User Manual
Contents
1. Sinking Circuits NPN If your output devices sink current then connect the terminals to your positive power supply and the terminals to your signals i e STEP DIR etc If you are using a TTL circuit to drive the PDO 3540 connect the terminals to your 5 volt bus No ground connection is needed If you are using a PLC or proximity sensor you ll need a power supply Sourcing Circuits PNP If your output devices can only source current some PLC outputs are this way connect the terminals to the ground of the DC power supply that powers your output circuits Then connect your signals to the terminals STEP DIR etc Note We refer to an input as being ON when current is flowing through the input A signal is OFF when no current is flowing An input is OFF when COM and the input terminal are at the same voltage or when the input is left unconnected open Tach Output The Tach Out signal is provided for measuring the motor speed It generates 100 pulses per revolution so if you connect a frequency counter the speed reads out in revs second with two decimal places Do not connect the Tach output to more than 24 VDC The current into the Tach terminal must not exceed 20 mA Enable Input ENABLE allows the user to turn off the current to the motor by setting this signal to logic 0 The logic circuitry continues to operate so the drive remembers the step postion even when the ampl2. 9014 842 1 38 1 38 x 1 57 power Automatic idle current reduction defeatable reduces HT17 068 1 65 1 65 x 1 30 parallel motor current to 50 of setting after one second Minimum 17 071 1 65x1 65x1 54 parallel motor inductance is 0 8 mH HT17 075 1 65x1 65x1 85 parallel 5023 122 2 22 x 2 22 x 2 0 parallel 60 20 Power Supply Linear toroidal transformer based for high reliability and low 5023 123 222 x 2 22 x 3 0 parallel noise 100 120 or 200 240 VAC input switch selectable 50 60 Hz DC voltage at nominal line voltage 35 VDC full load 23 124 x 2 22 x 4 0 150 3 5 x 2 22 x parallel 150 35 muta HT23 394 2 22 x2 22x154 paali 60 28 HT23 397 2 22x2 22 x 2 13 parallel Inputs Speed Enable optically isolated differential 5 24 VDC logic HT23 400 222x222x299 paalla 2200 ohms internal resistor 5034 348 3 38x3 38x2 50 parallel Step Direction optically isolated differential 5 12 VDC logic 680 ohms internal resistance 24 VDC with external 1000 ohm resistance Wiper 0 5 VDC analog signal Maximum recommended pot EDE power LED joystick impedance 1K 5K ohms Joystick dead zone 80 mV Potentiometer analog signal dead zone 40 mV Block Diagram 110 or 220 VAC AT In pulse amp direction mode motor steps on rising edge of STEP input falling edge of STEP 0 25 msec minimum pulse 2 MHz maximum step rate 1 msec minimum set up tim
3. Wht 6 6 White White NC lead jo mm lead motor motor Green A NC Green Re Rd Wht B plac B NC B Red YY Red Blac B B NC 6 Leads Series Connected 6 Leads Center Tap Connected Eight lead motors can also be connected in two ways 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 motors are shown below A Orange A Orange BIk Wht Org Wht 8 8 lead lead BIk Wht Org motor motor Wet A Black Black Yel Red low Red Red lyel Yellow Vel B Wht wht B B wht Red Wht B 8 Leads Series Connected 8 Leads Parallel Connected 9 Modes of Operation The PDO 3540 has four modes of operation selected by three dip switches Self Test Mode is used for trouble shooting If you are unsure about the motor or signal connections to the drive or if the PDO 3540 isn t responding to your step pulses you can turn on the self test To activate the self test slide switch 1 toward the E TEST label The drive will slowly rotate the motor SELF TEST SE 1 2 revolution forward then 1 2 revolution back ward The pattern repeats until you slide the switch away from the TEST label The PDO 3540 Self Test Mode always uses half step mode duri
4. and DIR outputs which many indexers do the connections are simple Just connect STEP to STEP STEP to STEP and so forth as shown below Indexer or Controller l PDO 3540 with Drive Differential Outputs B ARES optional signal Sinking Logic If your controller has STEP DIR and 5V outputs like the Applied Motion Products Si 1 indexer connect STEP and DIR to 5V Connect STEP to STEP Connect DIR to DIR Indexer or Controller PDO 3540 with Drive Sinking Outputs ee optional signal 11 Sourcing Logic If your controller has STEP DIR and GND ground or common outputs connect STEP and DIR to GND Connect STEP to STEP Connect DIR to DIR Indexer or Controller with Sourcing ren optional signal 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 PDO 3540 precisely control the amount of current in each phase at each step position as a means of electronically subdividing the steps even further The PDO 3540 offers a choice of 16 step resolutions in pulse amp direction mode The highest setting divides each full step into 254 microsteps providing 50 800 steps per revolution when using a 1 8 motor Note In oscilla tor j
