User Manual
Contents
1. 0 1 rp 0 1 Dr 0 1 S 0 2 0 2 DF 0 2 ew 3 3 0 40 EN 3 9 0 4 1 4 5 0 4 1 AMPS 0 8 AMPS 0 cil AMPS 0 8 d PHASE 4 6 o PHASE ol PHASE 161o 1 9 On 1 9 on 1 9 2 0 15 0 1 Cr 0 1 Tr 0 2 le 0 2 0 2 Ir Je 3 4 4 ET 4 0 0 4 4 6 0 4 0 AMPS 0 3 el AMPS 0 8 al AMPS 0 8 Oe PHASE 4 6 PHASE 6n l PHASE 6 o 1 9 A 1 9 AN 1 9 N 0 2 Te 0 2 ow 0 2 Te 3 5 0 421 4 1 0 4 Te 4 7 0 4 1 AMPS 9 5 AMPS 08 n l AMPS 0 8 2 PHASE 4 5 ah ol PHASE 6 ie PHASE 1 6Co 1 9 HS 1 9 ON 1 9 0 20 w 0 2 Oo 0 2 w 3 6 4 ET s 4 2 04e 4 8 0 4 Te AMPS 03 l AMPS 9 8 n l AMPS 058 a PHASE 6 o PHASE 6 PHASE el o 1 9 A 1 9 AIN 1 9 ATA 0 15 0 11 1 0 10 0 2 ew 0 221 0 2 Te 7 OA Te 4 3 0 4 EN 4 9 04e AMPS 0 3 el AMPS 0 8 n l AMPS 08e PHASE 1 6 n l PHASE 1 6 7 PHASE 16 5e 1 9 1 91ET LATA 0 1 Or 0 1 Or 0 1 0 2 Tw 0 2 le 0 2 Te AMPS 9 gl oe AMPS 9 8 n l AMPS 9 sao PHASE 5 Oho PHASE 1 6 Oe PHASE 4 5 Oe 1 9 AN 1 9 TN 1 9 ON 13 5 1 AMPS PHASE 5 2 AMPS PHASE 5 3 AMPS PHASE 5 4 AMPS PHASE 5 5 AMPS PHASE Current Setting Table Part 2 3 3 5 5 amps phase 0000 IBEN 9 Gy Eed s SOS O Oo S2. oanp 9 Gy Eed SSS No OOO Oo 9 Gy Ed 9 5 yv 8 d 9 Gy Eed Current Setting Table Part 1 0 5 3 2 amps phase 5 mA through the optocouplers For 12 volt logic the current is 12 mA Logic low or 0 for a given input occurs when the and signal pins have at least 4 volts DC across them In this state the LED is conducting current Logic high or 1 occurs when the and inputs are less than 1 volt apart or open Z9OGPVEE STEP tells the driver when to move the motor one step The drive steps on the falling edge of the pulse The minimum width is 1 microsecond DIRECTION signals which way the motor should turn See the step table on page 7 for details The D RECTION signal should be changed at least 1 microsecond before a step pulse is sent and held for at least 50 usec after the step pulse is sent If you change the state of the direction input and send a step pulse at the same instant the motor may take a step in the wrong direction nn Z9OGVEE EUD ENABLE allows the user to turn off the current to t
3. 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 Drives sizes 14 1 4 through 42 4 2 step motors e Built in 80 volt power supply accepts 110 or 220 VAC power 60 Hz only e MOSFET pulse width modulation switching amplifiers 3 state e Phase current from 0 5 to 5 5 amps phase switch selectable 51 settings e Step direction amplifier enable inputs fault output optically isolated e Microstepping from full step through 1 254 switch selectable 16 settings Overtemp and overcurrent short circuit and surge protection e idle current reduction 50 switch selectable e pluggable screw terminal connectors Block Diagram ee 110 220 O 2 power light step Power dirt Optical Amplifier dir Isolation enable enable Microstep Sequencer g spud 101001 y aseyd 10 0u microstep a motor resolution ae e current Fault Monitor ZN 50 idle on off overcurrent overtem fault O p Getting Started To use your Applied Motion Products motor control you will need the following v a power cable line cord v a source of step pulses capable of sourcing or sinking at least 5 mA v if your application calls for bidirectional rotation you ll also need a directio
4. from 110V to 220V carefully insert your scredriver into the slot and push the switch to the right AC POWER MOTOR osssad s onpoid uonoy JOAUQ 4o oyi d s p rddy Unplug these connectors 5u fuse switch in 110V position fuse switch in 220V position Installing an AC Line Cord Remove about 5 mm 3 16 inches 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 blue green The AC power plug that was shipped with your PD5580 might be one of two types The old style is shown below on the left The new style shown on the right comes with an insulating rubber boot Make sure you follow the proper sketch your connector style gt To Earth Ground gt To Neutral gt To Line Hot Old Style AC Povver Plug AC Povver Plug Nevv Style Always unplug the line cord from the wall before attaching it to the PD5580 e Connect the black or brown wire to the PD5580 L terminal of the AC power connector That is the line or hot connection e Connect the white or blue wire to neutral That s the N terminal eFinally and most im
