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U s e r M anual - Advanced Micro Controls Inc

1. Series 1 4 Torque oz in Power W For all SM34 motors connecting the motor in series will 0 NE 0 5 10 15 20 25 30 give you more torque at low speeds This is because the Speed RPS limiting factor on the motor current is the SD17040 drive not the motor See figures A 4 and A 5 on the following Figure 2 SM23 130 Torque Curves page to determine the cutoff speed 20 Gear Drive Plymouth Ind Park Terryville CT 06786 41 Tel 860 585 1254 Fax 860 584 1973 http www amci com A um CHOOSING YOUR MOTOR Determining Your Motor Current Setting continued Torque curves show the performance of the motor at the stated current which is the maximum setting for the motor or the drive whichever is less If you decide to use a lower current setting than the value listed in the curve be aware that a reduction in current proportionally reduces the holding torque However a reduction in cur rent may not lead to a proportionally reduction in torque at high speeds especially if the motor is series connected At high speeds motor torque is limited by the voltage bus of the drive and the inductance of the motor The sim plest explanation is that the drive does not have enough time to establish the full current through the motor before it must switch the current to the winding Torque oz in Power W Because of th
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3. 20 Gear Drive Plymouth Ind Park Terryville CT 06786 35 Tel 860 585 1254 Fax 860 584 1973 http www amci com INSTALLING THE 5017040 Step 4 Connecting the Motor Motor Connector The motor connector is shown in figure 6 6 The two Interlock termi INTERLOCK Q nals are a safety feature When these two terminals are not connected BCTAP q the drive will not power the motor outputs and the drive turns on the Motor Fault LED and the Fault Output For normal operation these D two terminals must be connected together with a short wire B The two center tap pins there for wiring con EARTH GND venience only They are electrically isolated from the rest of the drive A D and are not used to power the motor The EARTH GND pin is for the A D shields of the motor cable This pin is directly connected to the ground q ing lug of the SD17040 INTERLOCK q NOTE When powered the motor connector represents a shock Figure 6 6 Motor Connector with hazard because it has 170 Vdc present on its terminals Interlock Jumper A rubber boot that is included with the connector must be installed but is not shown in the following figures for clarity When installing the motor cable slide the rubber boot onto the cable before wiring the connector When you re sure the wiring is correct slide the boot over the connector to
4. Park Terryville CT 06786 39 Tel 860 585 1254 Fax 860 584 1973 http www amci com INSTALLING THE 6017040 Step 6 Testing the System You may what to uncouple the motor from its load while running the initial test 1 Verify all wiring and grounding before applying power to the SD17040 Make sure the rubber boots are on the drive s motor and power connectors 2 Apply 110Vac power With the motor attached the power and status LED s should come on green If either LED does not light or the Status LED is red then a problem exists Remove power and refer to Appendix C TROUBLESHOOTING which starts on page 49 3 Check for holding torque on the motor If you have less then you expected the most common cause is an improper motor current switch setting If this setting appears to be correct you may have the Idle Current Reduction turned on 4 Have your indexer make a slow move in the clockwise direction for one turn While the turn is in progress the STEP LED should blink Verify that the motor rotated in the correct direction for one complete turn If you are using an optical encoder or other position feedback verify that the indexer or controller is reading it properly 5 Repeat step 4 with a move in the counter clockwise direction Again verify that the motor rotated in the correct direction for one turn NOTE 5 Any problems at steps 4 and 5 are usually caused by not setting the Pulse Train Input switch correctly
5. SB1 3 NOTE 5 1 These switches are latched on power up You must cycle power to the drive after changing these settings 2 Switches SB1 4 and SB1 5 are not used when setting features on the drive These switches can be at either position without affecting the drive 400 Steps Rev Half Step 200 Steps Rev Full Step STEP RESOLUTION CCW Step amp Direction Step Resolution SB1 1 The SD17040 offers two step resolutions The resolu tion that you will choose depends on your applicaiton and equipment Full Step resolution which yields 200 steps per turn offers slightly better torque at high speeds but Half Step resolution which yields 400 steps per turn offers smoother operation at all speeds lt z oz 2 0 After 1 Sec No Reduction IDLE CURRENT REDUCTION SD17040 has a maximum input frequency of 25KHz Therefore the maximum speed that can be attained by the motor is 125 RPS when full stepping or 62 5 RPS when half stepping Figure 4 2 SB1 Switch Settings 20 Gear Drive Plymouth Ind Park Terryville CT 06786 21 Tel 860 585 1254 Fax 860 584 1973 http www amci com SWITCH SETTINGS SB1 Switch Settings continued Pulse Train Input SB1 2 You must define the format of the directional pulses from your indexer Directional pulses generally have one of two formats Step and Direction or CW CCW Some indexers can
6. able Input is turned off the drive restores current to the motor in the same phase relationship that existed before the Disable Input was turned on If the motor rotated while the Disable Input was active which is possible because there is no holding torque the motor may not start up correctly The SD17040 immediately drops the motor current to zero when the Disable Input is activated but ramps up the current when the Disable Input is released This ramp up time lasts for a maximum of 275 millisec onds Directional Pulses are not accepted until the current ramp up is complete 20 Gear Drive Plymouth Ind Park Terryville CT 06786 33 Tel 860 585 1254 Fax 860 584 1973 http www amci com INSTALLING THE 6017040 Step 2 Connecting the Indexer continued Fault Output Wiring The Fault Output is an optically isolated transistor capable of driving a typical DC PLC input or equivalent As shown in figure 6 5 both ends of the output are floating Therefore you can connect the fault output in a sourcing or sinking configuration Open Collector Sourcing Output 5 10 24 pr FAULT Ic HO i xk O SD17040 99 1 vaj 1 Fault Output 1 eee pud Twisted 4 PLC Sinking air Cable DC Input mE Vpc Open Collector Sinking Output 5 to 24V gh FAULT lc Ya H Lo s s 7 PLC Sourcing 7
7. 5APK for proper operation 2 Never attempt to power the drive with 230Vac Doing so will damage the drive and void its warranty If you are converting from an SD3520 to the 51017040 verify that the SD3520 was operating at 120Vac before applying power to the SD17040 If your installation only has 230 Vac you must install a step down transformer to power the SD17040 The transformer must be rated for a minimum of 750Va Both the Neutral and the Line power connections are internally fused in the SD17040 External fuses or circuit breakers can also be used They must be rated for at least 5 amps gt Grounding Lug A grounding wire from SD17040 s grounding lug to your system s ground bus must be installed See figure 6 10 Power and Grounding Connections on page 39 for more information 20 Gear Drive Plymouth Ind Park Terryville CT 06786 47 Tel 860 585 1254 Fax 860 584 1973 http www amci com B 2 UPGRADING THE 5017040 Notes ADVANCED MICRO CONTROLS INC 48 APPENDIX C TROUBLESHOOTING Stepper drive systems contain three components the indexer the drive and the motor An optional fourth component a position feedback encoder may also exist Most installation prob lems can be traced back to a wiring problem between these components or improper switch set ting that prevent them from working together properly Rarely does one of these components actually fail The following tables contain basi
8. DC Input Lo 8017040 FAUT ani Fault Output ee gee Shielded Twisted Pair Cable mE FAULT OUTPUT Electrical Specifications resistor may be needed to limit Vpc max 30Vdc the current through the Fault VcEgat 1Vdc 20 mA Output The value and power Ic max 20 mA rating of the resistor is dependent Power Dissipation 20 mW max on the value of Vpc the voltage drop across the input and the current requirements of the input Figure 6 5 Fault Output Connections The Fault Output conducts when the drive is operating normally and shuts off when the drive initializing on power up or whenever a fault occurs Detectable Faults on page 18 lists the conditions that trip the Fault Output Step 3 Installing the Stepper Motor Outline Drawings Outline drawings for all of our motors can be found on our website www amci com in the Document Retrieval section They are in AutoCad 12 DWG format If you do not have internet access or cannot open a DWG drawing contact AMCI and we will fax the information to you Mounting the Motor All AMCI motors have flanges on the front of the motor for mounting This flange also acts as a heatsink so motors should be mounted on a large unpainted metal surface Mounting a motor in this fashion will allow a significant amount of heat to be dissipated away from the motor which will increase the motor s life by reducing its operating temperature If you cannot mount