5. is eguipped with a feature that automatically reduces the motor current by 50 anytime the motor is not moving This reduces drive heating by about 50 and lowers motor heating by 75 This feature can be disabled if desired so that full current is maintained at all times This is useful when a high holding torque is required To minimize motor and drive heating we highly recommend that you use the idle current reduction feature unless your application strictly forbids it Idle current reduction is enabled by sliding switch 6 toward the 50 IDLE label as shown in the sketch below Sliding the switch away from the 50 IDLE label disables the reduction feature 50 IDLE 50 IDLE EP NN KN Idle Current Reduction Idle Current Reduction Enabled Disabled 20 Current Set Table Mounting the Drive You can mount your drive on the wide or the narrow side of the chassis Use for NARROW SIDE Use for WIDE SIDE mounting mounting where the ambient temperature exceeds 50 C 120 F Never put the drive where it can get wet Never allow metal particles near the drive Never use your drive in a space where there is no air flow or 21 22 Recommended Motors Technical Specifications aa Amplifiers Dual MOSFET H bridge 3 state pulse width modulated Motor Winding Max Torgue Current NE Number Anips PWM switching at 20 kHz 0 4 3 5 amps phase output current dip switch selectable 122 watts maximum output
6. sure you follow the proper sketch for you connector style 5 To Earth Ground gt To Neutral To Line Hot Old Style AC Power Plug New Style AC Power Plug Always unplug the line cord from the wall before attaching it to the PDO 3540 Connect the black or brown wire to the PDO 3540 L terminal of the AC power connector That is the line or hot connection Connect the white or blue wire to neutral the N terminal eFinally and most importantly connect the green wire to the GND terminal That connects the PDO 3540 metal enclosure and DC power supply ground to earth ground 7 Connecting the Motor Secure any unused motor leads insulate exposed conductors Never connect motor leads to ground or to a power supply Never connect or disconnect the motor to the driver when the AC power is on 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 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
7. switch 47 toward the EXT SPEED label The HI SPEED pot sets the maximum speed the motor speed when the analog signal is at 5 volt DC The range is 0 25 rev sec Wiring diagrams and a plot of speed v voltage are shown below and on the next page run stop switch closed run STEP 0 O 2 08 A Q direction switch 1 0 5V speed signal signal return CCW Simms mis Sed 17 0 5V speed signal signal return OvSE Odd Wiring for Speed Control by 0 5 Volt Analog Signal Unidirectional 25 20 speed rev sec 0 0 1 2 3 4 5 Speed vs Input Voltage EXT SPEED mode HI SPEED pot at maximum Connecting Digital Inputs The PDO 3540 contains optical isolation circuitry to prevent the electrical noise inherent in switching amplifiers from interfering with your circuits This arrange ment also allows a wide range of input voltages to be used and gives you the option of using sinking or sourcing inputs A schematic diagram of the input circuit is shown on the next page You must supply 5 12 volts DC to supply current to the LEDs on the input side of the optoisolators 5 24 VDC is acceptable for the SPEED and ENABLE inputs You can operate the STEP and DIR inputs at 24 VDC if you add a 1000 ohm resistor to each input Most CMOS and open collector TTL devices are directly compatible with this drive as are typical PLC and proximity sensor outputs 18 PDO 3540 Input circuit
8. Hardware Manual PDO 3540 Step Motor Driver w Oscillator CURRENT EI BASE 0 4 A ACCEL O 354 0 Step Motor Driver CEA Applied Motion Products motors drives controls 2 Table of Contents Introduction 4 Features 4 Getting Started 5 Connecting the AC Line 6 Connecting the Motor 8 Modes of Operation 10 Setting Up for Pulse amp Direction Mode 11 Microstepping 12 Selecting Microstepping Resolution 13 Joystick Mode 14 Oscillator Mode 15 Speed Control from 0 to 5 Volt Analog Signal 17 C
