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Stepper/Motor Indexer/Drive Installation and Hardware

1. OPTO ISOLATOR USER POWER SUPPLY 12 TO 24 VDC 1 0 5VDC 5VDC B 10K E 0 01 uF L 5VDC e f o 35K CD4503 L SOURCING TRANSISTOR 5220 Installation and Hardware Reference Manual Rev D Y1 Y5 IN4002 Distance RELAY COIL event output iS ood A j differential wiring M USER POWER SUPPLY 74HC7LS367 0 TO 24 VDC 50 mA SOURCE VoH 3 9V 20 mA SINK VoL 0 5V V RELAY LOAD yo 5 VDC Lu USER POWER SUPPLY 0 TO 24 VDC 74HC7LS367 50 mA SOURCE VoH 3 9V 20 mA SINK VoL 0 5V RESISTIVE LOAD 1 0 A 5 VDC C vl USER POWER SUPPLY 74HC7LS367 50 mA SOURCE VoH 3 9V 0 TO 24 VDC 20 mA SINK VoL 0 5V OPTO ISOLATOR LOAD yo 5 vpc C Hu bu USER POWER SUPPLY 74HC7LS367 0 TO 24 VDC 50 mA SOURCE VoH 3 9V 20 mA SINK VoL 0 5V LED INDICATOR LOAD 2 28 5220 Installation and Hardware Reference Manual Rev D 2 6 Jumper Settings LN Selection of different features and options of the 5220 controller depends upon the jumper setting inside the controller To have access to these jumpers the cover of the unit must be removed To do this remove the two screws near the front of the left side and the two screws near the back of the unit and pull the cover forward Warning Dangerous voltages exist inside the unit Remove powe
2. El and E2 These jumpers should be set to the appropriate RS 232 configuration for the terminal and cable being used Refer to Section 2 5 3 E5 Set to the H C position ICR enabled E4 Set to the L C position Half step mode E3 Set to the L C position Recirculating mode 2 Connect only J5 to the 5220 then apply power 3 Verify that the POWER GREEN LED is the only LED ON If it is not refer to Section 4 2 Troubleshooting 4 Switch power OFF 5 Connect the J3 motor connector 6 Switch power ON again Check that the POWER GREEN LED is the only LED ON If so then motor connection are OK If not refer to Section 4 2 Troubleshooting 5220 Installation and Hardware Reference Manual Rev D Signals test 1 8 Verify that the motor has holding torque by attempting to rotate the motor shaft The energized shaft is either immoveable or very resistance to rotation when the drive is enabled Jog the motor connect input pin J1 24 or J1 25 to 11 20 The motor moves at the default jog speed Remove the Jog input Connect the J2 RS 232 connector Cycle power to the controller If using a PC use the PACCOM disk to setup your PC as a dumb terminal as described in the program reference manual Send two consecutive space characters The controller should respond with a pre defined sign on message Sigma products Pacific Scientific 285 1 v1 06 23 From the
3. Communications interface fault Procedure Follow this procedure if the terminal does not communicate with the indexer drive Verify that baud rate NO Refer to PacCom and port are correctly Software Toolkit set in PacCom Instruction manual YES NO Refer to Section 2 5 Check that terminal nmm transmit amp receive lines from computer go to receive amp transmit lines on YES 1 Disconnect serial cable Computer fault Refer 2 Short pins 2 amp 3 NO to your computer 3 Type character on manual for keyboard troubleshooting procedure Is the character displayed YES Is Indexer input power NO Apply correct voltage J5 5 J5 6 within operational range 4 75 to 5 25 YES Internal failure Contact Pacific Scientific 4 4 5220 Installation and Hardware Reference Manual Rev D If 5220 is If you cannot correct the problem return the module to Pacific defective Scientific for replacement Return 1 Call Pacific Scientific at 978 988 9800 from 8 am to 6 pm procedure Eastern Standard Time to receive a Returned Materials Authorization Number RMA Note Do not attempt to return the stepper drive 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
4. Warning Always remove power before making or removing connections to the unit The motor terminals have high voltage present when the 5220 is On 2 Plug the mating connector firmly into the 5220 3 Plug the other mating connector into the motor and screw down the retaining collar 4 Reconnect power to the 5220 5220 Installation and Hardware Reference Manual Rev D 2 9 2 5 1 1 4 Lead Motor Introduction For the 4 lead standard systems motor with MS connector build and install the cable as follows Cable Use 18 to 16 gauge stranded wire for the cabling Obtain cable requirements with each winding pair refer to diagram twisted at about 3 to 4 turns per inch 1 to 1 5 turns per centimeter Make sure the cable contains a lead for grounding As an option the cable may be shielded to reduce radiated noise Cabling The colors references in the diagram follow the Pacific Scientific diagram stepper motor color code A Black 7 2 1 A Orange EL Q To Motor T Drive 27 in 7 mm _ 3 B Yellow DIS 7 Motor Case 40 Gnd Green md 4 2 10 5220 Installation and Hardware Reference Manual Rev D Procedure 1 Strip the wires to 0 27 inch 7 mm 2 Attach the wire to the connector as indicated in the diagram Note Make sure the screws on the Phoenix connector are tightened down firmly to the wiring Caution Do
5. connector Cable requirements Port connections The serial port transmits and receives RS 232 serial communication for the user interface of your unit You can configure installation to control single or daisy chained 5220s Interconnection diagrams for both configurations are shown in Section 2 5 3 1 J2 Serial port RS 232 Connection The J2 serial port mating connector supplied with the unit is an ITT Cannon DE 9P 9 pin plug in female D connector Use 22 gauge wire for the cabling As an option the cable may be shielded to reduce noise pickup Caution To avoid ground loops connect ground shield to indexer ground only These are the RS 232 transmit TXD and receive RXD terminals Pin Number Connection J2 2 RS 232 TXD RXD J2 3 RS 232 RXD TXD J2 5 RS 232 Common J2 7 RS 232 Common Note The function of the pins depends upon the jumper settings of El and E2 The factory default setting is 12 2 RXD J2 3 TXD 1 is set to L C and E2 set to H C 5220 Installation and Hardware Reference Manual Rev D Settings 1 Default Setting El jumper in the L C position and E2 jumper in the H C position will set J2 2 RXD and J2 3 TXD 2 Setting El jumper in the H C position and E2 jumper in the L C position will set J2 2 J2 3 RXD Baud rate Baud rate is established by setting jumpers E16 E17 and E18 There are seven different
6. 1 3 How to Use This Manual This manual contains information and procedures to install set up test with simple commands and troubleshoot the 5220 Refer to the 5220 Programming Reference Manual for programming instruction and references For a quick reference during installation Refer to Appendix C Connections summary Appendix D Jumper Settings and Appendix E I O Summary 1 4 Warranty The Pacific Scientific 5220 Indexer Drive has 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 5220 Installation and Hardware Reference Rev D 1 5 2 Installing the 5220 Indexer Drive In this chapter This chapter explain how to install the 5220 Indexer Drive Topics covered are e Unpacking and inspecting the 5220 e Selecting a motor e 5220 safety e Mounting the 5220 in your installation e Connecting input output cabling e Selecting jumper functions 2 1 Unpacking and Inspecting the 5220 Unpacking procedure Inspection procedure Storing the unit 5220 Installation and Hardware Reference Manual Rev D 2 1 Remove the 5220 from the shipping carton Make sure all packing materials are removed from the unit 2 Check the items against the packing list A label located on the side of the unit identifies the u