9. Figure 6 8 Six Lead Motor Connections 20 Gear Drive Plymouth Ind Park Terryville CT 06786 37 Tel 860 585 1254 Fax 860 584 1973 http www amci com INSTALLING THE 6017040 Step 4 Connecting the Motor continued Eight Lead Motor As shown in figure 6 9 an eight lead motor can be connected to the SD17040 in two ways A Series Con nected motor may offer more torque than a Parallel Connected motor at low speeds but a parallel connected motor will always offer higher torque at high speeds The operating temperature of a parallel connected motor is always higher than a series connected motor Eight Lead Series Connected Motor INTERLOCK 1 WHT RED BRN 5 Motor Connections shown BCTAP 0 WHT YEL ORG MOTOR for CW rotation i RED GRN Facing mounting flange B YEL WHT Mec Shields For CCW rotation reverse YEL Stepper Drive B ORG BLU connections WHT BLK RED INTERLOCK WHT ORG BLK WHT indicates white wires with colored tracers Colors in parentheses are Integral eight conductor cable alternate wire colors Eight Lead Parallel Connected Motor Case INTERLOCK gt WHT RED BRIN em Motor Connections shown WHT YEL ORG MOTOR for CW rotati
10. Torque Curves SM34 250D Parallel 4 0A Speed RPS Figure A 4 SM34 250 Torque Curves SM34 425D Series 3 2A Parallel 4 0A 0 5 10 15 20 25 30 Speed RPS Figure 5 SM34 425 Torque Curves 42 ADVANCED MICRO CONTROLS INC CHOOSING YOUR MOTOR A Unipolar Ratings continued Many motor manufactures still publish unipolar ratings for their motors instead of bipolar ratings Therefore you must convert the unipolar current rating to either the bipolar series or bipolar parallel current rating to determine the correct setting for the SD17040 Table A 1 lists the multipliers to convert from unipolar to either of the bipolar values Conversion factors for voltage winding resistance winding inductance and holding torque are also given As a conversion example assume a size 34 single stack motor with a unipolar current rating of 2 2 amps Because you application is rather high speed you decide to wire the motor in parallel The conversion from the Unipolar to Bipolar Parallel is 1 41 Therefore the maximum current setting for this motor is 2 2 1 41 3 1 amps In order to avoid confusion AMCI publishes the bipolar series and bipolar parallel current ratings on all of our motors For your convenience Table 3 4 Stepper Motor Specifications on page 19 lists the maximum series and parallel currents for our motors Desired Value Unipolar Bipo
11. an enclosure as close to the motor as possible The drive s differential I O is designed for long cable runs Installing the SD17040 as close as possible to the motor will limit power losses and EMI as well as the possibility of a ground loop between the motor and drive Dimensional Drawing The dimensional drawing of the SD17040 is given on the following page The drive is designed to be panel mounted in one of two ways Properly mounting the drive to a metal panel will allow a large amount of heat to be dissipated by the panel This will result in a lower operating temperature for the drive The preferred way of mounting the drive is by the two bolt holes in its back panel They accept 10 32 bolts The maximum length of the bolt is based on the thickness of your mounting plate and is given in the figure If it is impossible to mount the drive this way the second mounting option uses the mounting tabs at the top and bottom of the drive They accept 6 bolts one at the top and two at the bottom 20 Gear Drive Plymouth Ind Park Terryville CT 06786 29 Tel 860 585 1254 Fax 860 584 1973 http www amci com INSTALLING THE 6017040 continued rive ing the D Drawing cont Install Step 7 inued Imensiona D joued jo 861 29 0 8 joued sseuxotui 67 uiBue MaS seoe d OML 26 01
12. for one second The STEP FAULT LED does not Verify that your two directional inputs on the Indexer Connector are blink when the indexer sends not swapped or cross wired pulses to the drive The motor If the inputs are wired as a sinking or sourcing instead of differential does not turn verify that the proper current limiting resistor is installed and that they are wired correctly If your indexer has sourcing outputs then the inputs of the SD17040 must be wired as sinking inputs and vice versa The STEP FAULT LED is red The drive is experiencing a fault condition All faults are latched so power must be cycled to the drive before the fault will clear 1 Over Temp Fault Is the drive very hot It shuts down when its inter nal temperature exceeds 90 C 195 F 2 Interlock Fault The motor is not plugged into the drive or a wire jumper was not installed between the two Interlock pins on the Motor Connector Short in Motor Shut off the SD17040 and disconnect the motor Pull back the rubber boot and verify the following with an ohmmeter a Open circuit from A to B pins Tests for short between phases b Open circuit from A to Earth Ground and B to Earth Ground Tests for short between phase and case If any of these readings is not an open circuit then check your wiring The most common cause of a short between phases is cross wiring the phases when wiring the connector If yo
13. line it cannot be modified N to use 230 Vac power If your installation only has 230 Vac you must install a step down trans former to power the SD17040 The transformer must be rated for a minimum of 750Va GROUNDING LUG 2 Both the Neutral N and Line L terminals are Figure 3 4 Power Connector internally fused with 5 amp slow blow fuses If you plan to use external circuit breakers or fuses they should also be rated for 5 amps Detectable Faults The SD17040 can detect four different faults In all cases 1 Power is removed from the motor 2 The Fault Output on the Indexer Connector stops conducting current 3 The STEP FAULT LED turns on red 4 The fault is latched by the drive Because the fault is latched you must correct the fault condition and cycle power to the drive before the fault will clear Common fault causes and suggestions for tracking them down are given in Appendix C TROU BLESHOOTING which starts on page 49 The four faults are gt Over Temp Fault The temperature of the SD17040 s heat sink exceeded 90 C 195 F gt Interlock Fault The two Interlock Terminals on the motor are not connected gt Phase Phase Short There is an electrical short between two motor windings The short exists in the motor cable or the motor itself gt Phase Ground Short One of the motor s windings is shorted to earth ground The Earth GND termi nal of the Motor Output Connector is referenced The fau
14. may need Make as many copies as you need to document your setup NOTE 5 if you are using 5017040 to replace SD3520 refer to Apendix B UPGRADING TO THE SD17040 starting on page 45 for specific information on switch settings STEP 1 Determine Switch Settings Seechapter 4 SWITCH SETTINGS starting on page 21 for a description of the settings This chap ter also gives tables that show each switch setting Appendix A CHOOSING YOUR MOTOR which starts on page 41 gives information on determining motor current settings 1 1 Resolution Half Step or Full Step 1 2 Pulse Train Input CW CCW or Step Direction 1 3 Idle Current Reduction No Reduction or To 0 1 4 Determine if the motor will be wired in series or parallel to the drive Not a switch setting but wir ing configuration effects the motor current setting Refer to Appendix A CHOOSING YOUR MOTOR which starts on page 41 for the torque curves of all AMCI motors compatible with the SD17040 This information will help you determine your wiring configuration 1 5 Motor Current 0 9 to 4 0 Apk in 0 1 A increments Setting affected by the motor you select and its wiring configuration STEP 2 Determine I O Wiring 2 1 The directional inputs and disable input are designed as differential inputs but can be wired as sink ing or sourcing inputs as well The Worksheet on page 11 shows how to wire the inputs in any of these configurations and a table to document you dec
15. the circuit Wiring diagrams and a table of common current limiting resistor values are given below DIR CCW DIR CCW STEP CW STEP CW DISABLE DISABLE FAULT FAULT Differential Output From Indexer D17040 Input Indexer 5V Differential Output DIR CCW OR STEP CW OR DISABLE DIR CCW OR STEP CW OR DISABLE Shielded Twisted Pair Cable Open Collector Sourcing Output From Indexer E aV SD17040 Indexer Input DIR CCW OR STEP CW OR Output DISABLE Rum DIR CCW OR STEP CW OR DISABLE Shielded Twisted Pair Cable Open Collector Sinking Output From Indexer Voc 5 to 24V DIR CCW OR STEP CW OR DISABLE o Rum o DIR CCW OR STEP CW OR DISABLE Indexer Shielded Twisted Output Pair Cable Common Values of Rum Voc Rum None 12 Volts 2 0 15 Volts 5 24 Vol 9 The Fault output is an optically isolated transistor capable of driving a typical PLC input Both ends are uncommitted so it can be wired as a sourcing or sinking output The figure below shows a typical connection as a sourcing output Open Collector Sourcing Output Voc 5 to 24V 8017040 1 1 Fault Output L Shielded Twisted Pair Cable d A resistor may be needed to limit the current through the Fault Output The value and power rating of the resistor is dependent FAULT OUTP
16. to 0 instead of 50 the idle current reduction setting must be defeated for the closest compatibality with the SD3520 However if you do not require motor holding torque while it is idle enabling idle current reduction on the SD17040 will greatly reduce motor heating which will prolong its life gt Motor Current SB2 There are four CURRENT switches on the SD3520 If you have the man ual for the 5123520 it is easiest to look up the value the switches are set for and then look up the switch setting for the SD17040 on the worksheet If you don t have the manual use this procedure 1 On the 503520 add up all of the values that have a switch pushed towards the label Example The 1000 mA and 125 mA switches are the only two pushed towards their labels The sum is 1000 125 1125 mA 2 The SD3520 has a base current of 125 mA so add 125 mA to the sum found in step 1 This is the current setting for the SD17040 To finish the example 1125 125 1250 mA which equals 1 25 amps The closest setting on the SD17040 is 1 2 amps The section SB2 Switch Settings starting on page 23 contains tables that show all SD17040 motor current settings NOTE 5 Because of the SD17040 s higher bus voltage 170Vdc instead of 35Vdc a motor s torque will not drop off as fast at high speeds Because of this you actually may be able to lower your motor current setting without sacrificing torque If you can you will prolong your motor s life b