9. ck and oscillator modes the accel decel rate is set by the ACCEL pot The acceleration range is 1 to 250 rev sec sec Turning the pot clockwise makes the motor start and stop faster but if you set it too high the motor may run out of torque and stall In nearly all cases the accel decel rate you set is respected by the PDO 3540 For example if you switch the SPEED input while the motor is moving the drive will change speeds smoothly If you are operating in EXT SPEED mode and make a sudden change in the voltage to the WPR terminal the drive accelerates or deceler ates to the new speed smoothly according to the accel pot setting The only time the drive makes an instant change is when the SPEED input is on and the STEP input goes off That is done so that you can stop instantly and exactly from a low speed 16 run stop switch i 5 12 closed run SUPPLY 0t S Odd Typical Wiring for Oscillator Mode Using External Speed Control Pot Speed Control from a 0 to 5 Volt Analog Signal In oscillator mode the PDO 3540 can rotate the motor at a speed proportional to an analog voltage The voltage must be applied to the WPR terminal The direction of rotation is controlled by the digital DIR input and the motor can be stopped either by setting the analog input voltage to O or by turning the digital STEP signal off To use the PDO 3540 in this mode set switch 8 away from the JOYSTICK label and set
10. ctors European style pluggable screw termminal blocks E TES a Motor 4 position Wire size AWG 12 26 Q EH Signal Input Output 13 position Wire size AWG 16 28 2 2 AC Input 3 position Wire size AWG 12 20 Je is 5 e CE Marks Complies with 550118 EN50082 1 1996 EN50178 1997 A Fuses Wickman TR 5 style Order from Digikey 1 800 DIGIKEY 6 INM 110V P N WK4053BK ND 1 6 A UL 1 125 EE 0 750 PT 220V P N WK4046BK ND 0 8 A UL i 2 25 gt k 5 00 gt 5 40 25 26 Notes 27 Applied Motion Products Inc 404 Westridge Drive Watsonville CA 95076 800 525 1609 Tel 831 761 6555 Fax 831 761 6544 http www applied motion com Copyright 1999 5 10 99
11. e 50 msec minimum hold time for direction signal STEP DIRECTION ENABLE HI LO SPEED TACH Optical Isolation EXT SPEED INPUT Tach Output Optically isolated uncommitted open collector open emitter photo transistor 30 VDC 20 mA max 100 pulses per motor revolution 5096 duty cycle square wave joystick ext speed 05000 eseud Microstepping 16 switch selectable resolutions Steps per revolution with 1 8 motor 200 400 1000 2000 5000 10000 12800 18000 E 20000 21600 25000 25400 25600 36000 50000 50800 Waveform pure sine 12800 steps rev in OSC JOY mode steps rev osc bypass self test 23 24 Technical Specifications cont d Mechanical Outline Recommended Maurey Instrument Corp Chicago IL 773 581 4555 o 0 200 x6 Joystick JS31462S5T3 2 axis or SAJ2515 F 502 1 axis i U d J 8 0 200 E Speed Ranges LO speed range 0 5 rev sec S cB x6 8 HI speed range 0 25 rev sec NE B S Accel decel range 1 to 250 rev sec sec 5 mor B E WB Physical Constructed with black anodized aluminum heat sink and heavy 2 gauge steel housing 2 25 x 5 4 7 8 inches overall 4 0 Ibs O 1 di E Ambient temperature range 0 50 C See page 26 for detailed yi Ez drawing 7 80 ms i Conne
12. ifiers are disabled However the motor may move slightly when the current is removed depending on the exact motor and load characteristics f you have no need to disable the amplifiers you don t need to connect anything to the ENABLE input 19 Setting Phase Current Before you turn on the power supply the first time you need to set the driver for the proper motor phase current The rated current is usually printed on the motor label The current you set on the PDO 3540 is the peak current not RMS The PDO 3540 drive current is easy to set If you wish you can learn a simple formula for setting current and never need the manual again Or you can skip to the table on the next page find the current setting you want and set the DIP switches according to the picture Current Setting Formula Locate the bank of eight switches Five of the switches have a value of current printed next to them such as 0 2 and 1 6 Each switch controls the amount of current in amperes A that its label indicates There is always a base current of 0 4 A To add to that slide the appropriate switches toward their labels You may need your small screwdriver for this Example Suppose you want to set the driver for 2 2 amps per phase You need the 0 4 A base E current plus another 1 8 A Rr 2 2 TOTAL 0 4 BASE 1 6 0 2 amp W Slide the 1 6 and 0 2 A switches toward the OF labels as shown in the figure Idle Current Reduction Your drive