7. 4 4 Commutation F 1 Connections diagram 2 6 motor H 1 multiple units 2 19 summary C 1 test 3 1 Configuration E1 E2 2 29 Current control E3 2 29 5220 Index Daisy chain 2 19 C 3 Damage 2 1 Date code 2 1 Defective unit 4 5 Definition 1 1 Description 1 1 Dimensions mounting 2 4 Direction LIMIT 2 23 Direction LIMIT 2 23 Discrete inputs J1 2 27 Dissipation power 2 5 Distance event 2 25 DISABLE FAULT LED on 4 3 Enable Disable 2 26 External switches 1 3 Features 1 2 Frequency chopper A 1 Fuses A 1 5220 Instruction and Hardware Reference Manual Rev D Index 1 Getting help 2 2 Help getting 2 2 HI LO Jog speed 2 22 Home switch 2 23 Humidity A 2 Idle current control 1 2 2 31 Input current 1 voltage 1 Inspection 2 1 Installation 2 1 Interface fault 4 4 cables 2 6 discrete connection 2 20 summary E 1 Jog 2 22 Jog 2 22 J1 connection 2 20 J2 serial port connection 2 16 RS 232 connection 2 18 J3 connection 2 8 J5 connection 2 14 Jumper location 2 33 D 3 Jumper settings D 1 2 17 2 29 E1 E2 configuration 2 29 E3 current control 2 29 E 4 stepsize operation 2 30 E 5 Idle current control 2 31 K command 2 20 LED indicators 4 1 Low speed resonance G 1 Maintenance 4 1 Motor 4 lead 2 10 8 lead serial connection 2 11 8 lead parallel connection 2 12 Motor basics stepper F 1 Mountin
8. 5220 Installation and Hardware Reference Manual Rev D 2 33 3 Powering up the 5220 In this Chapter This chapter explains how to power up the 5220 after installation 3 1 Testing the Installation Background Perform the following test procedure to verify that the 5220 is installed properly and that it was not damaged internally during shipment Configuration The installation test power up procedure requires a motor and computer or terminal to test the basic functionality of the 5220 Procedure After performing the installation per the guidelines given in Chapter 2 Installing the 5220 test your installation as follows Warning AN Perform this initial power up with the motor shaft disconnected Jrom the load Improper wiring or undiscovered shipping damage can result in undesired motor motion Be prepared to remove power if excessive motion occurs 3 1 1 Connections test Introduction Before beginning the connections test please check the following e all wiring and mounting to verify correct installation specifications to ensure that voltages being applied do not exceed the voltages specified 5220 Installation and Hardware Reference Manual Rev D 3 1 Procedure 1 Verify the plug jumper settings are as follows Jumper Setting E16 E17 and These jumpers should be set to match the E18 baud rate of the terminal or PC being used to communicate with the 5220 Refer to Section 2 5 3
9. 988 9800 from 8 am to 6 pm Eastern Standard Time Fax 978 988 9940 Write Pacific Scientific Motion Techology Division 110 Fordham Road Wilmington MA 01887 B 2 5220 Installation and Hardware Reference Manual Rev D Appendix C Pin Out and Connections Summary Introduction J3 Motor connector 4 lead 8 lead series This appendix gives pinouts and summarizies the J1 to J4 connections that are covered in depth in Section 2 5 Connecting the Input Output Cabling The J3 motor connector is connected in one of three ways determined by the lead wiring form the motor For four lead wiring to the 5 pin connector wire as follows A Black To A Orange Motor B Red B Yellow Motor Case Gnd Green 27 in mm 27 in 7mm 27 in 7 mm 271 7mm r 27 in 7 mm K e a BR C 00000 pec Drive For eight lead series wiring to the 5 pin connector wire as follows A Black To A Orange Motor B Red B Yellow Motor Case Gnd Green 27m 7 mm gt 271 27 7mm 27 7mm 27 mm amp or 2 53 0 Q D oa To Drive In addition make the following connections at the motor Org Wht BIK Wht Yel Wht Red Wht QO6099ee 5220 Installation a
10. RS 232 baud rate setting available These jumpers must be set prior to power up Baud Rate E16 E17 E18 9600 L C L C L C 4800 H C L C L C 2400 L C H C L C 1800 H C H C L C 1200 L C L C H C 600 H C L C H C 300 L C H C H C Illegal H C H C H C Note 7he factory default setting is for 9600 baud all jumpers in the L C position Jumper settings are only read at power up Refer to Section 2 7 for jumper location 5220 Installation and Hardware Reference Manual Rev D 2 17 2 5 3 1 J2 Serial Port RS 232 Connection Introduction Connect the 5220 to your computer or terminal as follows Procedure 1 Solder the cable leads to the 9 pin connector as shown 2 Assemble the connector housing COMMON COMMON RXD TXD 232 TXD RXD 232 Build the cable to connect to your computer or terminal by referring to the documentation for the device Standard RS 232 pinouts for IBM compatible personal computers are shown as follows The 5220 is shipped with J2 2 connected to the RS 232 receiver and the J2 3 to the transmitter The function of these pins can be interchanged using the E1 and E2 jumper as shown below l H 1 25 SERIAL PORT f J2 2 2 2 TXD TRANSMIT 5220 J2 3 1 3 3 RXD RECEIVE He 22 5 P 7 SIGNAL GND i KL 1 2 l H
11. Scientific is not responsible or liable for damage resulting from improper packaging or shipment 3 Ship the stepper drive to Pacific Scientific 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 5220 Installation and Hardware Reference Manual Rev D 4 5 Appendix A Specifications Electrical Input voltages Drive Logic Supply 5 25 Vdc 150 mA and current Drive Motor Supply 12 to 40 Vdc 2 5 Amp Indexer Logic Supply 5 25 Vde 300 mA Fuse AGXA on the motor power supply Drive circuit Two phase bipolar chopper current regulated Bus voltage 12 to 40 Vdc fused input Rated current 2 5 Amp RMS nominal Step size Jumper selectable Steps motor 1 8 stepper motor Full 200 1 2 400 Chopper 17 kHz nominal frequency Maximum 10000 steps sec pulse rate 5220 Installation and Hardware Reference Manual R
12. amp 5 BIk amp Wht Org A puse 3 amp 6 Org amp Wht Blk A 2 amp 7 Red amp Wht Yel B 4 amp 8 Yel amp Wht Red B 6 lead unipolar 1 Black BIk A 3 Orange Org A 2 Red B 4 Yellow Yel B 6 amp 5 Wht Blk amp Wht Org none 7 amp 8 Wht Red amp Wht Yel none 5220 Instruction and Hardware Reference Manual Rev D 6 lead motor Connection table The 6 lead motor is normally used with unipolar drives In some cases the 6 lead motor can be used in a 4 lead series configuration for use with bipolar drives BLK WHT BLK ORG ORG WHT RED YEL Refer to the table below for detailed connection information Drive Connection Terminal Lead Color Connection 6 lead unipolar 1 Black Blk A 3 Orange Org A 2 Red B 4 Yellow Yel B 5 Wht Blk Org open 6 Wht Red Yel open 5220 Instruction and Hardware Reference Manual Rev D H 4 lead motor Connection table Drive Connection Terminal Lead Color Connection 4 lead bipolar 1 Black Blk A senas 3 Orange Org A 2 Red B 4 Yellow Yel B 5 Wht Blk Org None 6 Wht Red Yel None Note Terminals 7 and 8 are not used The 4 lead motor is for use only with bipolar drives BLK ORG RED YEL Refer to the table below for detailed connection information 5220 Instruction and Hardware Reference Manual R
13. are e 5220 definition System diagram e How to use this manual e Warranty information 1 1 5220 Definition The Pacific Scientific 5220 Indexer Drive combines a high performance bipolar MOSFET chopper drive with simple one letter mnemonic programmable indexer for stepper motor motion control 5220 Block diagram 120 230 VAC RS 232 POWER SUPPLIES 5 PROGRAMMABLE VOPORTS lt 2 L 5 VDC JOG HI LO JOG 2 PHASE JOG 3 P PHASEA STEP MOTOR LIMIT 1 PROGRAMMABLE gt S raerce gt INDEXER y LIMIT 2 3 OPTO 5210 HOME SWITCH BIPOLAR DRIVE Rs REMOTE START OPTO gt PHASE B REMOTE STOP gt DISABLE MOVING lt DISTANCE EVENT NOVRAM 5220 Installation and Hardware Reference Rev D 1 1 Drive features Output current Constant current 2 5 Amps per phase 1 25 Amps per phase with idle current reduction active Bipolar chopper drive Full bridge MOSFET high frequency inaudible 17 KHz PWM chopping drive Power supplies Operates from two or three DC supplies depending if the optical isolation between the indexer and drive is used The drive requires 5 Vdc logic supply at 150 mA and 12 to 40 Vdc motor supply with a current of 2 5 Amp The indexer can be powered from a separate isolated 5 Vdc power supply at 300 mA or fr