17. with possible damage to equipment and or injury to personnel If you decide to change settings while power is applied DO NOT make these changes while the motor is running The drive requires 110Vac to operate Both line and neutral are fused 10A MOTOR CONNECTIONS SERIES MOTOR CONNECTIONS PARALLEL MOTOR CONNECTIONS INTERLOCK INTERLOCK A L GEN we L Shields g L _____ U EARTH GND INTERLOCK Indexer Model Wiring Directional Input U Differential Sinking Current Limiting Resistor LJNot Needed OR Sourcing ohms Wiring Disable Input Differential Sinking Current Limiting Resistor Needed OR ohms Wiring Fault Output Q Sink L Source Current Limiting Resistor Needed OR 5017040 Worksheet INDEXER CONNECTIONS Directional Pulse Inputs Disable Input Motor current is off when active Fault Output Normally on Turns off when 1 Interlock Jumper missing 2 Short in motor phase to phase or phase to ground 3 Heatsink temperature exceeds 90 C 195 All inputs are designed to accept 5 Vdc differential signals from the indexer but they can be wired to accept sinking or sourcing outputs of up to 24Vdc If your indexer outputs are higher than 5 Vdc a current limiting resistor must be installed in
18. D ing space and budgetary constraints allow Because the 100 Parallel 28 losses the motor s windings manifest themselves as heat the maximum allowable motor temperature limits the motor s current Using the largest motor possible may E N 60 allow you to use a lower current setting on the SD17040 2T drive This lowers the losses which lowers the operat 8 40 ing temperature of the motor and increases the motor s 5 life 20 AP E 0 Determining Your Motor Current Setting 0 5 10 15 20 25 30 Your motor current setting is based on the amount of Spegd RPS torque needed from the motor In many cases the amount Figure A 1 SM23 90 Torque Curves of torque that you need will also determine how you attach the motor to the SD17040 Connecting the motor wind ings in parallel will give you more torque at higher speeds Each motor is tested in its dual shaft configuration with an SM23 130D encoder attached You will see a downward spike some where on most of the torque curves This represents the resonant frequency of the test system and this point will shift based on the load you attach to the motor You will need to test your system at all speeds to verify its correct operation If resonance may be a problem in your applica tion consider using the SD17063 drive which includes anti resonance circuitry a o Parallel 2 8A E N
19. Dual Shaft Factory Encoder Options Add DE To The Given Part Number A The Holding Torque specification assumes that the motor is attached to an SD17040 with the windings in series and the motor current is set to the maximum value for the motor Using a different drive may vary your holding torque significantly 9 1X10 17 0 10 3 26 5 10 3 114 0 X 10 B Specification is for dual shaft motors without factory encoders Table 3 4 Stepper Motor Specifications Encoder Option dual shaft stepper motors can have an optical incremental encoder factory installed A metal dust cover that covers the encoder and shaft is installed with the encoder Motor outline drawings that include the dimensions for the encoder are available on our website ht p www amci com Table 3 5 lists the main spec ifications of the incremental encoder A complete specification sheet is included with the motor when it ships with the encoder option Specification Resolution 1 000 lines 5Vdc Differential 20mA maximum load Input Power 135mA 5Vdc 5 Moment of Inertia oz in sec 17X107 max Output Drivers Operating Temperature 10 C to 85 C Table 3 5 Optical Encoder Specifications 20 Gear Drive Plymouth Ind Park Terryville CT 06786 19 Tel 860 585 1254 Fax 860 584 1973 http www amci com SPECIFICATIONS Notes ADVANCED MICRO CONTROLS INC ess CHAPTER 4 SWITCH SETTIN
20. GS Most of your drive s settings are determined by the motor you select This chapter assumes that you ve already selected the motor and you re now determining the appropriate drive settings If you have not selected you motor then refer to Appendix A CHOOSING YOUR MOTOR start ing on page 41 Information in this appendix includes guidelines for sizing your motor torque curves for all AMCI motors and information on determining current settings for non AMCI motors Location of the Programming Switches All of the SD17040 s programmable features are set 2 Rotate cover to with DIP switches located on the top of the drive As seres HUES shown in figure 4 1 you gain access to these switches by loosening two screws and rotating the cover out of the way Note that the switches are in two blocks of five This manual calls the switch blocks SB1 and SB2 with SB1 nearer the front of the drive The five switches in each block are labeled 1 through 5 with 1 nearer the front of the drive Therefore the third switch in the first block is SB1 3 and SB2 5 is the fifth switch of the sec ond switch block 1 Loosen these two screws Figure 4 1 Accessing the DIP Switches SB1 Switch Settings Figure 4 2 shows the switch settings for the features set by switch block 1 These features are 1 90105 gt Step Resolution 5 1 1 gt Pulse Train Input SB1 2 SBI SB2 gt Idle Current Reduction
21. Step Your step resolution choice is usually dependent on your appli cation Pulse Train Input Most indexers output their directional pulses in one of two formats CW CCW or Step and Direction By default the SD17040 uses the CW CCW format but can be configured for either Idle Current Reduction This feature reduces current to the motor when it is idle which significantly reduces motor heating To 0 stops all motor current once a pulse has not been rceived for one second No holding torque is available from the motor Not Reduced keeps the full current applied to the motor for maximum holding torque Motor Current The SD17040 can have its motor output current set from 0 9 to 4 0 amps in 0 1 amp increments The exact current setting is based on your motor s size and application requirements Motors that are rated for more than 4 0 amps can be used with the SD17040 but the maximum current through the motor will be limited to 4 0 amps and the motor will not provide its maximum torque 14 ADVANCED MICRO CONTROLS INC SPECIFICATIONS Indexer Connector Figure 3 2 shows the Indexer Connector on the 50017040 The inputs are typically connected to an indexer but the Disable input is sometimes con C nected to a push button The Fault Output is some i i i DIR CCW times used to drive a solid state relay that powers a e E Directional warning light instead o
22. TP1 will output CW CCW pulses by default Therefore the Pulse Train Input DIP switch SB1 2 should be set to zero when using this module External Power Supply 7 to 24 BELDEN DIR CCW 1 STEP CW 2 STEP CW 9 0 8 DISABLE 4 DISABLE 6 5 FAULT 6 FAULT 7 8 5017040 RH Indexer 9 Connector Bet 1 e 1746 HSTP1 Terminal Block Figure 6 3 Directional Pulse Connections Most indexers do not 5 Vdc differential outputs Figure 6 4 on the following page shows how to wire single ended sourcing or sinking output to the SD17040 Note that current limiting resistors must be installed for voltages above 5 Vdc The table in the figure gives appropriate resistor values 32 ADVANCED MICRO CONTROLS INC INSTALLING THE 6017040 A 9 Step 2 Connecting the Indexer continued A B MicroLogix 1500 Many customers have started to use the Allen Bradley MicroLogix 1500 as an indexer The MicroLogix 1500 has aPulse Train Output PTO Instruction that can be used to generate directional pulses to the SD17040 This instruction controls one output that generates the STEP pulses while your ladder logic controls an output that selects the DIRECTION Outputs on the MicroLogix 1500 must be 24 Vdc You can wire the outputs as either sinking o
23. UT Electrical Specifications Voc max 30Vdc VcEsar 1Vdc 20 mA Ic max 20 mA Power Dissipation 20 mW max on the value of Voc the voltage drop across the input and the current requirements of the input 20 Gear Drive Plymouth Ind Park Terryville CT 06786 11 Tel 860 585 1254 Fax 860 584 1973 http www amci com QUICK START Notes 12 ADVANCED MICRO CONTROLS INC NHL SPECIFICATIONS Drive Type Two bipolar MOSFET H bridges with 170V output bus 22KHz PWM current control Physical Dimensions Width 2 7 inches Depth 4 7 inches Height 6 2 inches 7 0 inches with mounting tabs Weight 4 3 Ibs 2 0 kg Inputs Electrical Characteristics for all Inputs Differential 1500 Vac dc opto isolated Can be wired as single ended inputs Step Motor steps on high going pulse 1501S min pulse width 25 KHz maximum input frequency Disable Active high Disables current to motor Drive does not accept steps while disabled Fault Output Electrical Characteristics Open Collector Emitter 1500 Vac dc opto isolated 30Vdc 20 mA max The Fault Output is normally on Turns off under the following conditions Reset The drive initialization 1s not yet complete on power up Short Circuit Motor Phase to Phase or Phase to Ground Over Temp Heat Sink temperature exceeds 90 C 195 F No Motor The motor interlock
