor Principal features include microstepping and mid band instability compensation for high resolution and smooth operation through both the low speed and mid band resonance regions The output current of the 6410 is dip switch selectable from 5A rms 7 1 A peak in microstep mode to 0 625A rms 0 88A peak in microstep mode The drive supplies regulated phase currents for supply voltages between 24 and 75 Vdc It is designed for use with Pacific Scientific s line of hybrid stepping motors and will work with either the standard line or the enhanced performance line Note The motor winding must be compatible with the output current of the drive 6410 Installation amp Hardware Reference Manual Rev E 1 1 Drive features Bipolar chopper drive patented 4 phase PWM pulse width modulation chopping electronically controls the motor winding currents at 20 KHz frequency This combines the best of recirculating and non recirculating current regulatio
47. r and Pacific Scientific stepper motors having MS connectors Connections are shown for 4 lead motors 8 lead motors with paralleled windings and 8 lead motors with series windings MS CONNECTOR TO J3 1 3 CASE B ie B D E DRIVE EARTH GROUND FOUR LEAD MOTOR MS CONNECTOR A 102371 CASE B DRIVE EARTH GROUND EIGHT LEAD MOTOR CONNECTED IN PARALLEL MS CONNECTOR CASE Dl DRIVE EARTH GROUND EIGHT LEAD MOTOR CONNECTED IN SERIES S 7 Power Max motor The figure below shows the connections required between the connections 6410 and Pacific Scientific Power Max Motors Power Max motors have an eight pin connector and can be configured with either parallel or series windings CONNECTOR Dl CASE DRIVE EARTH GROUND PARALLELED WINDINGS CONNECTOR CASE B DRIVE EARTH GROUND SERIES WINDINGS 2 16 6410 Installation and Hardware Reference Manual Rev E 2 5 2 2 Power Connector Introduction 2 power table Power connection 6410 Installation and Hardware Reference Manual Rev E 2 17 The J2 power cable connects the 6410 to the power supply Please refer to Appendix C for additional information on power supply considerations Input Pin Explanation DC J2 1 24 to 75 Vdc max at 5 amps The negative side of the power supply DC J2 2 connected to DC should be connected to Earth ground No
48. ransformer Selection Primary voltage and frequency rating Secondary voltage rating Make sure that the transformer is guaranteed to operate at the highest line voltage combined with the lowest line frequency that will ever be used to power your system Failure to do so can result in saturation large current increases and winding failure Maximum motor speed performance will be achieved by using as high a motor supply voltage as possible without ever exceeding 75 volts Of course lower voltages can also be used so long as the voltage is greater than the minimum specified value of 24 volts but motor torque will drop more rapidly as speed increases The peak bus voltage excluding any spiking due to current switching in the drive module or any regeneration effects is approximately equal to 1 414 Actual Secondary rms voltage 1 5 Note This assumes a 0 75 volt drop across each rectifier diode To insure this as well as to discharge the bus capacitor when AC power is removed it is recommended that a bleed resistor be placed across each bus capacitor as shown 6410 Installation amp Hardware Reference Manual RevE Example If for example the secondary rms voltage is 40 Vac the peak bus voltage will be 1 414 40 1 5 55 volts A transformer with 115 Vac primary and 40 Vac secondary would produce 55 volts peak bus voltage under nominal line conditions and at rated loading However if the line voltage increases 10 t
49. ripple voltage with a 60 Hz line increase capacitor values by 20 for use with a 50 Hz line Current Setting 30 Volt Bus 50 Volt Bus 70 Volt Bus 5 0 14 000 8300 6000 4 375 12 000 7300 5200 3 75 10 000 6300 4500 3 125 8700 5200 3700 2 5 6900 4200 3000 1 875 5200 3100 2200 1 25 3500 2100 1500 0 625 1700 1000 740 Bus Capacitance in Micro farads The bus capacitor s 120 Hz ripple current rating should equal or exceed the 6410 s current setting The capacitor s working voltage rating must exceed the maximum bus voltage under all line load and regen conditions Select a capacitor rated for at least 1 3 times the nominal bus voltage Suppose a 6410 is operating at 70 volts and is set for 5 A rms motor current Assuming a 60 Hz line a bus capacitor of 6000 micro farads should be used The capacitor should have a 120 Hz ripple current rating of at least 5 amps rms and a working voltage of at least 1 3 70 91 volts The bus capacitor should be connected to the 6410 using a twisted pair no longer than 3 feet in length 6410 Installation amp Hardware Reference Manual Rev E C 1 4 Fuse Selection The BUS MDA 10 slow blow fuse or equivalent is recommended when the 6410 is set for 5 Amps Fuses from the same family but with proportionally lower current rating can be used with lower current settings C 1 5 Regeneration Considerations The motor power supply voltage