14. ooiuF 5VDC 35K V CD4503 v SWITCH RELAY CONTACT 5VDC ik e 5VDC 0 01 5VDC VV e P 35K CD4503 i OPEN COLLECTOR 5VDC 5VDC 10K 0 01 uF 5VDC eww AA e P o 35K CD4503 e OPTO ISOLATOR USER POWER SUPPLY 12 TO 24 VDC 5VDC e 5VDC 10K 0 01 5VDC e gt o 35K 1 04503 1 1K SOURCING TRANSISTOR 5220 Installation and Hardware Reference Manual Rev D J1 Discrete cont 4002 5voc 74HC7LS367 To RELAY COIL m USER POWER SUPPLY 0 TO 24 VDC 50 mA SOURCE VoH 3 9V 20 mA SINK VoL 0 5V V RELAY LOAD yo 5 VDC 5 e Lb USER POWER SUPPLY 74HC7LS367 0 TO 24 VDC 50 mA SOURCE VoH 3 9V 20 mA SINK VoL 0 5V Vv RESISTIVE LOAD iru Du f ato 74HC7LS367 50 mA SOURCE VoH 3 9V 20 mA SINK VoL 0 5V OPTO ISOLATOR LOAD WM USER POWER SUPPLY 0 TO 24 VDC yo vpc 74HC7LS367 50 mA SOURCE VoH 3 9V 20 mA SINK VoL 0 5V LED INDICATOR LOAD 5220 Installation and Hardware Reference Manual Rev D Q NO USER POWER SUPPLY 0 TO 24 VDC Appendix Jumper Settings Introduction E1 and E2 E4 E5 This appendix provides a summary of jumper settings 1 and E2 are used to set RS 23
15. p SCIENTIFIC AUTOMATION TECHNOLOGY GROUP 5220 Stepper Motor Indexer Drive MOTION TECHNOLOGY DIVISION 110 Fordham Road Wilmington MA 01887 978 988 9800 Fax 978 988 9940 Part 903 522000 03 List Price 25 U S September 1997 Rev D Installation and Hardware Reference Rev D Table of Contents 1 Overview of 5220 1 1 14 5220 Definitio z Tu 626304858 au Pade G24 que VENE PS 1 1 1 2 System Diagram 5 6s e496 ee ee eee 469 BG ew 1 3 1 3 Use this ec e e p omeo 1 4 L4 Warranty i es kom RR G Q Pee W S 1 5 2 Installing the 5220 2 1 2 1 Unpacking and 5220 2 1 2 2 SelectingaMotor 2 2 2 3 5220 Safety u 5 c CRE EAE E 2 2 2 4 Mounting the 5220 in Your Installation 2 4 2 5 Connecting the Four Input Output 2 6 25 1 J3 MotorConnection 2 8 2 5 1 4 lead Motor u vce p sss dE GE 2 10 2 5 1 2 8 lead Motor Series Connected 2 11 2 5 1 3 8 lead Motor Parallel Connected 2 13 2 5 2 J5 Power Supply Connection 2 14 2 5 3 J2 Serial Port 2 16 2 5 3 1 RS 232 Connection 2 18 2 5 4 Discrete Inputs Outputs 2 20 2 6 J
16. parametric oscillation of the motor current resulting in a reduction of torque at mid range speeds Using the non recirculation mode will reduce the systems susceptibility to mid range instability Note The factory default setting is for recirculating mode E3 in L C position 2 6 3 E4 Step Size Operation The drive can be configured to FULL or HALF step operation The step size sets the amount of rotation per input step Step Size Full step 200 step rev Half step 400 step rev L C Settings Refer to Appendix F Stepping Motor Basic and Appendix I Phasing Sequencing for additional information Note The factory default setting is for Half step operation E4 in L C position 2 30 5220 Installation and Hardware Reference Manual Rev D 2 6 4 5 Idle Current Control If enabled the driver will reduce the output current to 1 25 Amp if no motor motion is commanded after 0 1 second Once the motor motion is commanded the output current will be boosted back to 2 5 Amp This feature reduces motor heating in idling case Settings Configuration 5 Idle Current Reduction On H C Idle Current Reduction Off L C Note The factory default setting is idle current reduction on E5 in H C position e When ICR is enabled the holding torque generated by the motor is reduced by approximately 50 e When ICR is enabled the motor st
17. terminal or computer type R1000 lt enter gt This will move the motor at velocity of 1000 steps per second clockwise Type R 1000 enter This will change the direction of the motor rotation Type S enter The motor should stop rotating If the controller passes all of the above then you may start exercising the unit on your own If the 5220 does not pass all of the above steps refer to Section 4 2 Troubleshooting 5220 Installation and Hardware Reference Manual Rev D 3 3 4 Maintaining Troubleshooting In this Chapter This chapter covers maintenance and troubleshooting of the 5220 indexer drive 4 1 Maintaining the 5220 Introduction The 5220 module is designed for minimum maintenance The following cleaning procedures performed as needed will minimize problems due to dust and dirt build up Procedures Remove superficial dust and dirt from the module using clean dry low pressure air 4 2 Troubleshooting the 5220 Introduction The LEDs located on the front panel indicate the controller status and are used for troubleshooting A table of the LEDs referencing the appropriate section for troubleshooting follows LED indicators problem When this Reference LED is on It signifies section Power Connection to logic supply is 3 2 1 within operational levels Disable Either an external or internal 3 2 2 short or internal power supply problem Communications inter
18. 150 mA and 12 to 40 Vdc motor supply with a current of 2 5 Amp The indexer can be powered from a separate isolated 5 Vdc power supply at 300 mA or from the same 5 Vdc supply used for the drive logic supply One advantage of using the isolated supply is that the motor return is not connected to the same return as the RS 232 source Use 18 to 16 gauge shielded wire for the cabling 5220 Installation and Hardware Reference Manual Rev D Cabling diagram MOTOR INPUT 45 49 a SUPPLY 16 20 LOGIC INPUT 5 POWER 2506 Ne 4 INDEXER INPUT 5 POWER 5 VDC 25 CHASSIS GROUND NUP Le Procedure 1 Strip the wires 0 27 inch 7 mm 2 Attach the wires to the connector as indicated in the diagram Note Make sure the screws on the Phoenix connector are tightened down firmly on the wiring Caution Do not pre tin solder the tips of the cables going into the Phoenix connector This can result in a loose connection Warning The chassis ground must be tied to earth ground Failure to do this leaves the potential for severe hazard Make sure the ground is connected via the ground stud on the front of the 5220 3 Plug the mating connector firmly into the 5220 5220 Installation and Hardware Reference Manual Rev D 2 15 2 5 3 J2 Serial Port Connection Introduction Single and multi unit control Mating
19. 2 3 2 4 Mounting the 5220 in Your Installation Cabinet Select a standard 8 inch 205 mm deep NEMA National selection Electrical Manufacturers Association enclosure appropriate for industrial applications Caution The internal cabinet temperature should not exceed 50 C 60 C with derating If the cabinet is ventilated by filtered or conditioned air make sure to prevent the accumulation of dust and dirt on the unit s electronic components The air should also be free of corrosive or electrically conductive contaminants Mounting dimensions gt lt 0 187 U TYP 13 PLACES U 55 U U DOM yD Zl i Lb TYP 13 PLACES i 2 60 MTG i 6 70 5 20 1 i MTG D 6 30 MTG 5 20 MTG i xX gt gt i i v n A n i 2 65 MTG gt k yy 50 55 5 5 30 MTG 1 55 MTG 75 75 lt gt 9 6 60 2 25 SIDE VIEW FRONT VIEW 2 4 5220 Installation and Hardware Reference Manual Rev D Mounting guidelines Mounting procedure Power dissipation for the cabinet Select a cabinet position that meets these guidelines e Flat solid surface capable of supporting the approximate 1 5 Ibs 0 70 Kg weight of the unit Free of excessive vibration or shock e Minimum unobstructed space of four inches 100 mm at the unit bottom four inches at the exhaust on the unit top a