24. Used When Setting Motor Current Figure 4 4 Motor Current Settings 4 0A to 3 1A 20 Gear Drive Plymouth Ind Park Terryville CT 06786 23 Tel 860 585 1254 Fax 860 584 1973 http www amci com Hz SWITCH SETTINGS SB2 Switch Settings continued Motor Current Continued MOTOR CURRENT Pg 2 of 2 Switch Block 2 Switches 1 5 ini 1 4 Amps au gt M 2 8 Amps 1 3 Amps gt 1 2 Amps 2 5 Amps lt a Not Used When Setting Motor Current Figure 4 5 Motor Current Settings 3 0A to 0 9A 24 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES This chapter gives general information on installing electronic controls in an industrial environ ment including the importance of proper wiring grounding and surge suppression If you are responsible for installing the SD17040 make sure you are familiar with these practices and follow them when installing the unit This chapter is presented as a tool in the hopes of avoiding common installation prob lems It is not a substitute for the safety practices called out in local electrical codes or in the United States the National Electrical Code published by the National Fire Protec tion Association If any conflicts exist local and national codes must be followed t is the responsibility of the userto determine what installation practices must be followed to conform to all local and na
25. able are two examples of acceptable cable 2 Cable from the indexer can be installed in conduit along with other low power cabling such as communication cables and low power ac dc I O lines It cannot be installed in conduit with cabling from the stepper motor ac dc power lines or high power ac dc I O 3 The shields of the cables must be grounded at the indexer only When installing the cable treat the shield as a signal carrying conductor Do not connect the shield to earth ground at any junction box or the SD17040 This will eliminate ground loops that could damage the SD17040 or indexer Wiring Directional Pulse Inputs The indexer also called the controller supplies the directional pulses to the drive One example of an indexer is AMCT s 3202 and 3204 Stepper Controller Modules for the ControlLogix programmable controller A sim ilar module exists for most programmable controller systems including the Allen Bradley 1746 Step per Controller Module for the SLC 500 programmable controller The 1746 HSTP1 module will be used as an example The SD17040 s Indexer Connector along with the connections to the 1746 HSTPI is shown in figure 6 3 The HSTP1 outputs 5 Vdc differential signals that the 5017040 is designed to accept If your indexer outputs a differential signal that is greater than 5 Vdc you need to install current limiting resistors in series with the input The resistor values are given in figure 6 4 Note that the HS
26. be programmed to output either Figure 4 3 shows the differences between the two formats and the SD17040 s switch settings for each The factory default setting is CW CCW Directional Inputs CW Rotation CCW Rotation gt OW s STEP U 1 71 DR Figure 4 3 Pulse Train Types STEP DIR CW CCW Idle Current Reduction SB1 3 The SD17040 can automatically reduce the current to the motor when it s not running to significantly reduce motor heating However this also eliminates the holding torque of the motor If you choose to enable the idle current reduction all motor current will be stopped after one second has passed without a step pulse from your indexer No holding torque will be available from the motor while it is idle Once the motor receives a step pulse from the indexer the motor current is immediately brought up to its 100 value on the first step Whenever possible you should reduce the idle current to reduce motor heating and prolong the motor s life The only time you should choose not to reduce the idle current is when you require holding torque from the motor 22 ADVANCED MICRO CONTROLS INC SWITCH SETTINGS 2 ER SB2 Switch Settings Motor Current SB2 1 2 3 4 5 Your motor current setting is based on the amount of torque needed from the motor Torque curves for our motors are available in Appendix A CHOOSING YOUR MOTOR starting on page 41 Table 4 1 gives the maximu
27. c troubleshooting steps that will solve most application problems if you cannot resolve your problem with these tables call AMCI technical support for assistance Motor Problems Symptom The motor has no holding torque Solution If the Step Fault LED is red then a problem exists with the drive or motor Refer to Detectable Faults on page 18 for information If the motor rotates when commanded but has no holding torque then your Idle Current Reduction switch is set to the To 0 setting which removes motor current when the drive is idle for more than one second See table dle Current Reduction SB1 3 on page 22 for information on setting the Idle Current Reduction switch The SD17040 ships with the motor current set to its minimum value of 0 9 amps See figures 4 4 and 4 5 Motor Current Settings start ing on page 23 for the proper switch settings 5017040 blinks its STEP FAULT LED green when pulses are applied to the drive but the motor only emits a high pitch noise It does not rotate The acceleration values may have been set too high when the indexer was programmed The motor may start to accelerate and stall as the acceleration increases The Step Resolution may be set to Full Step instead of Half Step See second indexer problem on the next page This effectively dou bles the acceleration value The motor only runs in one direc tion This problem is usually caused by the directional pulse in
28. cations of those decisions D CAUTION CAUTIONS tell you when equipment may be damaged if the procedure is not followed properly WARNINGS tell you when people may be hurt or equipment may be damaged if the pro cedure is not followed properly The following table shows the text formatting conventions Description Normal Font Font used throughout this manual Emphasis Font Font used the first time a new term is introduced When viewing the PDF version of the manual clicking on the cross reference text jumps you to referenced section Cross Reference 20 Gear Drive Plymouth Ind Park Terryville CT 06786 3 Tel 860 585 1254 Fax 860 584 1973 http www amci com ABOUT THIS MANUAL Trademark Notices DuraDrive DuraDrive Technology and AMCI logo are trademarks and is a registered trademark of Advanced Micro Controls Inc Adobe and Acrobat are registered trademarks of Adobe Sys tems Incorporated All other trademarks contained herein are the property of their respective holders Revision Record This manual 940 0S020 is the first revision of the manual It was initially released Feburary gh 2002 Revision History 940 08020 2 8 2002 Initial Release Where To Go From Here This manual contains information that is of interest to everyone from engineers to operators The table below gives a brief description of each chapter s contents to help you find the informa
29. ceptable connection supresses noise at its source The Power In Device wiring that connects the load to the power supply and contacts n o 8 will not radiate noise when the load is switched and noise will uppressor not be coupled into the power supply Power Return Un Acceptable Connection 1 Inductive This connection protects the power supply and contact but Power Iri Contact Device allows noise to radiate through the load s wiring where it can be coupled into other cables around it Suppressor Power Return 5 Un Acceptable Connection 2 pt Inductive This connection protects the power supply but nothing else Powerin Contact Device Noise can radiate through the load s wiring where it can be n o coupled into other cables around it and the contact may Suppressor eventually be damaged by high voltage inductive spikes Power Return Un Acceptable Connection 3 Inductive This connection protects the contact but nothing else Noise Power In Device _ radiate through the load s wiring where it can be coupled n o into other cables or into the power supply Noise in the supply S may affect any device powered by it Also if the suppressor Power Return shorts out the load will always receive power Figure 5 3 Installing Surge Suppression Devices 20 Gear Drive Plymouth Ind Park Terryville CT 06786 27 Tel 860 585 1254 Fax 860 584 1973
30. cover the screw heads WARNINGS 1 Always remove power from the SD17040 before connecting or disconnecting the motor 2 Never connect the motor leads to ground or to a power supply 3 Always verify that the motor case is connected to the cable shields before operation 4 Always connect the cable shield to the Earth Ground terminal of the SD17040 s Motor Connector Four Lead Motors As shown in figure 6 7 a four lead motor can be connected to the SD17040 in only one way Many four lead motors including AMCI s SM42 motors have eight wires inside the motor These wires are connected in series or parallel in the motor and four leads are brought out to the drive SD17040 Motor Output Connector Motor Case Torna INTERLOCK 4 Motor Connections shown BCTAP 0 LEAD for CW rotation I GRN YEL MOTOR Facing mounting flange p igo WHT For CCW rotation reverse D BLK BLU A Stepper Drive B and m A U N Terminal Numbers are 0 Colors in parentheses S connections for AMCI INTERLOCK i are alternate wire colors SM42 motors Integral four conductor cable Figure 6 7 Four Lead Motor Connection 36 ADVANCED MICRO CONTROLS INC INSTALLING THE 6017040 A 9 Step 4 Connecting the Motor continued Six Lead Motor As shown in figure 6 8 a six lead motor can be connected to the SD17040 in two ways A Series Connected mo
