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Hardware Manual 1240i Programmable Step Motor Driver

1. You can use normally open or normally closed limit switches Either way wire The 1240i input circuits can be used with _ _ them as shown here sourcing or sinking signals 5 to 24 volts inside 1240i aan E This allows connection to TTL circuits GW LIMIT PLCs relays and mechanical switches CN sso agi Oe CCW LIMIT Because the input circuits are isolated they f PME ae i 5 24 12401 require a source of power If you are N2 ka connecting to a TTL circuit or to a PLC you ee eee ee A should be able to get power from the PLC or CINS iet COW LIMIT MM TTL power supply If you are using relays or i ji AV Wiring a Limit Sensor mechanical switches you will need a 5 24 V IM 274 gt i Some systems use active limit sensors that produce a voltage output rather than a power supply This also applies if you are 20 RW el switch or relay closure These devices must be wired differently than switches connecting the 1240i inputs to another Si GIOGEWD 7 product from Applied Motion like the Si 1 JSEEGN aw AYO If your sensor has an open collector output or a sinking output wire it like this and Si 100 indexers or the 35401 Si3540 B ob tin l Ke Si5580 70801 and Si4500 indexer drives OWLIMITE 12401 CWLIMIT l Note If current is flowing into or out of an 12401 input the logic state of that input is low If no current is flowing or the input is n
2. 4 4 4 4 4 4 20 Technical Specifications 21 Mechanical Outline Optional MMI 22 3 Introduction Thank you for selecting an Applied Motion Products motor control We hope our dedication to performance quality and economy will make your motion control project successful If there s anything we can do to improve our products or help you use them better please call or fax We d like to hear from you Our phone number is 800 525 1609 or you can reach us by fax at 831 761 6544 Features e Precise pulse width modulation switching amplifiers providing up to 1 2 amps per phase and microstepping to 50 800 steps per revolution e Accepts 12 42 VDC power supply e Powerful flexible easy to use indexer e Connects by a simple cable to your PC for programming cable included e Microsoft Windows based software for easy setup and programming e Eight inputs for interacting with the user and other equipment e Three outputs for coordinating external equipment e External trigger I O is optically isolated 5 24V sinking or sourcing signals PC MMI port is RS 232 e 3 0 x 4 0 x 0 65 inch overall dimensions e Optional man machine interface MMI allows operator to enter distances speeds cycle counts and more e CE Compliant Block Diagram 12 42 VDC Internal Power 3 INPUTI Supply INPUT2 8 INPUTS Opt
3. JOG CW and JOG CCW Activating one of the inputs commands the drive to move the motor at a pre designated speed until the contact is opened A relay or mechanical switch can be used to activate the jog inputs 5 24 volt cir cuitrv can be used The schematic diagram of the input circuit is shown below If you re using a switch or relay wire one end to the JOG input and the other to the power supply negative terminal Then connect the COM input to the power supply positive terminal pSeSSSSSSS SSeS e eee ee ee eee 5 24 2200 AY VDC SUPPLV 2200 AY Limit Switches The 1240i has two limit switch inputs LIMIT CW and LIMIT CCW By connecting switches or sensors that are triggered by the motion of the motor or load you can force the 1240i to operate within certain limits This is useful if a program error could cause damage to your system by traveling too far The limit inputs are optically isolated This allows you to choose a voltage for your limit circuits of 5 to 24 volts DC This also allows you to have long wires on limit sensors that may be far from the 1240i with less risk of intoducing noise to the 1240i The schematic diagram of the limit switch input circuit is shown below CW LIMIT 1240i CW UMIT Controller CCW LIMIT Chip CCW LIMIT l Wiring a Mechanical Limit Switch Wiring Inputs
4. lower voltage Because of that unregulated power supplies are better They are also less expensive 7o Connecting the Motor Never connect or disconnect the motor to the driver when the power is on Insulate unused motor leads separately and then secure Never connect motor leads to ground or to a power supply You must now decide how to connect your motor to the drive Four lead motors can only be connected one way Please follow the sketch at the Blue right Yellow White B B 4 Leads Six lead motors can be connected in series or center tap In series mode motors produce more torque at low speeds but cannot run as fast as in the center tap configuration In series operation the motor should be operated at 30 less than the rated current to prevent overheating Wiring diagrams for both connection methods are shown below Note NC means not connected to anything Grn Wht A Grn Wht 6 6 Whit Whit No lead aa lead ae motor motor A Red een Red Wht enue Red aA Red Black B NC B B B NC 6 Leads Series Connected 6 Leads Center Tap Connected Eight lead motors can also be connected in two wavs series and parallel As with six lead motors series operation gives you more torque at low speeds and less torque at high speeds In series operation the motor should be operated at 30 less than the rated current to prevent overheating The wiring diagrams for eight lead moto