20. 2 configuration Configuration 1 2 J2 2 TXD 2 3 RXD H C L C J2 2 RXD J2 3 TXD L C H C E3 is used to set the current control Current Control Recirculating mode L C Non recirculating mode H C E4 is used to set step size Step Size E4 Full step operation H C Half step operation L C 5 is used to set idle current control Idle Current Control 5 Idle current reduction On H C Idle current reduction Off L C 5220 Installation and Hardware Reference Manual Rev D E16 E17 and These jumpers are used to set baud rate E18 Baud Rate E16 E17 E18 9600 L C L C L C 4800 H C L C L C 2400 L C H C L C 1800 H C H C L C 1200 L C L C H C 600 H C L C H C 300 L C H C H C Illegal H C H C H C Note These jumper settings are read only at power up D 2 5220 Installation and Hardware Reference Manual Rev D locations CURRENT CONTROL RS 232 PORT RS 232 BAUD MODE SELECT CONFIGURATION SELECTION RATE SELECTION FULL HALF STEP SELEC
21. 9 030 In addition make the following connections at the motor Org Wht 099 ani gt Wire Nuts RedWht 090060 Procedure 1 Strip the wires to 0 27 inch 7 mm 2 Referring to the diagram attach the wires to the connector Connect the white striped leads with wire nuts as shown Note Make sure the screws on the PCD connector are tightened down firmly on the wiring Caution Do not pre tin solder the tips of the cables going into the PCD connector This can result in a loose connection 3 Remove power from the 5220 Warning Always remove power before making or removing connections to the unit The motor terminals have high voltage present when the 5220 is On Plug the mating connector firmly into the 5220 Connect the cable shield to 5220 ground if applicable Plug the other mating connector into the motor BR Switch the 5220 2 12 5220 Installation and Hardware Reference Manual Rev D 2 5 1 3 8 Lead Motor Parallel Connected Introduction Cable requirements Cabling diagram Procedure For an 8 lead motor to be wired in parallel build and install the cable as follows Note For addtional information refer to Appendix H Series Parallel Connections Use 18 to 16 gauge stranded wire for the cabling Obtain cable with each winding pair see diagram twisted at about 3 to 4 turns per inch 1 to 1 5 turns per centimeter Make sure the ca
22. D 2 7 2 5 1 J3 Motor Connection Introduction Mating connector Making your own cable Pacific Scientific cable 2 8 The J3 motor cable connects the drive to the motor windings Motor cables are available from Pacific Scientific or you can make your own The J3 motor connector is for a PCD 5 pin screw mating connector The mating connector supplied with the unit is ELFH051 10 If you need to build the cable refer to the appropriate subsection as follows Motor type Refer to section 4 lead 29 11 8 lead series 2 5 1 2 8 lead parallel 2 5 1 3 If the motor cable is purchased from Pacific Scientific install as follows The Pacific Scientific order number is SPC xxx where is the length of the cable in one foot increments up to 50 feet For example SPC 050 is a cable 50 feet long 5220 Installation and Hardware Reference Manual Rev D Pacific If you are using Pacific Scientific motor cable with the mating Scientific connectors already attached install as follows cabling installation Pacific Scientific cable Q diagram T 9 S J1 JACKET mies Pal ORG MOTOR RED PHASES 3 1 CL SHIELD GRN GND 5 VU E 5 PIN PCD SPC XXX 5 PIN MS CONNECTOR MS3116F14 5S Procedure 1 Remove power from the 5220
23. T IDLE CURRENT REDUCTION ON OFF J1 C29 1 N e 2 U1 3 11 2 HCL 1 HOTI ES 012 26 9 10 11 12 BB 15 J3 g Oz C e 208 lg LED1 d T1 1 T1 2 E 1016 1 RED ASSY NO 105 524000 _ E J4 REV__ IMEC CORP SERIAL NO 5220 Installation Hardware Reference Manual Rev D Appendix E 1 0 Summary amp Pinouts J1 interface Pinout Description J1 1 Port 5 Out J1 2 Port 3 Out J1 3 Port 1 Out J1 4 Port 2 In J1 5 Port 1 In J1 6 I O 5 Vdc J1 7 Port 4 In J1 8 Remote Stop J1 9 Remote Start J1 10 Hi Lo Jog Speed J1 11 Distance Event J1 12 Direction Limit J1 13 Home Switch J1 14 Port 4 Out J1 15 Port 2 Out J1 16 I O 5 Vdc J1 17 I O 5 Vdc Output J1 18 Port 3 In J1 19 Port 5 In J1 20 I O 5 Vdc J1 21 Enable Disable J1 22 Moving J1 23 Direction Limit J1 24 JOG J1 25 JOG 5220 Installation and Hardware Reference Manual Rev D 42 RS 232 Pinout Description Interface J2 5 RS 232 Common J2 7 RS 232 Common J2 2 TXD or RXD J2 3 RXD or TXD Note All other pins on J2 are not connected Pinout Description J3 Motor J3 1 Motor Phase A J3 2 Motor Phase A J3 3 Motor Phase B J3 4 Moto
24. ating the motor using series connection since its current rating is lower in this mode Series connection also carries a greater likelihood of resonance problems due to high torque produced in the low speed region 5220 Instruction and Hardware Reference Manual Rev D Appendix Phasing Sequencing Introduction This appendix provides information on phase sequencing for the following set ups e Bipolar half step Bipolar full step Use the following key to interpret sequence tables Phase Sequencing Key 0 Off or Open Current in to winding Current out of winding Bipolar The table below shows phase sequencing for bipolar half step Half step motors un e gt l CW S gt S O 1 CCW Sirti nl na RU Rm 1 S 1 5220 Instruction and Hardware Reference Manual Rev D 1 1 Bipolar The table below shows phase sequencing for bipolar full step Full step motors Step A B B cw 1 2 3 E 4 1 CCW 5220 Instruction and Hardware Reference Manual Rev D Address 4 5 Altitude 2 Baud rate 2 17 2 32 Block diagram 1 1 Bus voltage A 1 Cabling PacSci diagram 2 9 Case temperature 2 2 Chopper frequency A 1 Cleaning unit 4 1 Communications interface fault
25. ble contains a lead for grounding As an option the cable may be shielded to reduce radiated noise The colors referenced in the diagram follow the Pacific Scientific stepper motor color code A BLACK ORG WHT gt 7 A ORANGE yP TO BLK WHT 2 TO MOTOR B RED DRIVE YEL WHT lr na B YELLOW V RED WHT GND GREEN LIE 7 mm 5220 Installation and Hardware Reference Manual Rev D 2 13 LN 1 Strip the wires so that the twisted ends will be the length shown 2 Referring to the diagram twist the striped and solid lead ends and attach the wires to the connector Note Make sure the screws on the PCD connector are tightened down firmly on the wiring Caution Do not pre tin solder the tips of the cables going into the PCD connector This can result in a loose connection 3 Remove power from the 5220 Warning Always remove power before making or removing connections to the unit The motor terminals have high voltage present when the 5220 is On 2 5 2 J5 Input Power Supply Connection Mating connector Power supplies Cable requirements The J5 input power is for a Phoenix 7 pin screw mating connector The connector supplied with the unit is type MSTB 1 5 7 ST 5 mm The drive operates from two or three DC supplies depending on whether the optical isolation between the indexer and drive is used The drive requires 5 Vdc logic supply at
26. c stepping motors are designed with a 1 8 full step or 0 9 half step commutation 5220 Installation and Hardware Reference Manual Rev D Appendix G Low Speed Resonance Problems A stepper motor is a rotary spring mass system The mass is the motor s rotor inertia plus any load inertia The spring is the torque produced by the motor which for small deflections is proportional to the angle between the actual and commanded positions If the shaft of the motor is displaced from its holding position by a small angle and then suddenly released it will swing back and forth around the holding position in a gradually decaying oscillation before eventually coming to rest As with any lightly damped resonant system a stepper motor can be made to oscillate at its natural or resonant frequency if it is excited by torque pulses occurring at this rate This will happen if the step rate equals the resonant frequency The resonant frequency of a stepper motor having 200 full steps per revolution is given by F resonant hz 1 1 SOR Holding Torque J totai where Holding Torque is given in oz in and Jii is the motor plus load inertia in oz in sec For example the resonant frequency of an unloaded E34HCHT LNK NS 00 motor having rotor inertia equal to 0 035 oz in and holding torque of 1222 oz in at 5 amps phase current is F resonant 1 1 SQR 1222 035 206 Hz If the motor were run at 206 full steps per second 62