50. rity of the DIRECTION signal and step the motor The direction of rotation should change Getting help If you need further assistance with your installation please contact your local distributor 3 8 6410 Installation and Hardware Reference Manual Rev E 4 Maintaining Troubleshooting In this chapter This chapter covers maintenance and troubleshooting of the 6410 unit 4 1 Maintaining the 6410 Drive Introduction The 6410 drives are designed for minimum maintenance The following cleaning procedure performed as needed will minimize problems due to dust and dirt build up Procedure Remove superficial dust and dirt from the unit using clean dry low pressure air 4 2 Troubleshooting the 6410 Drive Introduction The 6410 has an enabled output which is on when the drive is enabled and off when the drive is disabled or faulted due to any of the following Output overcurrent line to line or line to neutral short Bus overvoltage Low voltage supply out of tolerance o c m 6410 Installation and Hardware Reference Manual Rev E 4 1 Use the troubleshooting table and the simple circuit shown below to diagnose and correct most problems If you are unable to achieve satisfactory operation contact your local Pacific Scientific Distributor or the Applications Engineering Department Simple circuit diagram Meter Meter 6410 ATK J1 4 i User
51. ry any Products or parts thereof which prove to Pacific Scientific s satisfaction to be defective as a result of defective materials or workmanship in accordance with Pacific Scientific s stated warranty provided however that written notice of claimed defects shall have been given to Pacific Scientific within two 2 years after the date of the product date code that is affixed to the product and within thirty 30 days from the date any such defect is first discovered The products or parts claimed to be defective must be returned to Pacific Scientific transportation prepaid by Customer with written specifications of the claimed defect Evidence acceptable to Pacific Scientific must be furnished that the claimed defects were not caused by misuse abuse or neglect by anyone other than Pacific Scientific Pacific Scientific also warrants that each of the Pacific Scientific Motion Control Software Programs Program s will when delivered conform to the specifications therefore set forth in Pacific Scientific s specifications manual Customer however acknowledges that these Programs are of such complexity and that the Programs are used in such diverse equipment and operating environments that defects unknown to Pacific Scientific may be discovered only after the Programs have been used by Customer Customer agrees that as Pacific Scientific s sole liability and as Customer s sole remedy Pacific Scientific will correct documented failures of
52. sing a plug on jumper Note The current will return to 10096 at the next step pulse Step filter when enabled jumper installed rejects noise pulses on step input less than 50015 wide Useful if maximum step rate is 500 KHz Enable sense allows the polarity of the enable input to be reversed With the jumper installed the enable input opto isolator must be driven to enable drive With the jumper removed enable input opto isolator must be driven to disable 6410 Installation amp Hardware Reference Manual Rev E 1 3 Typical applications Typical applications for 6410 include X Y tables and slides Packaging machinery Robotics Specialty machinery Index feed of material Labeling machines 1 2 Other System Components Overview The other components that along with the drive comprise a complete motor control system are Indexer or step source Single power supply 24 75 volts Motor Installation guidelines for these components are described in Chapter 2 Installing the 6410 Stepper Motor Drive 6410 Installation amp Hardware Reference Manual Rev E System Diagram The following diagram shows an installation of the drive in a typical system UNREGULATED POWER SUPPLY 24 TO 75 i EARTH ue GROUND fp 1 DC MINUS J1 SCIETITIFIC DC PLU
