User Manual
Contents
1. 2200 TLP621 or 2501 Connecting a PNP Type Proximity Sensor to 35401 input Se SSS Sa a a SS When prox sensor activates 3540i input goes low 12 9 Wiring a Limit Switch You can use normally open or normally closed limit switches Either way wire them as shown here CW LIMIT CCW LIMIT 35401 as Ch ah a a ag cord Limit Sensors Some systems use active limit sensors that produce a voltage output rather than a switch or relay closure These devices must be wired differently than switches If your sensor has an open collector output or a sinking output wire it like this CW LIMIT 1 35401 CW LIMIT Sensor Wiring for Sinking or Open Collector Output If the sensor output goes low at the limit select the option closed If the output is open or high voltage choose open Other sensors have sourcing outputs That means that current can flow out of the sensor output but not into it In that case wire the sensor this way DC Power Supply Proximity Sensor Wiring for Sourcing Output If the sensor output goes high at the limit choose the program option closed the output is low at the limit select open 10 Wiring Inputs The 35401 input circuits can be used with sourcing or sinking signals 5 to 24 volts This allows connection to TTL circuits PLCs relays and mechanical switches Bec2. HT23 394_ 222x222x154 60 28 Mechanical Outline 3540i 4x 9 170 0 150 gt 120 K aasam i 4 70 500 025 015 lt x i 2x SLOT 875 170 WIDE FULLR 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 part is thicker and contains the telephone jack and cable that connects to the thin part MMI rear section MMI front section nd gasket When you flush mount the MMI in a 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 your box for this purpose panel 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 Surface Mounting 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 blac
3. INPUT3 Optical MOSFET INPUT4 Isolation 3 State CW JOG IN5 CCW JOG ING6 si Amplifier Microstepping CW LIMIT Optical hia aseydsojow aseyd 1 to PC MMI OUT1 OUT2 OUT3 Optical Isolation 3 Getting Started To use your 3540i motor control you will need the following power supply see page 5 for help in choosing a compatible step motor VY a small flat blade screwdriver for tightening the connectors an Applied Motion Products screwdriver suitable for this purpose is included with your drive VY personal computer running Windows 3 1 or Windows 95 with a 9 pin serial port 486 or better with 8 MB ram recommended V the Si Programmer software that came with your 35401 the programming cable that came with your 35401 Si Programmer manual The sketch below shows where to find the important connection and adjustment points Please examine it now power connector e DC power supply motor mounting hole 1 of 6 connector power LED connector input 1 2 3 4 S F jog cw connector S jog Always use the blue amp white Applied cwlimit Motion screwdriver with these e cow limit connectors Larger screwdrivers may remove the plastic dimples that prevent the screws from falling out 4 Recommended Motors e la Number Connection oz in 5023 122 2 22 2 22 20 parallel 60 20
4. better if you mount it on the narrow side Please use narrow side mounting whenever possible 6 screws narrow side mount wide side mount The amplifiers in the 3540i generate heat To operate the drive continuously at maximum power you may need additional heat sinking or forced air cooling Never use your drive in a space where there is no air flow or where other devices cause the surrounding air to be more than 50 Don t put the drive where it can get wet or where metal particles can get on it Mounting the Optional MMI There are two ways to mount the MMI in your application No matter which method you choose you ll need to connect the MMI to your 3540i with the programming cable You will not however need the adapter plug The MMI has the same telephone style connector as the 35401 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 3540i 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 15 Microstepping Most step motor drives offer a choice between
5. 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 3540i precisely control the amount of current in each phase at each step position as a means of electronically subdividing the steps even further The 3540i 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 5 pitch lead screw you get 0001 inches step The microstep resolution of the 35401 is set by the Si Programmer software 14 Connecting the Motor Never connect the motor to the driver when the power is on Secure any unused motor leads Never disconnect the motor while the power is on Never connect motor leads to ground or to a power supply You must now decide how to connect your motor to the drive Red