31. ding ControlLogix SLC500 and 1771 I O GE Fanuc 90 70 and 90 30 and Modicon Quantum Modules include resolver LDT and SSI interfaces programmable limit switches indexers and registration control modules gt RESOLVER TRANSDUCERS AMCI is the only company in the market place to manufacturer its own resolvers Not only do we make the resolvers for our own products we also produce resolvers with dif ferent electrical specifications for other position feedback applications such as servo control For additional information on these items and the rest of our product lines browse through our website www amci com or contact AMCI or your local AMCI distributor ADVANCED MICRO CONTROLS INC CHAPTER QUICK START This chapter can help you get the SD17040 up and running It assumes you are an experienced user with a solid understanding of stepper drive functionality and proper installation techniques such as wiring grounding and surge suppression The chapter also contains references to the other sections in this manual where more information can be found If you don t feel you have enough information or background to complete the steps listed here always read the referenced sections before attempting to complete a step Page 11 is a worksheet that shows all of the switch settings along with motor and I O wiring It also gives you a place to write down your wiring decisions including any current limiting resistors you
32. e gt gt gt gt Connections to the indexer are made through opto isolated differential inputs Differential inputs have greater noise immunity than single ended inputs This means you can run longer cables up to 300 feet from the indexer to the SD17040 and place the drive closer to the motor A shorter motor cable means less power loss from cable resistance which means more torque from the motor What s Included in the Drive Package The following table lists the items included with the SD17040 drive when shipped from AMCI If you do not have all of these parts contact your distributor or AMCI for help Description AMCI Part Number Stepper Drive Indexer Connector Motor Connector w Rubber Boot MC 1 Power Connector w Rubber Boot 1 Screwdriver 890 90303 Table 1 1 5017040 Ship List ADVANCED MICRO CONTROLS INC INTRODUCING THE 5017040 Other AMCI Stepper Products The following table lists some of our other stepper products but the line is constantly growing so the list may be incomplete For the latest information on all of our products browse through our website www amci com Model Product Number Type Description Microstepping drive with an 170 Vdc motor bus and output current up to 6 3Arms With RMS current control the motor does not experience a 70 SD17063 reduction in torque when DEM which occurs with drives that only Rev B control peak current to the motor The drive also
33. efer to the Disable Input Wiring section found on page 33 for wiring diagrams CAUTION 20 NOT activate the Disable Input while the motor is running When the Disable Input is active there is no current to the motor and the motor is free to rotate NOTE gt 5017040 does not accept directional pulses when the Disable Input is active Therefore when the Disable Input is turned off the drive restores current to the motor in the same phase relationship that existed before the Disable Input was turned on If the motor turned while the Disable Input was active which is possible because there is no holding torque the motor may not re start correctly Fault Output The Fault Output is an opto isolated 30Vdc output that is capable of driving a typical PLC input or equivalent Both ends of the output are floating Therefore it can be wired as a sinking or sourcing output The Fault Output acts as the contacts of a normally closed relay Its active state is off meaning that the output will not conduct when the SD17040 is initializing or when a problem exists with the drive The Fault Output s inac tive state is on when the drive is operational The output will turn off when power is removed Therefore a loss of power to the SD17040 will appear as an error condition There is a total of four faults that trigger the Fault Output The Detectable Faults section of this chapter start ing on page 18 describes these faults and how the Fau
34. ers and their targeted audiences Audience This manual explains the set up installation and operation of AMCI s SD17040 stepper motor drive with DuraDrive Technology It is written for the engineer responsible for incorporating the SD17040 into a design as well as the engineer or technician responsible for its actual installation Navigating this Manual This manual is designed to be used in both printed and on line formats Its on line form is a PDF document which requires Adobe Acrobat Reader version 4 0 to open it Bookmarks of all the chapter names section headings and sub headings were created in the PDF file to help navigate it The bookmarks should have appeared when you opened the file If they didn t press the F5 key on Windows platforms to bring them up Throughout this manual you will also find green text that functions as a hyperlink in HTML documents Clicking on the text will immediately jump you to the referenced section of the manual If you are reading a printed manual most links include page numbers The PDF file is password protected to prevent changes to the document You are allowed to select and copy sections for use in other documents and if you own Adobe Acrobat version 4 05 or later you are allowed to add notes and annotations Manual Conventions Three icons are used to highlight important information in the manual NOTE 5 NOTES highlight important concepts decisions you must make or the impli
35. ests R C networks for all AC applications A varistor is a solid state device that turns on and conducts when the voltage across its terminals exceeds its rated value Herein lies the problem with using a varistor as an AC suppressor The voltage problem must be generated before the varistor responds In our testing we have found that hard contacts will still arc when a varistor is placed across an AC load This arcing is due to the fact that the breakdown voltage of the air between the contacts when they first open can be less than the rated voltage of the varistor If the instanta neous AC voltage applied to the contacts is above the breakdown voltage of air but less than the rated voltage of the varistor the contacts will arc On the other hand an R C network acts as a low pass filter instantaneously dampening fast transients when they occur The main drawback of R C networks is that they are harder to correctly specify than varistors Varistors only require you to specify breakdown voltage and power dissipation ratings R C networks require you to balance the need of suppression when the contacts open against the amount of surge current the relay can tolerate when the contacts close Table 5 1 shows the trade offs you must be aware of when specifying R C networks When Contacts Close When Contacts Open Low Resistance Higher surge current through relay contacts ower transient voltage spike Positive High Capacitance to charge capac
36. f driving a fault input on the Pulse Inputs indexer STEP CW DISABLE n H All inputs are opto coupled 5Vdc differential The DISABLE 3 Disable Input Fault Output is an isolated 30Vdc un committed E Fault Output open collector emitter that can be wired as either a sinking or sourcing output Directional Pulse Inputs Figure 3 2 Indexer Connector Directional pulses from your indexer control the motor s position speed and direction of rotation The two Directional Pulse Inputs on the SD17040 are opto isolated and designed for 5 Vdc differential signals They can also be used as either sinking or sourcing single ended inputs by connecting one side to your power supply and driving the other side Wiring schematics are given in the Wiring Directional Pulse Inputs section starting on page 32 NOTE 5 A current limiting resistor must be used for voltages greater than 5Vdc The next section I O Electrical Specifications lists appropriate resistor values The resistor values are also given in the Single Ended Input Connections figure on page 33 Disable Input The Disable Input shuts off the motor current when it is active Once the Disable Input is released the motor current ramps up to its last value instead of being applied instantaneously Ramp up time is a maximum of 275 milliseconds Like the Directional Pulse Inputs the Disable Input can be wired as a differential sinking or sourcing input R
37. gauge and be stranded Do not use solid wire A 1 2 wire braid is also acceptable gt Any non isolated power supply attached to the 5017040 must be connected to the same chassis ground as the unit to avoid ground loops AAA 5 lt All isolation transformer secondary windings that are 5 av 25 to 2 to or pn must be EQUIPMENT ENCLOSURE 2 5 rounded to the same earth ground as the machine ground sounded te 5 5017040 9 Mounted to Back of Enclosure vv AMCI strongly suggests the use of a ground bus in the enclosure that houses the SD17040 As shown in figure 5 1 the ground bus becomes the central grounding point for the enclosure and its equipment The ground bus is directly connected to your ground ing electrode system Figure 5 1 Ground Bus System Wiring The most important aspect of wiring is determining the amount LOW POWER CONDUIT of voltage and power carried by the cable and separating low Indexer and other cabling power cabling from high power cabling Inside of an enclo a sure separate the two types of cabling with as much physical Ont BK JA distance as possible and keep the wiring neat Outside of the E enclosure low and high power cabling must be run in separate EN conduits 3 To mdr doch a Sey gt Indexer Cabling Low Power 1 Indexer Cabling includes the Directional Pulse Input