5. 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 Blk Wht Org Wht 8 8 lead lead Blk Wht Org motor motor Wht A A Back Black Yel Red low Redi Red yel Yellow Yel B4 Wht wht B B wht Red Wht p_ 8 Leads Series Connected 8 Leads Parallel Connected Step Table full stepping DIR 0 cew Step 2 is the Power Up State Connecting Logic The PD5580 drive contains optical isolation circuitry to 680 prevent the electrical noise inherent in switching amplifiers from interfering with your circuits A R schematic diagram of the step input circuit is shown below The DIRECTION and ENABLE circuits are the same as STEP PD5580 Input Circuit Your logic signals can be sourcing sinking or both differential The input current will be about 1 mA per volt Thus if your logic signals are 5 volts you ll be putting 8
6. 4 18 96 User s Manual PD5580 Step Motor Driver 50 IDLE 0 1 CURRENT 02 BASE 5 A 04 16 MICROSTEP RESOLUTION PD5580 Step Motor Driver Motion Products MOTOR ERP I I I I I 1 I AC POWER Applied Motion Products Inc 404 Westridge Drive Watsonville CA 95076 Tel 408 761 6555 800 525 1609 Fax 408 761 6544 Applied Motion Products motors e drives e controls Mechanical Outline k 8 00 gt AC POWER MOTOR Pree ez 6 H BEEE 10401 dors osssdd 8 97 1 lt 9 25 0 06 TT b 5 30 1 545 2 02 NN 19 Technical Specifications Amplifiers Power Supply Inputs Fault Output Microstepping Physical Connectors Dual MOSFET H bridge 3 state pulse width modulated switching at 20 kHz 0 5 5 5 amps phase output current switch selectable in 0 1 increments 400 watts maximum output power Overcurrent and overtemperature protection Automatic idle current reduction defeatable reduces current to 50 of setting after one second Minimum motor inductance is 0 8 mH Linear toroidal transformer based for high reliability and low noise 110 or 220 VAC input switch selectable 60 Hz only
7. 5580 with Drive Sinking i Outputs optional signal 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 Outputs 2242 optional signal If Your Logic Voltage is not 5 to 12 Volts The PD5580 optical isolation circuits have built in resistors for 5 12 volt logic If your logic voltage is greater than 12 volts but no more than 24 volts you can add series resistors to the signal pins i e STEP DIR etc Use 1 4 watt 1000 ohms 10 Using the Fault Output The PD5580 has a fault output to tell you if the drive has overheated or if a short circuit has occured at the motor outputs The fault output is optically isolated for noise immunity This makes it more flexible and more reliable but also harder to hook up To connect to 5 volt logic follow the sketch below For other connections consult the factory The photo transistor turns on when there is a fault In circuit below the signal will be high near 5 volts when there is no fault The signal will go low 0 volts if a fault occurs 5 VDC PD5580 Resistor 10k 1 4W AAN 1 1k 1 i TTL or CMOS input 1 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 usual
8. a 50 Hz version for overseas operation can be special ordered 400 W max DC voltage at nominal line voltage 75 VDC full load 90 VDC no load Step direction and enable optically isolated differential 5 12V logic 5 mA mininum 20 mA maximum input current Motor steps on falling edge of step input 1 usec minimum pulse 2 MHz max step rate 1 usec minimum set up time 50us minimum hold time for direction signal Optically isolated uncommitted open collector open emitter photo transistor 30V 20 mA max 16 switch selectable resolutions Steps per revolution with 1 8 motor 200 400 1000 2000 5000 10000 12800 18000 20000 21600 25000 25400 25600 36000 50000 50800 Waveform pure sine standard Other waveforms available upon request Constructed with black anodized aluminum heat sink and heavy gauge steel housing 3 x 5 3 x 8 inches overall 7 8 lbs 70 max heat sink temperature Power overtemp and overcurrent LEDs Mounting brackets and switch cover included See back cover for detailed drawing European style pluggable screw terminal blocks Motor 4 position Signal Input output 8 position AC Input 3 position 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