5. you see is a transistor NPN type that closes or conducts current when the output is low When the output is high the transistor is open 5 Supp Connecting an Input to the Si 1 Motion Output Set Si 1 motion signal to in position Si 1 will trigger 1240i at end of each a a we 0 SAQ Note At power up the 1240i sets all three programmable outputs high open es A a i circuit r l IS I i S 8 l GERIT 5 24 The maximum voltage between any pair of and output si S i COM OMS l VDC N terminals is 24 volts DC Never connect AC voltages to the s wD Power FA output terminals Maximum current is 100 mA per out e E ER L Supply FL er 1 09 Lense Connecting a 3540i Si3540 Si5580 7080i or Si4500 12401 When output closes 1240i input goes low Controller Chip 5 24 G 2 Schematic Diagram of 1240i Output Circuit i VDC suit i Since there is no electrical connection to the 1240i you must provide the source of Power Proximity ae current and voltage typically from a power supply You must also limit the current Supply ar to less than 100 mA so that the output transistor is not damaged You would normally use a resistor for this but some loads such as PLC inputs limit the current automatically Connecting an NPN Type Proximity Sensor to a 1240i input en PON SGOT idea EMO INDUL goes ow The diagram below shows how to connect an 1240i output to an optically is
6. 25600 36000 50000 50800 Waveform pure sine 12800 Hz Constructed on 0 063 inch thick printed circuit board Four mounting holes 0 156 inch diameter Overall size 3 00 x 4 00 x 0 65 inches 0 15 Ib 0 to 50 C ambient operating temperature See page 20 for detailed drawing European style screw terminal blocks Power Supply and Motor 6 position Wire size AWG 16 28 Signal input output 19 position Wire size AWG 16 28 CE compliant to EN55011A EN50082 1 1997 21 Mechanical Outline Optional MMI 4 90 2 988 i 0 960 3 875 CENTERED of SE gt ca oO 22 Notes ar 1240iweb p65 4 24 2000 Applied Motion Products Inc 404 Westridge Drive Watsonville CA 95076 Tel 831 761 6555 800 525 1609 Fax 831 761 6544 http www applied motion com 23 Copyright 2000
7. Hardware Manual 12401 Programmable Step Motor Driver CE Applied Motion Products motors drives e controls Table of Contents Introduction 22 22 2e ree ee ee ee centre ne nen nec ee renee m 4 FOALULES 2 202 2c0n en nwrwe nnn nwne nn tenn ee renew nen nne ce rene ee nareneserern nes 4 Block Diagram 222 222 necro re cece cece centre neeee renee eene ne nentores 4 Getting Started 2 2 2 2c cee ec en ene screen ene se ncen ene sencenese sens 5 Connecting the Power Supply 6 Choosing a Power Supply 7 Connecting the Motor 8 Connecting to the PO 9 JOGGING nnn e new ne ene e rene ennn 10 Limit Switches 2 22 2222 cence eee ne nen ne nen ne 10 Wiring a Mechanical Limit Switch 11 Wiring a Limit Sensor 11 Wiring Inputs 20222022 cee n cee nen e cnn ne nce re cen ecee ne neneenes 12 Wiring Outputs 2 22 22 2e 2s eee nen e nee nee 14 Microstepping 22 ene no nee rwe 15 Mounting the Drive 202222 ence seen eee erence ne nen tere sence eee 16 Mounting the Optional MMI 2 222 222 2222 2e2c ee nee 17 Recommended Motors 19 Mechanical Outline
8. ical MOSFET z INPUT4 Isoation 3 State CW JOG IN5 PWM l CCW JOG IN6 ana Pn 3 owumir Optical _ Mierer S CCW LIMIT Isolation Sequencer E ao e jer to PC MMI Optical OUTI Isolation OUT2 OUT3 As Getting Started To use vour 1240i motor control vou will need the following 4 apower supply see page7 for help choosing one acompatible step motor see page 19 for recommended motors V asmall flat blade screwdriver for tightening the connectors an Applied Motion Products screwdriver suitable for this purpose is included with your drive 4 apersonal computer running Windows 3 1 95 98 or NT with a 9 pin serial port 486 or better with 8 MB ram recommended V the Si Programmer software that came with your 1240i V the programming cable that came with your 1240i J Si Programmer software manual on the CD that came with your 1240i The sketch below shows where to find the important connection and adjustment points Please examine it now All Mating connectors included pc mmi mounting hole 1 of 4 connector i o connector puig jibki power motor jaq ew power LED connector cw limit DC power supply cew limit T Pa motor out 1 2 3 Always use the blue amp white Applied Motion screwdriver with these connectors Larger screwdrivers may remove the plastic dimples that prevent the screws from falling out 5 Connecting the Power Supply If you need information about choosing a power supply
9. l like rubber or RTV gasket included sealant not included panel 18 Recommended Motors Mechanical Outline Motor Max Torque Current Setting Number Connection oz in Amps phase HT11 012 series 7 1 0 HT11 013 series 10 1 0 5014 842 series 19 1 0 HT17 068 22 1 2 Ce C HT17 072 32 1 1 Pre pane HT17 076 52 fi T HT23 393 45 1 2 iiie HT23 396 115 1 2 HT23 399 170 1 2 pana aaa a LEELEE EEE E gi EEE E E E g g INNOTA EE NN BENEMMME IM BEB EBEERESE BEB EBEEBRES 4 HOLES 0 156 DIA 19 20 Technical Specifications Amplifiers Power Supplv Inputs Outputs Microstepping Motion Update Physical Connectors Agency Approvals Dual H bridge 3 state pulse width modulated PWM switching at 25 kHz 0 2 1 2 amps phase output current software selectable 48 watts maximum output power Automatic idle current reduction software programmable reduces current to motor when idle Mini mum motor inductance is 0 8 mH Accepts 12 42 VDC power supply 1 2 amps typical max load 5 24 VDC optically isolated 2200 ohms internal resistance Can be configured for sinking NPN or sourcing PNP signals Optically isolated 5 24 VDC 100 mA max 13 software selectable resolutions Steps per revolution with 1 8 motor 2000 5000 10000 12800 18000 20000 21600 25000 25400