13. ints Please examine it now All mating connectors are included Connector step amp direction enable Speed tachometer out ext potentiometer Dip Switches oscillator mode current setting microstep resolution idle current EXT SPEED DLE CURRENT 54 0 Step Motor Driver Power LED Trim Pots oscillator speed accel amp decel HIGH SPEED spero Motor Connector L Always use the blue amp white AC Power Connector 4 Applied Motion screwdriver with m this connector Larger screwdrivers may remove the plastic dimples that prevent the q screws from falling out Connecting the AC Line The PDO 3540 is set for 110 VAC operation at the factory If you use 110 VAC power all you need to do is install a power cord and plug it in If you plan to use 220 VAC power follow the instructions below Note you plan to hard wire the PDO 3540 to AC power consult a qualified electrician and observe all building and electrical codes AC power can be dangerous Do not attempt to change the 110 220 volt switch setting until power has been removed from the drive for at least five minutes 220 VAC Instructions In order to use 220 volts you ll need to change a switch setting inside the case Remove all mating connectors from the drive Set the drive on it s widest side so that you can read PDO 3540 Step Motor Driver prope
14. ng the self test no EE J matter how you set the steps rev switches The self test ignores the STEP and DIRECTION inputs OSC BYPASS ESI while operating The ENABLE input continues to SELFTEST function normally Pulse amp Direction Pulse amp Direction Mode the PDO 3540 receives step pulses from an indexer such as the p 4 Applied Motion Si 1 Si 100 Steps revolution TOEIC ISI o are set by switches 3 6 see page 13 SC BYPASS mined by an external analog voltage STEP and SELFTEST EL DIR inputs can be used for limit switches SPEED input selects speed range LO SPEED and HI Joystick mode speed and direction are deter SPEED pots adjust the 2 speed ranges Oscillator mode speed be controlled by joystick board potentiometers and or by an external analog voltage STEP input starts and stops the motor DIR input controls direction of rotation SPEED bso BYPASS input selects th range input selects the speed range SELF TEST i i Oscillator Mode E 10 Setting up for Pulse amp Direction Mode To operate the drive in Pulse amp Direction mode you must v Connect an indexer controller to the STEP and DIR inputs v Set the microstep resolution steps rev Turn off the SELF TEST switch and turn on the OSC BYPASS switch Differential Logic If your controller has STEP STEP DIR
15. ntial sourcing or sinking Speed amp Enable 5 24 VDC Step amp Direction 5 12 VDC Digital oscillator provides smooth accel decel ramps and precise speed control Easy to configure with on board switches and potentiometers for all settings Oscillator Mode operates from internal pots external pots 0 5 V analog signal or analog joystick Two speed ranges can be selected on the fly by a digital signal with automatic ramping between speeds e Tach Out signal allows easy measurement of speed Built in self test for troubleshooting Accepts 110 or 220 volt AC power factory preset for 110 volts Sturdy 2 25 x 7 8 x 5 inch metal chassis Pluggable screw terminal connectors for motor AC power and I O signals makes wiring easy and TUV Compliant 4 Getting Started To use your PDO 3540 motor control you will need the following V apower cable line cord acompatible step motor V asmall flat blade screwdriver for tightening the connectors an Applied Motion Products screwdriver suitable for this purpose is included with your drive For pulse amp direction mode asource of step pulses usually an indexer is used For oscillator mode v an instrument for measuring motor speed tachometer freq counter or o scope For joystick mode v an analog joystick see page 25 for recommended joystick The sketch below shows where to find the important connection and adjustment po
16. onnecting Digital Inputs 18 Enable Input 19 Setting Phase Current 20 Current Set Table 21 Mounting the 22 Recommended Motors 7 23 Block Diagram 23 Technical Specifications 24 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 theres 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 Powerful precise and efficient mosfet driver providing up to 3 5 amps per phase and microstepping to 50 800 steps per revolution Reliable efficient low noise 40 VDC linear toroidal power supply e Automatic idle current reduction reduces motor and drive heating saves power Inputs and outputs are optically isolated differe