6. 1 16 98 35401 Programmable Step Motor Driver Copyright 1998 Applied Motion Products Inc Applied 404 Westridge Drive Watsonville CA 95076 Motion Products 408 761 6555 800 525 1609 Fax 408 761 6544 g 4 90 gt 5 875 INI 1 Technical Specifications Amplifiers Power Supply Inputs Outputs Microstepping Motion Update Physical Connectors Dual MOSFET H bridge 3 state pulse width modulated switching at 20 kHz 0 2 3 5 amps phase output current software selectable 147 watts maximum output power Overcurrent and overtemperature protection Automatic idle current reduction software programmable reduces current to motor when idle Minimum motor inductance is 0 8 mH Accepts 12 42 VDC power supply 3 5 amps typical max load 7A maximum power on surge 5 24V optically isolated 2200 ohms internal resistance Can be configured for sinking NPN or sourcing PNP signals Optically isolated 24V 100 mA max 13 software selectable resolutions Steps per revolution with 1 8 motor 2000 5000 10000 12800 18000 20000 21600 25000 25400 25600 36000 50000 50800 Waveform pure sine 12800 Hz Constructed on black anodized aluminum chassis heat sink 1 5 x3 x5 inches overall 12 oz 0 70 C ambient temp range Power LED See
7. 4 A lead motor Four lead motors can only be connected one way Please follow the sketch at the Blue right Yellow White 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 series operation the motor should be operated at 30 less than the rated current to prevent overheating Winding diagrams for both connection methods are shown below Note NC means not connected to anything A Grn Wht A Grn Wht White White 6 NC lead lead motor motor Green A N 7 Re 1 Red Wht Red Red Black B 6 Leads Series Connected 6 Leads Center Tap Connected Eight lead motors can also be connected in two ways series and parallel 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 Urange Blk Wht Org Wht 8 lead a Bik Wht Org motor motor wit Black Black Yel ta low Red Red Yellow B4 Wht wht B B F Red Wht p_ 8 Leads Series Connected 8 Leads Parallel Connected Connecting to the PC e Locate your computer within 6 feet of the 35
8. 40i e Your 3540i was shipped with a black adapter plug has a telephone style jack at one end and a larger 9 pin connector at the other Plug the large end into the COM1 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 35401 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 e Your 3540i 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 RS232 jack on your 35401 Never connect the 3540i to a telephone circuit It uses the same connectors and cords as telephones and modems but the voltages are not compatible Programming Note Always apply power to 3540i after the Si Programmer software is running on your PC 8 Wiring Outputs Before we discuss the output conditions we need to talk about the circuitry All three 35401 outputs are optically isolated That means that there is no electrical connection between the indexer drive and the output terminals The signal is transmitted to the output as light What 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 At power up
9. ally open momentary switch for jogging 11
10. ause the input circuits are isolated they require a source of power If you are connecting to a TTL circuit or to a PLC you should be able to get power from the PLC or TTL power supply If you are using relays or mechanical switches you will need 5 24 volt power supply This also applies if you are connecting the 35401 inputs to another Si product from Applied Motion like the 51 1 Si 100 indexers or the 515580 7080i MC8400 indexer drives gt inside 35401 WA C COM 2500 kV Ne 2200 CIN2_ Na mows i 2200 TR 2200 gt 2200 CWJOG Na i NVV 2 1 i 2200 AV ctwJ0G he Note if current is flowing into or out of an 3540 input the logic state of that input is low Ifno current is flowing or the input is not connected the logic state is high The diagrams on the following pages show how to connect 3540i inputs to various devices The maximum voltage that can be applied to an input terminal is 24 volts 0 Never apply AC voltage to an input terminal es eet i i 12 24 VDC switch or relay Power closed logic low Supply Connecting an Input to a Switch or Relay Use normally open momentary switch to trigger 3540i using Wait Input instruction Use single throw switch for parameter selection using If Input instruction Use norm
11. 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 lf 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 milliseconds 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 lower voltage Because of that unregulated power supplies are better They are also less expensive 6 Mounting the Drive You can mount your drive on the wide or the narrow side of the chassis If you mount the drive on the wide side use 6 screws through the four corner holes For narrow side mounting applications you can use 6 screws in the two side holes The 35401 drive will dissipate heat