10. olated PLC input 5 24 VDC Power Supply Proximity Sensor Connecting a PNP Type Proximity Sensor to a 1240i input When prox sensor activates 1240i input goes low 13 14 Microstepping Most step motor drives offer a choice between full step and half step resolutions In full step mode both motor phases are used all the time Half stepping divides each step into two smaller steps by alternating between both phases on and one phase on Microstepping drives like the 1240i precisely control the amount of current in each phase at each step position as a means of electronically subdividing the steps even further The 1240i offers a choice of 13 step resolutions The highest setting divides each full step into 254 microsteps providing 50 800 steps per revolution when using a 1 8 motor In addition to providing precise positioning and smooth motion microstep drives can be used for motion conversion between different units The 25 400 step rev setting is provided as a means of converting motion from metric to english there are 25 4 mm in an inch Other settings provide step angles that are decimal degrees 36 000 steps rev makes the motor take 0 01 steps Some settings are used with lead screws When the drive is set to 2000 steps rev and used with a 0 2 pitch lead screw you get 0 0001 inches step The microstep resolution of the 1240i is set by the Si Programmer software 15 Mounting the Dri
11. ot connected the logic state is high output Sensor Wiring for Sinking or Open Collector Output The diagrams on the following pages show how to connect 12401 inputs to various devices fade ree aaa L ni a i The maximum voltage that can be applied to an input terminal is pan 9 9e pois 24 volts DC Never apply AC voltage to an input terminal Other sensors have sourcing outputs That means that current can flow out of the 1111000000 sensor output but not into it In that case wire the sensor this way O COM i 5 24 l i 7 output eee at voo switch or relay 1240i i si Power closed logic low A 1240i Supply CJI7 mw Z LIMIT b seal pera Wd i a 1 Wiring for Sourcing Output Connecting an Input to a Switch or Relav l ma A Fir Use normally open momentary switch to trigger 1240i using Wait Input instruction lf the H output jon high at the limit choose the program option closed if Use pija switch li parameter elat using Tf Input FOR the output is low at the limit select open Use normally open momentary switch for jogging 11 12 Reena Wiring Outputs D EZETA 5 24 Before we discuss the output conditions we need to talk about the circuitry All 8 ues EOM VDC i three 1240i outputs are optically isolated That means that there is no electrical c connection between the indexer drive and the output terminals The signal is pig transmitted to the output as light What
12. part is thicker and contains the telephone jack and a cable that connects to the keypad assembly When you flush mount the MMI ina panel only the thin section will stick out from your panel the large portion mounts behind your panel You ll need to cut a precise section from your panel There is a cardboard template in the MMI s shipping box for this purpose If you want the MMI to be dust proof and watertight you must place the black rubber gasket between the thin part of the MMI and your panel Assemble the two halves using the eight small screws provided Surface Mounting MMI rear section MMI front section and gasket An easier way to mount the MMI is to bolt the two halves together ahead of time using the eight small screws If you want the MMI to be dust proof and watertight put the black rubber gasket between the two halves before screwing them together Then cut a hole in your panel for the cable that runs between the MMI and the 1240i The hole must be at least 5 8 in diameter for the connector to fit thorugh You will also need two holes that line up with the big mounting holes in the MMI The mechanical outline on page 22 shows the location of the big mounting holes When you mount the MMI to your panel you will need to use some kind of sealant to keep dust and liquid out Silicone or latex caulking is okay or you can make your own gasket from a sheet of compliant materia