27. d motor Connecting the two half windings of an 8 lead motor in parallel allows the current to divide itself between the two coils It does not change the effective number of turns and therefore the inductance remains the same At a given drive current the torque characteristics will be the same for the two half windings in parallel as it is for one of the windings on its own Connecting the windings of an 8 lead motor in parallel has the same effect as halving the total resistance For the same power dissipation in the motor the current may now be increased by 40 Therefore the 5 amp motor will accept 7 amps with the winding in parallel This provides a significant increase in the available torque Parallel in a 6 lead motor refers to the use of one half winding only The current rating of a stepper motor is determined by allowable temperature rise Unless the motor manufacturer s data states otherwise the rating is a unipolar value and assumes both phases of the motor are energized simultaneously Therefore a current of 5 amps means that the motor will accept 5 amps flowing in each half winding As a general rule parallel connection is preferred over the other options It produces a flatter torque curve and greater shaft power Series connection is useful when a high torque is required at low speeds It allows the motor to produce full torque at low speeds from lower current drives Care should be taken to avoid overhe
28. e 5 msec minimum will initiate program execution starting at address 0 Equivalent to G 0 command This input is TTL compatible and internally pulled via a 10 KW resistor to 5 Vdc Refer to input figure below Remote Stop J1 8 Forcing this input to a low state 5 msec minimum while a motion is in progress will cause the motor to decelerate to a stop If a program is being executed the program execution will be terminated This input is equivalent to the S command in the COMMAND immediate mode This input is TTL compatible and is pulled internally via a 10 KW resistor to 5 Vdc Refer to the input figure below Input circuitry 5V 10K 33K 0 01 uF 5V 5V JT 8 9 CD4503 V 2 24 5220 Installation and Hardware Reference Manual Rev D Input Output Pin Number Explanation Moving J1 22 This output is forced low while the motor is being commanded to move If the motor falls out of sync but is still being commanded to move this output is still low The output goes high whenever the motor is not being commanded to move This output is TTL compatible and has a sourcing capability of 5 mA Refer to outputs figure below Distance Event J1 11 This output is used as a position trigger indicator It is a programmable output using the 0 and Y64 commands refer to the programming manual This outpu
29. ent will Pacific Scientific Company be responsible or liable for indirect or consequential damage resulting from the use of this product Safety To minimize shock hazard all components should be connected background to a common earth point 2 2 5220 Installation and Hardware Reference Manual Rev D The internal drive circuitry will vary from 38 volts above to 38 volts below earth ground potential Warning The circuits in the 5220 are a potential source of severe electrical shock Follow the safety guidelines to avoid shock Safety To avoid possible personal injury whenever you are working with guidelines the 5220 Do not power up the unit without the chassis tied to earth ground Do not operate the unit without the motor case tied to earth ground Do not make any connections to the internal circuitry The indexer is optically isolated from the drive module All user I O circuitry is connected to this board Always remove power before making or removing connections from the unit Allow the unit to sit for five minutes to discharge the bus capacitors when power is turned off Be careful of the motor terminals when disconnected from the motor With the motor disconnected and power applied to the drive the motor terminals have high voltage present Do not use the disable input as a safety shutdown Always remove power to the drive for a safety shutdown 5220 Installation and Hardware Reference Manual Rev D
30. ev D Drive Connection Terminal Lead Color Connection 4 lead bipolar 1 Black Blk A 2 Orange Org A 3 Red B 4 Yellow Yel B Note Terminals 5 7 and 8 are not used Winding Connections Series Parallel Connecting both halves in series results in the drive current flowing through twice as many turns compared with using one half winding only For identical currents this doubles the amp turn and produces a corresponding increase in torque In practice the torque increase is seldom 100 due to the non linearity of the magnetic material Equally the same torque will be produced at half the drive current when the windings are in series Doubling the effective number of turns in the windings means that the inductance increases by a factor of four This causes the torque to drop off much more rapidly as speed increases As a result the series mode is only useful at low speeds The maximum shaft power obtainable in series is typically half that available in parallel using the same current setting on the drive Conversely connecting the windings in series will double the total resistance and the current rating is reduced by a factor of 1 4 The provides a safe current of 3 5 amps for a 50 amp motor series 5220 Instruction and Hardware Reference Manual Rev D H 8 lead 6 lead Summary Winding can be connected in parallel is either an 8 lead motor of 6 lea
31. ev D Environmental Operating temperature Storage temperature Humidty Altitude Mechanical Dimensions Weight 0 to 50 degrees C at full rated current 0 to 60 degrees C 2 5 Amp RMS with idle current reduction enabled 25 to 85 degrees C 10 to 90 noncondensing 5 000 feet 1500 meters For an estimate of the power dissipation for use in cabinet cooling requirements assume 20 watts power dissipation in the 5220 Refer to Section 2 4 1 5 lbs approximately 0 7 Kg 5220 Installation and Hardware Reference Manual Rev D Appendix Order Number amp Ordering Information Background 5220 part number table This appendix lists the 5220 part numbers and gives information on ordering Part Order Number Comment Indexer Drive 5220 Connector kit 106 522000 01 25 pin D connector 9 pin D connector 7 pin Phoenix 5 pin PCD Installation 903 522000 03 Manual Programming 903 524000 02 Manual Paccom disk 904 000201 01 Paccom manual 903 000201 01 Motor cable SPC xxx 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 5220 Installation and Hardware Reference Manual Rev D How to order Contact Pacific Scientific to order these parts Call 978
32. face 3 2 3 5220 Installation and Hardware Reference Manual Rev D 4 2 1 POWER LED Not On 5220 does not power up Procedure Follow this procedure if the 5220 POWER LED will not light when power is applied Is Drive logic supply NO Connect Drive logic applied supply J5 3 J5 4 YES Is Drive logic supply NO Apply correct voltage within operational range 4 75 to 5 25 YES Internal failure Contact Pacific Warning Do not operate the unit without the chassis tied to earth ground Contact with energized components causes severe shock or burn 4 2 5220 Installation and Hardware Reference Manual Rev D 4 2 2 DISABLE FAULT LED On 5220 contains power fault Procedure Follow this procedure if the 5220 DISABLE FAULT LED lights during operation Remove all input power NO Check hardware disable and then the motor Does DISABLE LED go off connector J1 Reapply power Does DISABLE YES No LED go off 5220 DISABLE Check software C fault fixed command Does DISABLE LED go YES Check cables for shorts Check connections NO Reapply power Does Cable or internal failure DISABLE LED go off Contact Pacific Scientific YES 5220 DISABLE fault fixed 5220 Installation and Hardware Reference Manual Rev D 4 2 3 5220 Does Not Respond