38. ge 41 or www amci com for a complete listing of available motors Size 34 stepper motors that are available in 1 2 or 3 stack configurations SM34 x Size 34 Other options include double shafts and or integrated optical encoders for Motors position feedback Go to Appendix A CHOOSING YOUR MOTOR start ing on page 41 or www amci com for a complete listing of available motors Size 42 stepper motors that are available with double shafts and or integrated SM42 x Size 42 optical encoders for position feedback Go to Appendix A CHOOSING Motors OUR MOTOR starting on page 41 or www amci com for a complete listing of available motors Table 1 2 AMCI Stepper Products 20 Gear Drive Plymouth Ind Park Terryville CT 06786 7 Tel 860 585 1254 Fax 860 584 1973 http www amci com E INTRODUCING THE 5017040 Other Products From AMCI AMCT has been serving the industrial automation sector since 1985 and we have a broad range of other prod ucts that are used in industrial applications gt DURACODERS Absolute Analog or Incremental encoders that replace the fragile glass disk and sen sitive optics of optical encoders with an industrial resolver The size 25 DuraCoders are drop in replace ments for similar sized optical encoders In motion applications a DuraCoder is typically used for position feedback gt PLC PLUG IN MODULES offers a broad range of PLC plug in modules for most major PLC brands inclu
39. has settings for Idle Current Reduction Antiresonance Current Loop Gain and Output Waveform Dif ferential I O supports cable lengths of up to 300 feet from indexer to drive Programmed over ControlNet or a RS 232 485 port the unit is a microstep ping drive with an 170 Vdc motor bus and output current up to 9 8Arms With other drive specifications similar to 5017063 Rev B this unit also has an integral indexer that accepts commands from the ControlNet or serial ports Designed to save the cost of a seperate indexer module for applications that are already using ControlNet the indexer supports blended move profiles as well as velocity mode programming SD17098IC Indexer Drive Combination Two channel stepper indexer module for the ControlLogix backplane with 3202 ControlLogix incremental encoder position feedback Featuring blended move profiles and Module profiles based on encoder feedback the module also has multiple inputs for homing and over travel protection Four channel stepper indexer module for the ControlLogix backplane Fea turing blended move profiles the module also has multiple inputs for homing and over travel protection ControlLogix e Module Size 23 stepper motors that are available in 1 2 or 3 stack configurations SM23 x Size 23 Other options include double shafts and or integrated optical encoders for Motors position feedback Go to Appendix A CHOOSING YOUR MOTOR start ing on pa
40. he Fault Output should be off not conducting Remove power and re attach the motor Power the drive Consider altering the motor current or enabling the Idle Current Reduction if it is not already enabled Lowering the motor current or enabling Idle Current Reduction can greatly reduce motor heating ADVANCED MICRO CONTROLS INC QUICK START 81 1 2345 SB2 1 Switch Not Used i 1 0 SWITCH RESOLUTION Steps per Tum HALF STEP 400 FULL STEP 200 PULSE TRAIN INPUT CW CCW O PULSE DIR 1 IDLE CURRENT REDUCTION TO 0 CURRENT AFTER 1 SEC NO IDLE CURRENT REDUCTION Power Must Be Cycled When Changing These Switches I II 5 5 5565 2 5 5 5 5 4499 SO solo o 2 O Z Z PO s Las Z o i CO C9 Go 02 60 cool vln o ho 69 Doo KO O Z o no NI oko Ol Om m m m m m m For safety reasons DO NOT change switch settings when power is applied to the drive Unexpected operation may result
41. he motor with a maximum current of 4 0Apk SD17040 also has a fault diagnostic output that warns you of problems with the drive or motor This output is typi cally fed back to the indexer gt The Motor Stepper motors are available in many different sizes to met specific torque requirements AMCI offers motors that range in size from NEMA 23 to NEMA 42 A position feedback device such as an optical encoder or resolver can be added to the system if desired The feedback is between the motor and the indexer and therefore its specification and installation is not covered in this manual 20 Gear Drive Plymouth Ind Park Terryville CT 06786 5 Tel 860 585 1254 Fax 860 584 1973 http www amci com IE INTRODUCING THE 5017040 The SD17040 with DuraDrive Technology 5017040 is an advanced high power drive for NEMA 17 through NEMA 34 frame size motors The many features of the drive include gt DuraDrive Technology protects the drive from extremes in temperature input voltage and motor regen eration currents Programmable motor current setting from 0 9 to 4 0 amps Programmable idle current reduction Detection of motor wiring shorts Both winding to winding and winding to case Interlock pins on motor connector removes the bus voltage from the connector when the motor is not attached to the drive gt Motor Disable input gt Fault Output to signal the indexer or other device of a problem with the driv
42. hields in the box Also cabling for these signals should not be routed in conduit with high voltage high power conductors such as the motor cabling Wire the Motor Connector Shielded cable must be used because switching the phase currents gen erates a large amount of electrical noise Do not run the motor cable in the same condiut at the Indexer I O wiring Also in order for the fault current circuitry to work correctly the shields of the motor cable must be attached to the Earth Ground pin of the SD17040 s Motor Connector and the case of the motor In order to prevent ground loop currents make sure the SD17040 and motor are at the same ground potential Wire Power The SD17040 requires a nominal 110Vac for operation Both the line and neutral con nections are fused internally in the SD17040 at 5A If codes allow it power wiring can be placed in the same conduit as the motor cabling Do not run power cabling in the same conduit as the indexer I O cabling STEP 4 Verify Your System Setup 4 1 4 2 4 3 4 4 4 5 Verify all wiring and grounding before applying power to the SD17040 Make sure the rubber boots are on the drive s motor and power connectors Apply 110Vac power With the motor attached the power and status LED s should come on green If either LED does not light or the Status LED is red then a problem exists Remove power and refer to Appendix C TROUBLESHOOTING which starts on page 49 Check for holding to
43. http www amci com 15 GENERAL INSTALLATION GUIDELINES Surge EMI Suppression continued Surge Suppression DC Outputs All inductive DC loads require a commutating or fly back diode across the load Inductive DC loads include relays solenoids and DC motors Unlike resistors diodes have a polarity and only conduct current in one direction Therefore care must be taken when installing diodes As shown in the figure below the cathode of the diode which is denoted by the white or black band on one end of the diode must be installed on the positive side of the load If you install the diode backwards it will most likely destroy itself as soon as you apply power to the load DC Load Connection _ Inductive Contact Device Power In n o COLORED BAND Power Return Figure 5 4 DC Output Surge Suppression The diode must be sized to handle the inductive surge of the load when it turns off gt Some devices can be ordered with built in fly back diodes or the device manufacturer will offer sup pressors designed specifically for the device These types of devices are strongly recommended Surge Suppression AC Outputs If you are also switching AC loads with hard contacts such as mechanical relays or contactors then you must install a suppression network on the load switched by these hard contacts The two most common suppres sors for AC loads are varistors and R C networks gt AMCI strongly sugg
44. id motors can be wired to the SD17040 Wiring diagrams are given in the Step 4 Connecting the Motor section of chap ter 6 starting on page 36 Internally each motor phase is driven by a bipolar MOSFET H bridge The 170Vdc bus used by the H bridges is derived from the 110Vac input power When the motor is powered 170 Vdc is on the motor connector pins To reduce the risk of elec trical shock always install the factory supplied rubber boot on the motor connector Interlock Terminals The two INTERLOCK terminals are a safety feature The SD17040 will not power the motor outputs unless these two terminals are connected by a short wire If these terminals are not connected the Step Fault LED is red and the Fault Output is active Center Tap Terminals 5 8 288 INTERLOCK 2x6 8 85 x58 B n 853 s EARTH GND 8 582 258 A n 0 5 5 0 5 08 n o See INTERLOCK Figure 3 3 Motor Connector The two center tap pins A CTAP and B CTAP are for wiring convenience only They are electrically isolated from the rest of the drive and are not used to power the motor EARTH GND Connection The EARTH GND connection on the Motor Connector is for the shields of the motor s cable This point is internally attached to the chassis and grou