9. 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 1 toward the 50 IDLE label as shown in the sketch below Sliding the switch away from the 50 DLE label disables the reduction feature 50 IDLE 50 IDLE Idle Current Reduction Selected No Current Reduction 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 PD5580 precisely contro the amount of current in each phase at each step position as a means of electronically subdividing the steps even further The PD5580 offers a choice of full and half step as well as 14 other 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
10. he motor by setting this signal to logic 0 The logic circuitry continues to operate so the drive remembers the step position even when the amplifiers are disabled However the motor may move slightly when the current is removed depending on the exact motor and load characteristics If you have no need to disable the amplifiers you don t need to connect anything to the ENABLE input Z9OGVEE AMPS PHASE 4 6 PHASE 1 6 1 9 Differential Logic If your controller has STEP STEP DIR and DIR outputs which many indexers do the connections are simple Just connect STEP to STEP STEP to STEP and 1 6 04 04 so forth as shown below AMPS 0 8 PHASE 4 6 1 9 196 6 2 Indexer or Controller PD5580 with Drive Differential Outputs L9G9p Ec 5 pena optional signal PHASE 6 1 9 16 1 9 5 a 5 Z9OGVEE y 5 9 Sinking Logic If your controller has STEP DIR and 5V outputs like the Applied Motion Products S 1 indexer connect STEP and DIR to 5V Connect STEP to STEP Connect DIR to DIR Indexer or Controller PD
11. ly printed on the motor label The current you set on the PD5580 is the peak current not RMS The PD5580 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 Six of the switches have a value of current printed next to them such as 0 1 and 1 6 Each switch controls the amount of current in amperes A that it s label indicates There is always a base current of 0 5 A To add to that slide the appropriate switches toward their labels You may need your small screwdriver for this Example 0 1 CE Suppose you want to set the driver for 4 amps 021 CHo per phase You need the 0 5 A base CURRENT 04 EL current plus another 1 6 and 1 9 A J 4 0 TOTAL 0 5 BASE 1 5 51 3 SASED 5A 09 Slide the 1 6 and 1 9 A switches toward the labels as shown in the figure 44 1 IN
12. 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 14 Connecting the Motor Never connect the motor to the driver when the AC power is on Secure any unused motor leads Never disconnect the motor while the AC 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 4 A lead motor 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 Winding diagrams for both connection methods are shown below Note NC means not connected to anything 9__Srn Wht _Grn Wht White White 6 NC lead A lead motor motor Green A een t Red Blac Red Black B NC 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
13. n signal capable of sourcing or sinking 5 mA VY a compatible step motor v a small flat blade screwdriver for tightening the connectors an Applied Motion Products screwdriver suitable for this purpose is included with your drive v if you want to power the drive from 220 volts you ll need a Philips screwdriver to remove the cover The sketch below shows where to find the important connection and adjustment points Please examine it now All mating connectors are included ie logic connector DIR STEP ENABLE FAULT OUT LEDs POWER OVER TEMP FAULT OVER CURRENT FAULT switches IDLE REDUCTION PHASE CURRENT switches PD5580 MICROSTEP Step Motor Driver RESOLUTION Applied Motion Products connector MOTOR FTP connector AC POWER AC POWER Recommended Motors The following tables lists motors and current settings that are recommended for the PD5580 drive Number 1 Connection ei i BA uu 5023 122 parallel 27 5034 349 parallel 300 15 50 som ale 96 W 55 17 Fault Protection The PD5580 provides protection against motor short circuits and excessive drive temperature If the OVERTEMP light is on the PD5580 has detected a thermal problem and shut down the amplifiers The first thing you should do is to unplug the drive from the po