33. g dimensions 2 4 Moving 2 25 Multi axis 1 3 Multiple units 2 19 Operating temperature A 2 Ordering information B 2 Order number B 1 Output current 1 2 Overview 1 1 Index 2 5220 Instruction and Hardware Reference Manual Rev D P System diagram 1 4 Pacific Scientific cabling 2 9 Packing list 2 1 T Parallel connection H 1 Temperature A 2 Phase sequencing I 1 Pinout C 1 E 1 Pet PH connections 3 1 Port connections 2 16 signals 3 3 Power dissipation 2 5 POWER LED not on 4 2 Power supply 2 14 A 1 E 2 Power up 3 1 U Troubleshooting 4 1 Protection short circuit 1 2 Pulse rate A 1 Unpacking 2 1 Voltage input A 1 Remote start 2 24 Remote stop 2 24 Returns 4 5 4 5 Warranty 1 5 S Y Safety 2 2 Sequencing phase I 1 Y command 2 20 Serial port connection 2 16 Serial number 2 1 Series connection H 1 Short circuit protection 1 2 Signals test 3 3 Specifications 1 Step Size 1 operation 2 30 Stepper motor basics F 1 Storage temperature 2 1 A 2 Storing unit 2 1 5220 Instruction and Hardware Reference Manual Rev D Index 3
34. iffness around the holding position is reduced by approximately 50 5220 Installation and Hardware Reference Manual Rev D 2 31 2 6 5 E16 E17 and E18 Baud Rate Setting There are 7 different RS 232 baud rate settings available These jumpers must be set prior to power up Baud Rate E16 E17 E18 9600 L C L C L C 4800 H C L C L C 2400 L C H C L C 1800 H C H C L C 1200 L C L C H C 600 H C L C H C 300 L C H C H C Illegal H C H C H C Note The factory default setting is for 9600 baud all jumpers in the L C position Jumper settings are only read at power up 2 6 6 Jumper Location 2 32 5220 Installation and Hardware Reference Manual Rev D CURRENT CONTROL RS 232 PORT RS 232 BAUD MODE SELECT CONFIGURATION SELECTION RATE SELECTION FULL HALF STEP SELECT IDLE CURRENT REDUCTION ON OFF J1 c29 1 N 2 e 2 2 u1 3 J5 31 1 2 HCL 1 H Es L U12 C26 228 E9 E10 E11 E12 EB E14 22 s Qu Ee c QO g 5 O LED1 9 T1 1 T1 2 ILED2 x 1 RED m 3 ASSY NO 105 524000 _ J4 REV__ IMEC CORP SERIAL NO
35. l 9 PIN M SERIAL PORT Lo 12 2 TXD TRANSMIT 5220 1 323 2 2 RXD RECEIVE J2 5 re 5 5 SIGNAL GND V tb 1 2 18 5220 Installation and Hardware Reference Manual Rev D Procedure Note Pinouts vary among computer manufacturers Check the cont d hardware reference manual for your machine before wiring the serial port 4 Plug the connector into the input and affix the connector to the unit with screws Multiple units Multiple 5220s can be connected as follows J2 RXD COMMON TXD RS 232 J2 2 TXD COMMON HOST OR PC 3 TXD RXD COMMON RXD TXD COMMON J2 5220 Installation and Hardware Reference Manual Rev D 2 19 2 5 4 J1 Discrete Inputs Outputs Connection Introduction J1 connector contains all programmable inputs and outputs There are five user programmable bi directional I O ports To avoid confusion it is recommended that each port be used as an input or output only Note Refer to the K and Y commands in the programming section Port Pin Number Command T O Port 1 J1 5 KI Input 1 J1 3 YI Output 1 Port 2 11 4 K2 Input 2 J1 15 Y2 Output 2 Port 3 J1 18 K3 Input 3 J1 2 Y3 Output 3 Port 4 J1 7 K4 Input 4 J1 14 Y4 Output 4 Port 5 J1 19 K5 Input 5 J1 1 Y5 Output 5 The i
36. nd one inch on each side The front view is preferred as it allows for greater surface area e Operating temperature of to 50 degrees C at full rated current 0 to 60 degrees C at 2 5 amp current setting with idle current reduction enabled Refer to the dimensions figure and mounting guidelines The 5220 dissipates power causing cabinet heating Power dissipation is determined by a number of factors such as output current motor winding impedance input step rates and idle current reduction The 5220 is factory preset for 2 5 amps phase current and idle current reduction enabled Maximum power dissipation under these conditions is 20 watts Use this value to determine cabinet cooling requirements 5220 Installation and Hardware Reference Manual Rev D 2 5 2 5 Connecting the Four Input Output Cables Introduction Connection diagram DISCRETE I O SERIAL PORT PORT 5 OUT PORT 3 OUT PORT 1 OUT PORT 2 IN PORT 1 IN 1 0 5 Vdc RTN PORT 4 IN REMOTE STOP REMOTE START HI LO JOG SPEED DISTANCE EVENT DIRECTION LIMIT HOME SWITCH PORT 4 OUT PORT 2 OUT 1 0 5 Vdc RTN 1 0 5 Vdc OUT PORT 3 IN PORT 5 IN 1 O 5 Vdc RTN ENABLE DISABLE MOVING DIRECTION LIMIT JOG JOG RS 232 TXD RXD RXD DEFAULT RS 232 TXD RXD TXD DEFAULT RS 232 COMMON RS 232 COMMON 120 230 Vac 50 60 Hz POWER J3 Motor J5 Input power J2 RS 232 serial port J1 Discrete inpu
37. nd Hardware Reference Manual Rev D gt Wire Nuts ED 8 lead parallel For eight lead parallel wiring to the 5 pin connector wire as follows A BLACK ORG WHT 7 A ORANGE TO BLK WHT MOTOR BRED DRIVE YEL WHT s B YELLOW RED WHT ize GND GREEN 7 mm J5 Power supply A MOTOR INPUT 12 TO 40 LOGICINPUT 5VDC N 2 POWER 5 VDC N 3 e 40 INDEXER INPUT 5 N POWER 5 VDC 5o 6 CHASSIS GROUND r IN R 2 5220 Installation and Hardware Reference Manual Rev D J2 Serial port RS 232 E2 H l c 25 PIN MN SERIAL PORT E J2 2 2 2 TXD TRANSMIT 5220 J2 3 E1 3 3 RXD RECEIVE five J2 5 KM 7 7 SIGNAL GND v IL 1 2 l H 1 9 PIN M SERIAL PORT G 3 3 TXD TRANSMIT 5220 J2 3 E1 2 2 RXD RECEIVE H u2 5 Ls d SIGNAL GND if ov 1 Multiple units 12 daisy on chained COMMON TXD RS 232 J2 2 TXD RXD COMMON HOST OR PC 3 TXD RXD COMMON RXD TXD COMMON J2 5220 Installation and Hardware Reference Manual Rev D C 3 J1 Discrete 5VDC I O e 5 0 10K
38. nit by model number serial number and date code Inspect the unit for any physical damage that may have been sustained during shipment If you find damage either concealed or obvious contact your buyer to make a claim with the shipper Do this as soon as possible after receipt of the unit Store the 5220 in a clean dry place humidity 10 to 90 non condensing The storage temperature must be between 25 to 85 C To prevent damage during storage place the unit in the original shipping carton 2 2 Selecting a Motor The 5220 is designed for use with Pacific Scientific s line of hybrid 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 equal to or greater than the output current of the indexer drive package 2 5 Amps The electrical and magnetic losses of the motor must not exceed the motor power dissipation rating This is a concern at higher speeds and with low inductance motors The case temperature should not exceed 100 degrees C 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 2 3 5220 Safety Your As the user or person applying the unit you are responsible for responsibility determining the suitability of this product for any application you intend In no ev