13. please read Choosing a Power Supply on the next page If your power supply does not have a fuse on the output or some kind of short circuit current limiting feature you need to put a 1 amp fast acting fuse between the drive and the power supply Install the fuse on the power supply lead Connect the motor power supply as shown below Use no smaller than 18 gauge wire Be careful not to reverse the wires Reverse connection may destroy your driver void your warranty and generally wreck your day DC Power Supply 12 42 V 1A fuse SG Choosing a Power Supplv Please follow the recommendations below for choosing a power supply Voltage Chopper drives like the 1240i work by switching the voltage to the motor terminals on and off while monitoring current to achieve a precise level of phase current To do this efficiently and silently you ll want to have a power supply with a voltage rating at least five times that of the motor Depending on how fast you want to run the motor you may need even more voltage than that If you choose an unregulated power supply do not exceed 28 volts This is because unregulated supplies are rated at full load current At lesser loads like when the motor s not moving the actual voltage can be up to 1 4 times the rated voltage For smooth quiet opera tion a lower voltage is better Current The maximum supply current you could ever need is the sum of the two phase Currents Ho
14. rs are shown below Ay Orange A Orange BIk Wht Org Wht 8 8 lead lead BIk Wht Org motor motor td Black Black Yel Red low Red Red Yei Yellow Yel e By Wht wht B B wht Red Wht B 8 Leads Series Connected 8 Leads Parallel Connected Connecting to the PC eLocate your computer within 6 feet of the 12401 eVour 1240i was shipped with a black adapter plug It has a telephone style jack at one end and a larger 9 pin connector at the other Plug the large end into the COM 1 serial port of your PC Secure the adapter with the screws on the sides If the COM1 port on your PC is already used by something else you may use the COM2 port for the 1240i On some PCs COM2 will have a 25 pin connector that does not fit the black adapter plug If this is the case and you must use COM2 you may have to purchase a 25 to 9 pin serial adapter at your local computer store eVour 1240i was also shipped with a 7 foot telephone line cord Plug one end into the adapter we just attached to your PC and the other end into the PC MMI jack on your 1240 Never connect the 1240i to a telephone circuit It uses the A same connectors and cords as telephones and modems but the voltages are not compatible Programming Note Always apply power to the 1240i after the Si Programmer software is running on your PC 9 Jogging Two of the 1240i input terminals are provided for jogging the motor The inputs are labeled
15. ve The 1240i has four 0 156 inch diameter holes in the circuit board for mounting Always use standoffs or spacers to support the 1240i a 1240i with power connected will be damaged if you set it on a conductive surface without supports The standoffs or spacers can be up to 0 25 inch in outer diameter You can use 4 or 6 screws to fasten the 12401 0 156 inch Diameter mounting holes 0 156 inch Diameter mounting holes 16 Mounting the Optional MMI There are two wavs to mount the MMI in vour application No matter which method you choose you ll need to connect the MMI to your 1240i with the programming cable You will not however need the adapter plug The MMI has the same telephone style connector as the 1240i Depending on how you mount the MMI and cable in your application you may find that it is difficult to remove the cable from the back of the MMI If this is the case and you need to reprogram the 1240i you can use any telephone line cord as a programming cable They are available at most supermarkets and discount stores Please be careful not to lose the adapter plug that connects the telephone cord to the COM port of your PC The adapter is a custom made part and is only available from Applied Motion 17 Flush Mounting When you remove the MMI from the shipping carton you will notice that it has two parts The first is a fairly thin section that contains the keypad display and some circuit boards The other
16. wever you will generally need a lot less than that depending on the motor type voltage speed and load conditions That s because the 1240i uses switching amplifiers converting a high voltage and low current into lower voltage and higher current The more the power supply voltage exceeds the motor voltage the less current you ll need from the power supply A motor running from a 24 volt supply can be expected to draw only half the supply current that it would with a 12 volt supply We recommend the following selection procedure 1 If you plan to use only a few drives get a power supply with at least twice the rated phase current of the motor 2 If you are designing for mass production and must minimize cost get one power supply with more than twice the rated current of the motor Install the motor in the application and monitor the current coming out of the power supply and into the drive at various motor loads This will tell you how much current you really need so you can design in a lower cost power supply If you plan to use a regulated power supply you may encounter a problem with current fold back When you first power up your drive the full current of both motor phases will be drawn for a few millisec onds while the stator field is being established After that the amplifiers start chopping and much less current is drawn from the power supply If your power supply thinks this initial surge is a short circuit it may fold back to a

Hardware Manual 1240i Programmable Step Motor Driver

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