53. ss of torque occurs in any step motor drive system due to the motor back EMF modulating the motor winding currents at certain speeds Mid speed instability can be explained as a region of potential instability that occurs as a result of the electronic magnetic and mechanical characteristics of any stepping motor system The circuitry used to control this phenomenon does so by advancing or delaying the switching of the output current with respect to the incoming pulse train This should be taken into account if the user is attempting to employ pulse placement techniques Enable the digital electronic damping function by placing DIP switch S1 position 4 in the open position as shown This is the default position and should be used for most applications if your application is affected by loss of torque at mid range speeds If pulse placement techniques are being used disable the digital electronic damping function by placing DIP switch S1 position 4 in the open position This feature controls torque loss at mid range speeds When enabled the motor maintains torque at mid range operation provided the torque load does not exceed motor torque ratings 6410 Installation and Hardware Reference Manual Rev E 3 1 3 Idle Current Reduction Definition The Idle Current Reduction ICR function reduces the phase current at times when no motion is commanded Motor current is reduced when no step commands are received for a given time This ti
54. ther 2 phase stepper motors The drive works with either the standard line or the enhanced high performance line of stepper motors The motor winding current rating must be compatible with the output current of the drive package Refer to the Torque Speed Curves in the Pacific Scientific Motion Control Solutions Catalog or contact your local Pacific Scientific distributor for sizing and motor compatibility assistance Selecting power A single power supply is required to operate the 6410 unit supply Note Jn multi axis applications it is preferable to run each power connection from supply to drive and not daisy chain the power connections The power supply can vary from 24 to 75 Volts maximum at a maximum current of 5 amps It does not have to be a regulated supply Note The supply voltage cannot exceed 75 volts IMPORTANT NOTE Important information about the power supply is outlined in Section 2 5 2 and Appendix C Read these sections carefully before applying power to the drive 6410 Installation and Hardware Reference Manual Rev E 2 3 S 7 2 4 Mounting the 6410 Unit Cooling plate mounting Power dissipation vs current 30 WATTS 25 20 0 625 For optimal thermal performance and minimum panel usage mount the 6410 bookcase style to a cooling plate typically an Aluminum plate or heatsink with enough thickness and surface area to maintain the 6410 s chassis below 60
55. tween the Connection 6410 connector J3 and Pacific Scientific motors having flying leads Connections are shown for 4 lead motors 8 lead motors with paralleled windings and 8 lead motors with series windings Wire nuts may be used for the winding connections at the motor end CASE A A B S 7 B DRIVE EARTH GROUND FOUR LEAD MOTOR A WHI ORG CASE DRIVE EARTH GROUND EIGHT LEAD MOTOR CONNECTED IN PARALLEL CASE DRIVE EARTH GROUND EIGHT LEAD MOTOR CONNECTED IN SERIES 6410 Installation and Hardware Reference Manual Rev E 2 13 Terminal board connections The figure below shows the connections required between the 6410 connector J3 and Pacific Scientific stepper motors having a terminal board in the rear end bell Connections are shown for 4 lead motors 8 lead motors with paralleled windings and 8 lead motors with series windings gt A B B DRIVE EARTH GROUND DRIVE EARTH GROUND DRIVE EARTH GROUND TERMINAL CASE FOUR LEAD MOTOR TERMINAL CASE EIGHT LEAD MOTOR CONNECTED IN PARALLEL TERMINAL TO J3 2 CASE TO J3 3 TO J3 4 TO J3 5 EIGHT LEAD MOTOR CONNECTED IN SERIES 6410 Installation and Hardware Reference Manual Rev E MS connectors connection 6410 Installation and Hardware Reference Manual Rev E 2 15 The figure below shows the connections required between the 6410 J3 connecto
56. ws the full wave bridge capacitor input configuration most commonly used to power one or more 6410 drive modules A single transformer provides isolation and transforms the AC input voltage to a level that when rectified provides the desired DC bus voltage Fusing should be between the rectifier and individual bus capacitors This allows fuse size to be based upon the current requirements of a single module to provide the greatest protection The capacitors must be connected to the 6410 DC and DC inputs using twisted pairs no longer than three feet in length as shown to control winding inductive effects A regen clamp to absorb power transferred from the motor to the 6410 s is sometimes required This section provides selection guidelines for the power supply components Block diagram J2 3 2 1 6420 J2 3 BLEEDER FUSE RESISTOR TwisteD BUS Ir 115 MDA10 VAC 1 RECTIFIER REGEN 6420 ENER 3FEETMAX EARTH SAFETY GROUND 6410 Installation amp Hardware Reference Manual Rev E C 1 LN Warning Power supply design must insure that the voltage between J2 2 and J2 1 never exceeds 75 volts under any operating conditions These conditions include high line voltage transformer regulation effects voltage spiking due to current switching within the module and regeneration Failure to do this can result in permanent damage to the 6410 C 1 1 Line T
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