45. is its difficult to calculate the exact amount of high speed torque a motor will give you when you reduce its current setting It s often easier to determine your optimum current setting by testing your machine at various current settings and then deciding which setting gives you the best performance Unipolar Ratings By convention most motor specifications including maxi mum motor current are based on a unipolar motor con nection The first stepper drives were called Unipolar Drives because of the way they controlled the rotational direction of the motor Torque oz in Power W A typical stepper motor has four windings A Unipolar Drive uses two of these windings to drive the motor clock wise and the other two windings to drive the motor counter clockwise Therefore two of the windings in the motor are always off which means the available torque is less than if you could use all four windings together A Bipolar Drive such as the SD17040 has the additional electronics that allow it to switch the direction of current flow through its output drivers Therefore a Bipolar Drive can use all four windings at the same time thereby increasing the available torque from a motor Torque oz in Power W SM23 240D N Parallel 4 0A eo 0 5 10 15 20 25 30 Speed RPS Figure A 3 SM23 240
46. ision Note that sinking or sourcing configura tions that use greater than 5Vdc require a current limiting resistor 2 2 The Fault Output is an un committed transistor that can be wired as a sinking or sourcing output Refer to the worksheet for a sourcing output wiring diagram electrical specifications and fault con ditions that trigger the output STEP 3 Install The SD17040 3 1 Mounting and clearance dimensions are given in the Step 1 Installing the Drive section of chapter 6 starting on page 30 3 2 After mounting the SD17040 bond the drive to your ground bus using the grounding lug on the front panel Like all stepper drives the SD17040 generates quite a bit of electrical noise while oper ating so this bonding wire is required At a minimum it should be a 8 gauge stranded wire 20 Gear Drive Plymouth Ind Park Terryville CT 06786 9 Tel 860 585 1254 Fax 860 584 1973 http www amci com D QUICK START STEP 3 Install The SD17040 continued 3 3 3 4 3 5 Wire the Indexer Connector Note that all I O on the Indexer Connector is low voltage low power and requires shielded cable Ground the shields at the indexer only Do not ground the shields at the 5017040 as it is an electrical noise generator and do not connect the shields to ground at both ends Any splice in the cable must be made in a grounded junction box In the junction box treat the shield as a signal carrying conductor Do not ground the s
47. ith the model number and serial number if applicable along with a description of the problem A RMA number will be issued Equipment must be shipped to with transportation charges prepaid Title and risk of loss or damage remains with the customer until shipment is received by AMCI 24 Hour Technical Support Number 24 Hour technical support is available on this product For technical support call 860 583 7271 Your call will be answered by the factory during regular business hours Monday through Friday 8AM 5PM EST During non business hours an automated system will ask you to enter the telephone number you can be reached at Please remember to include your area code The system will page one of two engineers on call Please have your product model number and a description of the problem ready before you call We Want Your Feedback Manuals at AMCI are constantly evolving entities Your questions and comments on this manual are both welcomed and necessary if this manual is to be improved Please direct all comments to Technical Docu mentation AMCI 20 Gear Drive Terryville CT 06786 or fax us at 860 584 1973 You can also e mail your questions and comments to techsupport amci com ADVANCED MICRO CONTROLS INC ABOUT THIS MANUAL Read this chapter to learn how to navigate through the manual and familiarize yourself with the conventions used in it The last section of this chapter highlights the manual s remaining chapt
48. itor Negative High Resistance Lower surge current through relay contacts Low Capacitance to charge capacitor Positive Table 5 1 R C Network Trade offs In general capacitor values range from 0 1 to 1 0 uF and resistor values range from 150 to 680 ohms Higher transient voltage spike Negative The easiest way to specify a R C network is by following the recommendations of the load s manufacturer Most manufacturers have tested and specify standard R C networks and many sell networks that are designed to integrate with their products If you cannot get help from your load s manufacturer feel free to contact AMCI for assistance 28 ADVANCED MICRO CONTROLS INC CHAPTER 6 INSTALLING THE 5017040 Installation Steps Installing the SD17040 is broken down into six steps Step 1 Installing the Drive Step 2 Connecting the Indexer Step 3 Installing the Stepper Motor Step 4 Connecting the Motor Step 5 Grounding and Powering the System Step 6 Testing the System A Note On Grounding Effective grounding of the stepper motor and SD17040 drive is critical to safe and proper operation 5017040 must be connected to earth ground Failure to properly ground the chas sis leaves the potential for severe electrical hazard and or problems with normal opera tion The chassis ground connection of the SD17040 and the body of the motor are connected through the shield of the motor s cable When installing the sy
49. lar Series Bipolar Parallel Multiplier Multiplier Multiplier 0707 1 Bipolar Center Tap refers to six lead motors that are connected to Amps 0 707 141 the drive from Bipolar DE enter Tap configuration only Holding Torque Volts 0 707 1 41 1 half or the winding is used If the current specification of the motor is listed as bipolar and you decide to connect the motor from center tap to end Bipolar Series 25 Mos pa Known Value 49 a s NI 01 Bipolar use the Bipolar Parallel Series to Unipolar inductance multiplier Holding Torque 0 707 Table A 1 Motor Conversion Factors 20 Gear Drive Plymouth Ind Park Terryville CT 06786 43 gt Tel 860 585 1254 Fax 860 584 1973 http www amci com A ug CHOOSING YOUR MOTOR Notes 44 ADVANCED MICRO CONTROLS INC APPENDIX B UPGRADING TO THE SD17040 This appendix gives information on upgrading from an AMCI SD3520 This information is valu able if you re replacing one of these units or upgrading the design of your system Information on setting the switches of an SD17040 to mimic the SD3520 is given as well as information on wiring and operation changes Replacing a SD3520 03520 is an older AMCI stepper drive that has been phased out and replaced by the 5017040 The 5103520 is still supported b
50. lt Output behaves during each of them 20 Gear Drive Plymouth Ind Park Terryville CT 06786 15 Tel 860 585 1254 Fax 860 584 1973 http www amci com SPECIFICATIONS Indexer I O Specifications The following tables lists the electrical specifications of the SD17040 indexer inputs and output Directional Pulse Inputs STEP CW amp DIR CCW RLIMIT Suggested Current 5 Volts Limiting Resistors 12 Volts 15 Volts 24 Volts Tmin eno IM inom OFF Time I For STEP DIR Directional Pulse Type Only Setup time on direction change 150 uS before first pulse Table 3 1 Directional Pulse Input Specifications Disable and Reset Inputs npr type Optorisolated 5 Vae Differential _ RLIMIT Suggested Current 5 Volts Limiting Resistors 12 Volts 15 Volts 24 Volts Time listed are the amount of time needed from the release of the input until the SD17040 is ready to accept pulses Table 3 2 Disable and Reset Input Specifications ADVANCED MICRO CONTROLS INC SPECIFICATIONS Indexer I O Specifications continued Fault Output Output Type Opto isolated 30 Max ce Output Configuration Can be wired as a sinking or sourcing output Output Isolation 1500 Vdc Vic Xm Allowable Output Current 20 mAdc max Table 3 3 Fault Output Specifications Motor Output Figure 3 3 shows the motor connector on the SD17040 Two phase four six or eight lead hybr
51. lt can be in the motor cable or the motor itself ADVANCED MICRO CONTROLS INC SPECIFICATIONS Stepper Motors offers a total of 21 different stepper motor configurations Three different NEMA sizes are available size 23 34 and 42 The size 23 and 34 motors are available in one two and three stack configurations All motors have single and dual shaft configurations and the dual shaft models can have an incremental optical encoder factory installed The part numbers are given below NOTE gt Outline drawings for all of the motors are available on our website http Avww amci com Additional information on our motors is available in Appendix A CHOOSING YOUR MOTOR starting on page 41 This information includes guidelines for sizing your motor torque curves for all AMCI motors and information on determining current settings for non AMCI motors Note that the SM42 and SM34 650 motors are not recommended for use with the SD17040 because of their current requirements If you must use one of these motors consider using the SD17063 drive instead Specification SM23 90 SM23 130 SM23 240 SM34 250 SM34 425 SM34 650 SM42 1250 NEMA Size 23 34 Max Parallel Current 2 4 0A 4 3A Max Series Current 1 2 0A 2 2 Holding Torque 240 oz in 240 oz in Motor Length w o 3 1 in 2 5 in shafts Rotor Inertia oz in sec Motor Weight 48 oz For The Dual Shaft Option Add D To The Given Part Number For The