39. not pre tin solder the tops of the cables going into the Phoenix connector This can result in a loose connection 3 Remove power from the 5220 Warning Always remove power before making or removing connections to the unit The motor terminals have high voltage present when the 5220 is On Plug the mating connector firmly into the 5220 4 5 Connect the cable shield to 5220 ground if applicable 6 Plug the other mating connector into the motor 7 Switch On the 5220 2 5 1 2 8 Lead Motor Series Connected Introduction For an 8 lead motor to be wired in series build and install the cable as follows Note For addtional information refer to Appendix H Series Parallel Connections Cable Use 18 to 16 gauge stranded wire for the cabling Obtain cable requirements with each winding pair see diagram twisted at about 3 to 4 turns per inch 1 to 1 5 turns per centimeter Make sure the cable contains a lead for grounding As an option the cable may be shielded to reduce radiated noise 5220 Installation and Hardware Reference Manual Rev D 2 11 Cabling The colors referenced in the diagram follow the Pacific Scientific diagram stepper motor color code A Black A 27 C mm To Drive A Orange L 2 7 mm To Motor B Red EN C B Yellow 27 7 mm Motor Case Zum Gnd Green 1 LD LILIA LS LG O
40. nput ports through K5 are TTL compatible and have a 10 KW pull up resistor to 5 Vdc The output ports through Y5 are also TTL compatible and with a source capability of 5 mA and a sink capability of 20 mA 2 20 5220 Installation and Hardware Reference Manual Rev D Bi direction I O port circuitry power circuitry 5V 5V 5V gt 0 014F READ PORT ar R COMMAND 33K K1 K5 o e J1 4 5 7 18 19 CD4503 V ESV SET PORT Y COMMAND Y1 Y5 J1 1 2 5 mA SOURCE 74HCTLS367 3 14 15 VoH 3 9V 20mA SINK v VoL 0 5V Pin Input Output Number Explanation I O 5 Vdc Output J1 17 I O 5 Vdc RTN 11 6 11 16 11 20 The 5 output is current limited by an internal 47 W resistor Refer to the I O power figure below 47 5 Q 1 0 5VDC O J1 17 5 o 5V 1 6 16 20 5220 Installation and Hardware Reference Manual Rev D Input Output Pin Number Explanation HI LO Jog Speed J1 10 JOG J1 25 JOG 11 24 These inputs are used to jog the stepping motor The two JOG speeds hi or low are programmable through the 11 hh command Refer to the programming section The selection of the jogging speed depends on the input of JOG HI LO input A high 5 Vdc input selects the LO speed and a low 0 Vdc i
41. nput selects the HI speed The JOG and JOG input causes motor rotation in the appropriate direction when pulled low These inputs are TTL compatible and are pulled up internally via a 10 KW resistor to 5 Vdc Refer to Input figure below Input circuitry 5V 5V J1 10 24 25 2 22 CD4503 5220 Installation and Hardware Reference Manual Rev D Input Output Pin Number Explanation Direction LIMIT J1 12 Direction LIMIT J1 23 These inputs are intended to be used as overtravel limit switches The motor motion will be ceased in the appropriate direction when either input is forced to a low state These inputs are TTL compatible and internally pulled up via a 10 KW resistor to 5 Vdc Refer to the input figure below Home Switch J1 13 This input provides a mechanical position reference for the indexer Refer to command in the programming section This input is TTL compatible and internally pulled up via a 10 KW resistor to 5 Vdc Refer to the input figure below Input circuitry O 5V 10K 33K 0 01 5V 5V J1 12 13 23 CD4503 5220 Installation and Hardware Reference Manual Rev D Input Output Pin Number Explanation Remote Start J1 9 This input can be used to initiate an execution of a stored program Forcing this input to a low stat
42. om the same 5 Vdc supply used for the drive logic supply To increase noise immunity and prevent ground loops the optically isolated connection is recommended so the motor return is not connected to the same return as the RS 232 and discrete I O returns Short circuit protection Latches the drive off and lights the DISABLE LED if a short circuit occurs on the motor outputs After removing the short circuit the DISABLE LED will go off Reset the 5220 by switching the power OFF and then ON Overtemperature The drive is equipped with an overtemperature shut down detection circuit Step size Sets the amount of rotation per step There are two settings full and half step Idle current reduction ICR reduces motor windings current by 50 during motor dwell periods ICR begins 0 1 second after the last input step Status indicators LEDs for operation and troubleshooting information 5220 Installation and Hardware Reference Rev D Indexer features The indexer circuit provides programmable motion control and allows flexible interfacing to the application Features include Mnemonic commands Twenty seven simple one letter commands used for motion control Serial port RS 232 communications Interfacing with computer or terminal programming and or computer control 300 to 9600 baud selectable Multi axis Daisy chain allows controlling multiple 5220 controllers through a single host or computer Input Output p
43. orts Five general purpose bi directional user programmable input output ports Memory Indexer is made to implement 256 bytes of non volatile NV memory allowing storage of power up default parameters and user s program 1 2 System Diagram The diagram on the following page shows an installation of the indexer drive in a typical system Your system may vary from this configuration Typical components used with 5220 include Stepper motor e Computer or terminal External switches 5220 Installation and Hardware Reference Rev D 1 System diagram PORT 5 OUT 1 JACKET PORT 3 OUT 2 PORT 1 OUT 3 n SHIELD 2 PORT 2 IN 2 A PHASE PORT 1 IN 5 3 B STEPPING 1 0 5 Vdc RTN 4 B MOTOR PORT 4 IN 7 5 SHIELD REMOTE STOP REMOTE START 6 J3 HI LO JOG SPEED 10 m DISTANCE EVENT 11 m DIRECTION LIMIT 12 HOME SWITCH 13 2 PORT 4 OUT 14 a PORT 2 OUT 15 1 0 5 RTN 16 1 0 5 Vdc OUT 17 PORT 3 IN 18 SCIENTIFIC PORT 5 IN 19 1 0 5 RTN 20 5220 ENABLE DISABLE 21 MoVNG 22 INDEXER DIRECTION LIMIT 23 DRIVE JOG 24 JOG 25 J1 y 9 232 TXD RKD AXD DEFAULT 2 RS 232 TXD RXD TXD DEFAULT 9 4 a RS 232 COMMON 5 lt s 6 5 RS 232 COMMON 7 8 9 J2 m 1 120 230 Vac 2 50 60 Hz POWER J4 777 1 4 5220 Installation and Hardware Reference Rev D
44. r Phase J3 5 Motor Ground Pinout Description J5 1 Drive motor input J5 Power J5 2 12 to 40 Vdc at 2 5 Amp Supply J5 3 Drive logic input power J5 4 5 25 Vdc at 150 mA J5 5 Indexer input power 15 6 5 25 Vdc at 300 mA J5 7 Frame ground E 2 5220 Installation and Hardware Reference Manual Rev D Appendix Stepper Motor Basics Hybrid A hybrid stepping motor can be simplified to the diagram shown stepping motor below The stator consists of two phase windings and the rotor is a permanent magnet The rotor aligns itself with the magnetic field created by the stator windings By controlling the winding currents in the proper sequence torque is produced and the rotor will rotate in the desired manner The phase currents are bidirectional and sequencing of these phase currents is termed commutation There are three basic types of stepping motor commutation possible with the 5240 module e One phase on Drive or Wave Drive e Full step Drive Half step Drive One Phase On Drive or Wave Drive In this type of commutation only one phase of the stepping motor is on at any given time Phases are energized in the following sequence AA BB AA BB Note AA means that the phase current is flowing from A to A 5220 Installation and Hardware Reference Manual Rev D F 1 The figure below shows the commutation sequence for clockwise rotation of a
45. r to the unit whenever the covered is removed 2 6 1 E1 and E2 RS 232 Port Configuration Settings These jumpers provide flexibility in adapting different RS 232 cables Both the input RXD and output TXD functions can be swapped between J2 2 and J2 3 Configuration 1 2 12 2 TXD 72 3 RXD H C L C J2 2 J2 3 TXD L C H C Note The factory default setting is J2 2 RXD J2 3 TXD EI set to L C and E2 set to H C 2 6 2 Current Control Settings The drive has two modes of current control E3 jumper sets the current mode of the controller Configuration E3 Recirculating mode L C Non recirculating mode H C 5220 Installation and Hardware Reference Manual Rev D 2 29 In most applications recirculation mode is preferred The power losses in the module and stepping motor are lower in the recirculation mode due to the lower amplitude ripple current This mode should be used whenever possible For some applications it may be necessary to use the non recirculation mode While this mode introduces higher module and motor losses due to higher ripple currents it reduces the module s sensitivity to back EMF from the motor This improved back EMF rejection reduces mid range stability problems Mid range stability problems are inherent in any stepping motor system and can cause the motor to fall out of synch due to the