14. orth America ina country where the powerline frequency may be less than 60 Hz you must order the special 50 Hz version of the PD5580 110 Volts The PD5580 is set for 110 volt operation at the factory All you need to do is install a power cord and plug it in If you want to direct wire the PD5580 to AC power you must consult a qualified electrician and observe all building and electrical codes The AC cord you can install yourself but be careful AC power can be dangerous 220 Volts The PD5580 is set for 110 volt operation at the factory In order to use 220 volts you ll need to change a switch setting inside the case However you can do this from the outside with your Applied Motion screwdriver Do not open the PD5580 case AN Do not attempt to change the 110 220 volt switch setting until the power has been removed from the drive for at least five minutes Before you can change the 100 220 volt switch setting you must remove the motor connector and the AC power connector from the drive Set the drive on the widest side so that the heat sink fins are pointing upward Once you ve done that you ll see an opening in the case just above the three position and four position green connectors If you look into the slot you should see two black objects The one on the left is the fuse The black object to the right of the fuse is the 110 220 volt switch The sketches below and on page 6 show the two positions of the switch To change
15. portantly connect the green wire to the GND terminal That connects the PD5580 metal enclosure and DC power supply ground to earth ground 6 Selecting Microstep Resolution 200 STEPS REV FULL 400 STEPS REV HALF 1000 STEPS REV 1 5 2000 STEPS REV 1 10 5000 STEPS REV 1 25 10000 STEPS REV 1 50 12800 STEPS REV 1 64 18000 STEPS REV 02 NOILNTOSSH NOILMIOSIU NOILNTOSIU NOILNTOSIU NOILNTOSSY NOILNTOSIU NOILNTOSJY dILSOHIIN 43150 dJLSOYJIN dILSOYJIN 44150 43150 43150 N01111053u d3LSOYIIN 20000 STEPS REV 1 100 21600 STEPS REV 1 arc min 25000 STEPS REV 1 125 25400 STEPS REV 1 127 25600 STEPS REV 1 128 36000 STEPS REV 01 50000 STEPS REV 1 250 50800 STEPS REV 1 254 NOILNTOS3Y NOILMIOSIU NOILNTOSIU NOILNTOSIU NOILNTOSIU NOILNTOSJY d3LSOYDIN d3LSOYDIIN 43 50 43150 43 150 dILSOYJIN N01111053u d3LSOYDIN 220 BE os co cn x m 25 PEt EE Idle Current Reduction Your drive is equipped 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
16. wer source Next touch the heat sink with your fingers If it is very hot the drive has probably overheated Usually this means you need more air flow around the drive If the OVERCURRENT light is on the PD5580 has detected a short circuit and has shut down the amplifiers Unplug the drive from the power source Check the motor wiring carefully Make sure that the connections to the drive are secure and that any unused motor leads are insulated from the drive and power supply and from each other Check the motor leads for shorts between phases or to ground Mounting the Drive You can mount your drive on the wide or the narrow side of the case Either way you ll need to get the brackets and screws out of the accessory bag and bolt them onto the PD5580 If you re mounting on the narrow side you ll first have to remove one of the screws from the heat sink then put it back with the bracket in place as shown in the figure Bracket position for wide side mounting Place brackets on top and bottom of drive Bracket position for narrow side bottom of drive This screw is already in the drive Never use your drive in a space where there is no air flow or where the ambient temperature exceeds 50 C 120 F Never block the fins of the heat sink or the vent holes Never put the drive where it can get wet Never allow metal particles near the drive 16 Connecting the AC Line If you plan to operate the PD5580 outside of N
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