12. k rubber gasket between the two halves before screwing them together gasket included Then cut a hole in your panel for the cable that runs between the MMI and the 35401 The hole must be at least 5 8 in diameter for the connector to fit through You will also need two holes that line up with the big mounting holes in the MMI The mechanical outline on page 19 shows the location of the big mounting holes sealant not included panel 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 material like rubber or RTV 16 Connecting the Power Supply If you need information about choosing a power supply please read Choosing a Power Supply below The PS430 from Applied Motion Products is a good supply for this drive 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 4 amp fast acting fuse between the drive and power supply Install the fuse on the power supply lead Connect the motor power supply as shown below Use no smaller than 20 gauge wire Be careful not to reverse the wires Reverse connection will destroy your driver void your warranty and generally wreck your day 4A fuse DC Power Supply 12 42 volts Choosing a Power Supply We recommend using a
13. n Applied Motion Products PS430 power supply with this drive The PS430 provides 30 volts DC at 4 amps as well as 500 mA of well regulated 5 volt power for your logic circuits If you do not choose an supply please follow the recommendations below Voltage Chopper drives like the 35401 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 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 operation a lower voltage 1 better 5 Current The maximum supply current you could ever need is the sum of the two phase currents However you will generally need a lot less than that depending on the motor type voltage speed and load conditions That s because the 3540i 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
14. page 17 for detailed drawing Power motor screw terminal block Wire size AWG 12 28 1 0 Signals screw terminal block Wire size AWG 16 28 18 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 408 761 6544 Features e Powerful precise and efficient mosfet driver providing up to 3 5 amps phase and microstepping to 50 800 steps per revolution e Accepts 12 42 VDC power supply Powertul flexible easy to use indexer Connects by a simple cable to your PC for programming cable included e Microsoft Windows based software for easy set and programming e Eight inputs for interacting with the user and other equipment e Three outputs for coordinating external equipment e All 1 0 is optically isolated 5 24 V sinking or sourcing signals Except PC MMI port which is 12V RS 232 e Sturdy 1 5 x 3 x 5 inch metal chassis e Screw terminal connectors for motor DC power and 1 0 signals Optional man machine interface MMI allows operator to enter distances speeds loop counts and more Block Diagram 12 42 VDC Internal Logic INPUT1 Supply INPUT2
15. the 3540 sets all three programmable outputs high open circuit The maximum voltage between any pair of and output terminals is 24 volts DC Never connect AC voltages to the 3540i output terminals Maximum current is 100 mA per output 5V inside 3540i 35401 Controller Chip Schematic Diagram of 3540i Output Circuit OUT1 oun Optoisolator PS2502 or equiv Since there is no electrical connection to the 3540i you must provide the source of current and voltage typically from a power supply You must also limit the current 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 The diagram below shows how to connect an 3540i output to an optically isolated PLC input pe eae pac eas a See 13 Jogging Two of the 35401 input terminals are provided for jogging the motor The inputs are labeled 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 circuitry 12 24 lt Sit indexer 10958 Supply can also be used The schematic diagram of the input circuit is shown below ae a 1 We Connecting an Input to the SI 1 Motion Output If yo
16. u re using a switch or relay wire one end to the JOG input and the other to the Set 51 1 motion signal to in position 1 1 will trigger 35401 at end of each move power supply terminal Then connect the COM and power supply terminals eee ane inside 3540i Oo TEES AWW 12 24 2200 Art SEWON power coe 8 5 0072 Supply 105 00 Connecting 15580 70807 MC8400 When output closes 3540 input goes low Limit Switches The 3540i has two limit switch inputs LIMIT CW and LIMIT CCW By connecting Switches or sensors that are triggered by the motion of the motor load you can 12 24 force the 3540i to operate within certain limits This is useful if a program error VDC could cause damage to your system by traveling too far Power i Supply The limit inputs are optically isolated This allows you to choose a voltage for your limit circuits of 5 to 24 volts DC It also allows you to have long wires on limit sensors that may be far from the 35401 with less risk of introducing noise to the Connecting an NEN Type Proximity Sensor Ui input 3540i The schematic diagram of the limit input circuit is shown below When prox sensor activates 3540i input goes low inside 35401 5V 5 10K s 35401 cw LIMIT ya Controller CCW er chip i CCW LIMIT VVV l
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