46. rpm the resonance will be excited If the oscillations become large enough the motor will drop out of synch and stall Using the 5220 with 36 Vdc motor input supply the solution to the resonance problem is to avoid running the motor near the speed that will excite the resonance frequency This is easily accomplished by setting the maximum start speed above the speed that excites the resonance 5220 Instruction and Hardware Reference Manual Rev D G Appendix Series Parallel Connections Introduction Several motor connections are possible when using a bipolar drive e 8 lead motor e 6 lead motor 4 lead motor The various connection schemes produce different torque speed characteristics They also affect the current rating in the motor 8 lead motor The 8 lead motor is the most versatile configuration It can be connected by the user in either an 8 lead 4 lead series or parallel or 6 lead configuration BLK WHT BLK WHT ORG ORG RED WHT RED o WHT YEL YEL 5220 Instruction and Hardware Reference Manual Rev D H 1 Connection table Refer to the table below for detailed connection information Drive Connection Terminal Lead Color Connection 4 ead bipolar 1 Black Blk A SER 3 Orange Org A 2 Red B 4 Yellow Yel B 6 amp 5 Wht BIk amp Wht Org 7 amp 8 Wht Red amp Wht Yel 4 lead bipolar 1
47. selected by forcing the HALF FULL input low prior to applying power to the module and keeping the input low The module is now set for Full step operation Do NOT change the state of the HALF FULL input state during operation since the Full step or Wave drive mode is selected based upon the state of the module outputs when the HALF FULL input is pulled low Half Step Drive 5220 Installation and Hardware Reference Manual Rev D This type of commutation alternates between one phase energized and two phases energized This halves the step size doubles step resolution but gives irregular torque The torque with two phases energized is 1 4 times higher than that produced with one phase energized The commutation sequence is The figure below shows the half step drive sequence A A AO A B B B BH SeN B B Z B O toc H B B B B Nes B B B O 3 This type of commutation is selected by forcing the HALF FULL input high or leaving it unconnected when applying power to the drive Do NOT change the state of the HALF FULL input state during operation since the Full step or Wave Drive mode is selected based upon the state of the module outputs when the HALF FULL input is pulled low Note All figures are simplified and show a stepping motor with a 90 full step or 45 half step commutation Pacific Scientifi
48. stepping motor with wave drive commutation The rotor is simplified to a bar magnet with North and South poles This type of commutation is typically not used since Full step drive provides equivalent step resolution with 1 4 times more torque A AO A AO ol D 0 Ul This type of commutation is selected by applying power to the module with the HALF FULL input high or unconnected This will set the module for Half step operation starting in the Zero state Input one pulse into the STEP input This will force the outputs to one of the Wave Drive commutation states Now force the HALF FULL input into the low state The module will be set for Wave Drive operation The Full step wave drive mode can be set with the output disabled enable line pulled low so that the motor will not move during wave drive selection Note Do NOT change the state of the HALF FULL input state during operation since the Full step or Wave Drive mode is selected based upon the state of the module outputs when the HALF FULL input is pulled low Full Step Drive In this type of commutation both stepping motor phases are energized at all times The commutation sequence is pe ee F 2 5220 Installation and Hardware Reference Manual Rev D The following figure shows this commutation sequence for clockwise motor rotation A A A A 4 yes HE s So A A A This type of commutation is
49. t is toggled each time the programmed position has passed This output is TTL compatible and has a sourcing capability of 5 mA and a sinking capability of 20 mA Refer to the outputs figure below Output circuitry 5V i Q J1 11 22 5 mA SOURCE VoH 3 9V 20mA SINK VoL 0 5V 5220 Installation Hardware Reference Manual Rev D 2 25 Input Output Pin Number Explanation Enable Disable J1 21 If this output is forced low the driver will be disabled In the disabled state the chopping is disabled and both phase currents go to zero When the driver is disabled the indexer is still active and will put out step pulses if it was executing a motion command The indexer will continue executing the programmed commands The enable input is TTL compatible and internally pulled up by a 10 KW resistor to 5 Vdc Refer to the input figure below Input circuitry 5V 10K 5V 0 01 33K 5V SS J1 21 2 26 TS 74HCTS367 V 5220 Installation and Hardware Reference Manual Rev D J1 Discrete inputs 1 0 5VDC 5VDC oot uF 5VDC VW e P o V om CD4503 v SWITCH RELAY CONTACT 1 0 5VDC e 5VDC 0 01 uF 5VDC WW 4 35K CD4503 e OPEN COLLECTOR 1 0 5VDC 5VDC 10 0 01 uF 5VDC e e P o 35K CD4503 Vs
50. ts and outputs The four input output cables are J4 P SCIENTIFIC 5220 INDEXER DRIVE m gt These inputs and outputs are shown as follows JACKET SHIELD 2 PHASE I STEPPING wl w gt gt MOTOR J3 5220 Installation and Hardware Reference Manual Rev D Wiring is application specific Noise pickup reduction Shock hazard reduction In this section 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 than described here Power and signal wiring should be routed separately to reduce the possibility of noise pickup Signal wiring should be shielded Motor phase wiring should be twisted to reduce radiated noise Refer to section 2 3 for safety information that must be followed to reduce shock hazard To install connector Refer to section J3 2 5 1 J5 2 5 2 12 2 5 3 2 5 4 5220 Installation and Hardware Reference Manual Rev
51. umper Settings sc cg poatea eb Sees 2 29 2 6 1 El and E2 RS 232 Port Configuration 2 29 2 6 2 E3 Current Contool se sy oqo beh set ob ede SS 2 2 29 2 6 3 E4 Step Size Operation 2 30 2 64 5 Current Control 2 31 2 6 5 16 E17 E18 Baud Rate 2 32 2 6 6 Jumper Location 2 33 5220 Installation and Hardware Reference Rev D 3 Powering Up the 5220 3 1 3 1 Testing the Installati n 3 1 3 1 Connections Test 24349 Su q SU S S k See 3 1 4 Maintaining Troubleshooting 4 1 4 1 Maintaining the 5220 4 1 4 2 Troubleshooting the 5220 4 1 421 POWER LED Not On us xo OR A 4 2 4 2 2 DISABLE FAULT TED 4 3 4 2 3 5220 Does 4 4 Appendix A Specifications A 1 Appendix B Order Number amp Ordering Information B 1 Appendix C Pinout and Connections Summary C 1 Appendix D Jumper Settings D 1 Appendix E Summary and Pinouts E 1 Appendix F Stepper Motor Basics F 1 Appendix G Low Speed Resonance Problems G 1 Appendix Series Parallel Connection H 1 Appendix Phasing Sequencing l 1 Index Rev D 5220 Installation and Hardware Reference 1 Overview of 5220 Indexer Drive In this Chapter This chapter introduces the 5220 Indexer Drive Topics covered

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