17. oystick mode the microstep resolution is fixed at 12800 steps rev regardless of the dip switch settings 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 provded 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 12 Selecting Microstep Resolution 2 0 0 STEPS REV T 2 0 0 0 0 STEPS REV FULL 2 1 100 21 00 STEPS REV STEPS REV STEPS REV STEPS REV 1 125 2 9400 STEPS REV 1 127 STEPS REV 2 9600 STEPS REV 1 128 STEPS REV STEPS REV STEPS REV 90000 STEPS REV 1 250 STEPS REV 5 0 8 0 0 STEPS REV STEPS REV 1 254 Joystick Mode In this mode speed and direction are determined by the voltage applied to the WPR wiper terminal 2 5 volts is stopped no speed Increasing the WPR voltage toward 5 volts results in forward motion speed increases with voltage Decreasing the WPR voltage from 2 5 toward O results in reverse motion with speed increasing as voltage decreases In joystick mode the PDO 3540 operates at 12800 steps rev The maximum speed is determined by two
18. perates at 12800 steps rev switches joystick ext speed joystick ext speed OFF open joystick OFF open si speed set when STEP when STEP 7 amp 8 by goes ON goes OFF instant stop accel to speed 1 SN accel to speed instant stop accel to speed decel to stop accel to speed decel to stop There are two speed ranges in oscillator mode One is the low speed range which is activated when the SPEED input is on The low speed can be set from 0 to 5 rev sec 0 300 rpm by adjusting the LO SPEED pot Turning the pot clockwise increases the speed The high speed setting is used when the SPEED input is off or open If switch 7 is toward the words EXT SPEED then the high speed is proportional to the voltage applied to the WPR terminal and is trimmed by the HI SPEED pot You can connect an external 1K 5K pot to the WPR CW and CCW terminals or you can apply 8 0 to 5 volt analog signal to the WPR terminal ground your analog signal to the CCW terminal The high speed range is 0 25 rev sec 0 1500 rpm You can reduce the range by turning down the HI SPEED pot For example if you want the motor to go 750 rpm when the external pot is on maximum turn the HI SPEED pot down about half way When switch 7 is away from the EXT SPEED label the high speed is set by the HI SPEED pot and the WPR input does nothing Never apply more than 5 volts DC or less than 0 volts to the WPR pin In joysti
19. rly Remove the four 4 phillips head screws that mount the chassis sheet metal to the chassis heat sink See page 17 for a mechanical outline of the drive The 110 220 switch is located near the position of the AC power connector next to the toroidal transformer see sketch below For 220 VAC operation slide the switch towards the bottom of the drive or towards the transformer end of the drive The position of the switch is labeled on the PC board also 230 being for 200 240 VAC operation and 115 for 100 120 VAC operation Replace the fuse next to the switch with the 220 VAC fuse that came with the drive See technical specifications on page 25 to order more fuses Replace the drives cover and assembly screws PC Board 110 220 VAC Switch X AC Power Fuse Connector Switch set for 110 VAC Switch set for 220 VAC 6 Installing an AC Line Cord Remove about 5 mm 3 16 inces of insulation from each of the three wires of your line cord That s right three wires For safety always use a three wire power cord on anything with a metal case Depending on where you got your power cord it may have black white and green wires or brown white and green wires The AC power plug that was shipped with your PDO 3540 might be one of two types The old style is shown below on the left The new style which comes with an insulating rubber boot is shown below on the right Make
20. things the state of the SPEED input and the HI SPEED and LO SPEED trimpots When the SPEED input is ON the speed range of the joystick can be adjusted with the LO SPEED pot up to 5 rev sec 300 rpm When the SPEED input is OFF or open the joystick speed range is adjusted with the HI SPEED pot up to 25 rev sec 1500 rpm Turning the pots clockwise increases the speed In joystick mode limit switches can be connected to the PDO 3540 to prevent motion outside of defined limits The forward limit should be connected to the STEP input and the reverse limit should be connected to the DIR input When the forward limit is ON the motor will not move forward that is when the joystick voltage is between 2 5 and 5 volts When the reverse limit is ON the motor will not move when the joystick is in the 0 to 2 5 volt range If you don t need limits you can leave the STEP and DIR inputs unconnected 0r S Odd RA joystick fire button fwd i rev 1 CCW Typical Wiring for Joystick Mode 14 speed rev sec Speed vs Input Voltage Joystick Mode SPEED input off open HI SPEED pot at maximum Oscillator Mode In oscillator mode the PDO 3540 uses the direction set by the DIR input Off or open gives clockwise motion if the motor is wired according to pages 8 and 9 Motor speed and the function of the STEP input can be determined from the following table In oscillator mode the PDO 3540 o
Download Pdf Manuals
Related Search