52. m current settings for all of our stepper motors For three SM34 motors the maximum parallel cur rent of 4 0 amps is the limit of the SD17040 not the motor NOTE 3 If you do not need the maximum torque available from the motor you do not have to set the current to this value In fact setting it to a lower value will decrease motor heating which will prolong its life Specification SM23 90 SM23 130 SM23 240 SM34 250 SM34 425 SM34 650 Series Current 1 4 1 4 2 0 2 2 3 2 3 8 A Parallel Current 2 8 A 2 8 A 40A 40A 4 0A 40A Table 4 1 Maximum AMCI Motor Current Settings 1 Never increase the current setting to a value greater than that specified for the motor Excessive current may cause motor overheating and failure 2 The motor current setting is not latched Changes to these switches are applied immediately Be aware that changing these switches while power is applied to the motor may cause unexpected operation including loss of holding torque This could result is possible damage to equipment and or injury to personnel Therefore can only recommend changing these settings while power is removed from the drive If you decide to change these switches while power is applied to the drive DO NOT make changes while the motor is running Figures 4 4 and 4 5 show the switch settings for the motor current MOTOR CURRENT Pg 1 of 2 Switch Block 2 Switches 1 5 0 0 012345 a Not
53. m m a 40E ADVANCED CONTROL 5 mc 5017040 Stepper Drive Manual 940 0S020 Built With DuraDrive Technology Motion GENERAL INFORMATION Important User Information The products and application data described in this manual are useful in a wide variety of different applica tions Therefore the user and others responsible for applying these products described herein are responsible for determining the acceptability for each application While efforts have been made to provide accurate information within this manual AMCI assumes no responsibility for the application or the completeness of the information contained herein UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS INC BE RESPONSIBLE OR LIABLE FOR ANY DAMAGES OR LOSSES INCLUDING INDIRECT OR CONSEQUENTIAL DAM AGES OR LOSSES ARISING FROM THE USE OF ANY INFORMATION CONTAINED WITHIN THIS MANUAL OR THE USE OF ANY PRODUCTS OR SERVICES REFERENCED HEREIN No patent liability is assumed by with respect to use of information circuits equipment or software described in this manual The information contained within this manual is subject to change without notice This manual is copyright 2001 by Advanced Micro Controls Inc You may reproduce this manual in whole or in part for your personnal use provided that this copyright notice is included You may distribute copies of this complete manual in electronic format provided
54. make connections to these pins for nor mal operation These pins are electrically isolated from the drive and are for wiring conve nience only These pins are used with six lead motors and also with eight lead motors wired in series Check your wiring diagrams to see if you can use these pins Wiring diagrams for six and eight lead motors can be found in the manual section Step 4 Connecting the Motor on pages 37 and 38 gt A Phase Can be brought over directly to 5017040 gt Phase WIRING MUST BE REVERSED The wires in the B terminal of the 503520 go to the B terminal of the SD17040 and the wires in the B terminal of the 5123520 go to the B termi nal of the SD17040 If the B phase wiring is not reversed the motors rotation will reverse Com manding it to rotate clockwise will rotate it counter clockwise and a counter clockwise command will result in a clockwise rotation Failure to observe this warning can result in undesired operation with possible damage to equipment or injury to personnel gt Earth GND Shields Not used on the 503520 The shields of the motor cable must be connected to the terminal for normal operation ADVANCED MICRO CONTROLS INC 46 lt UPGRADING TO THE SD17040 H Replacing a SD3520 continued Power Connector Wiring Changes gt Power Connector Can be brought over directly to the SD17040 WARNINGS 1 Input power must be 95 to 132 Vac 50 60 HZ and able to supply
55. n order to assure proper convectional airflow around the SD17040 you must follow the clearance guidelines given in figure 6 2 If you do not have this amount of area around the drive you may need to install a small coolin g fan below it to force air up through the drive 2 0 51 DIR CCW DIR CCW STEP CW STEPICW DISABLE DISABLE FAULT FAULT DIR CCW DIR CCW STEPICW STEP CW DISABLE DISABLE FAULT FAULT STEP FAULT O STEP FAULT INTERLOCK BCTAP B EARTH GND INTERLOCK INTERLOCK BCTAP boot over con B EARTH GND INTERLOCK 10 1 257 TTOVdc present when interlock pins are comecied To reduce risk of shock install TTOVdc present when interlock pins are comecied To reduce risk of shock install factory supplied rubber boot over connector 5 5017 50170 POWER 5 AC POWER 95 132 Vac 95 132 Vac 50 60 Hz 50 60 Hz AMICI 2 0 51 1 5 38 1 5 1 0 1 0 38 25 25 4 2 5 2 5 0 107 132 127 Figure 6 2 Mounting Clearance Dimensions Installation Notes gt In order to dissipate hea
56. nding lug of the 5017040 Motor Insulation and Inductance Specifications Because of the high voltage bus generated by the SD17040 for the motor be sure that the winding insulation for you motor is rated for 500 Vdc minimum This rating applies to the phase to phase and phase to case insulation ratings All AMCI motors meet this specification The ideal inductance value for a motor connected to an SD17040 is between 2 5 and 45 mH However the All AMCI motors that are SD17040 will work with motors that have an inductance value as low as 1 mH compatible with the SD17040 fall within the 2 5 to 45 mH range 20 Gear Drive Plymouth Ind Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com 17 3 SPECIFICATIONS Input Power Figure 3 4 shows the SD17040 s power connector and grounding lug Input power must be between 95 and 132 Vac 50 60 Hz for proper operation A wiring diagram is given in the Step 5 Grounding and Powering the System section of chapter 6 starting on page 39 When power is applied 110 Vac is on the AC POWER WARNING power connector pins To reduce the risk of 95 132 Vac O N electrical shock always install the factory 50 60 Hz supplied rubber boot on th t 2 pplied rubber boot on the power connector NOTE 1 Because 5017040 derives motor power ANINE directly from the AC
57. nnected to the case of the motor and is connected to earth ground at the motor through the motor s mounting The shield is also connected to earth ground at the SD17040 Extending the motor cable will greatly increase the chances of forming a ground loop between the motor and the SD17040 Ideally the motor and SD17040 should be connected to the same point on your earth grounding system Even though it is possible to extend the cable length an additional forty feet AMCI recommends installing the 51017040 as close as possible to the motor This will decrease the chance of forming a ground loop and has the added benefit of limiting the amount of power loss in the motor cable If you must extend the cable you should use a cable with twisted pairs 18 AWG or larger and an overall shield Belden 9554 eight wire 9553 six wire and 9552 four wire meet these specifications Installing the Motor Cable 1 All of the motor connections are high power high voltage signals Cable from the motor can be installed in conduit along with ac dc power lines or high power ac dc I O as long as safety codes are followed It cannot be installed in conduit with low power cabling such as cabling from SD17040 to the indexer communication cables or low power ac dc I O lines 2 If you decide to extend the motor cable treat the shield as a signal carrying conductor when installing the motor cable Do not connect the shield to earth ground at any junction box
58. on RED GRN Facing mounting flange EE q YEL WHT pe Shields Y For CCW rotation reverse EARTH 2 BLK YEL A Stepper Drive B and TS ORG BLU N connections RA WHT BLK RED INTERLOCK Ds WHT ORG BLK H N m 7 WHT indicates white wires with colored tracers Colors in parentheses are Integral eight conductor cable alternate wire colors Figure 6 9 Eight Lead Motor Connections 38 ADVANCED MICRO CONTROLS INC INSTALLING THE 6017040 A 9 Step 5 Grounding and Powering the System The chassis of the SD17040 must be connected to earth ground Failure to properly ground the chassis leaves the potential for severe electrical hazard and or problems with normal operation Properly grounding the SD17040 is accomplished by using the grounding lug Run a minimum 8 gauge stranded wire or 1 2 wire braid from the drive s grounding lug to your system ground bus The wire should be as short as possible Also use an oxide inhibiting joint compound at both connections when installing the wire AC power connections are made to the SD17040 using the PC 1 connector kit that ships with the drive The PC 1 kit includes the power connector and rubber boot Figure 6 10 below shows how to properly wire and ground the drive NOTE For clarity the rubber boot is not shown in the figure When installing the power cable slide the rubber boot onto the cable before wiring the connector When you re
59. or programming the wrong number of pulses in the indexer profile The second problem is most commonly seen when replacing an SD8055 with the SD17040 The SD8055 was a microstepping drive so profiles written for the SD8055 will most likely need to be mod ified before working with the SD17040 6 If you are using the Disable Input verify its operation with the motor stopped Note that the motor will have no holding torque while this input is active and the motor s shaft will be free to rotate 7 If you are using the Fault Output verify that it is On conducting Remove power from the SD17040 disconnect the motor and re apply power The STEP FAULT LED shold be red and the Fault Output should be off not conducting 8 Remove power and re attach the motor Power the drive 9 Consider altering the motor current or enabling the Idle Current Reduction if it is not already enabled Lowering the motor current or enabling Idle Current Reduction can greatly reduce motor heating If your system fails any of these tests refer to Appendix C TROUBLESHOOTING starting on page 49 for suggestions on possible causes for the problems When you are finished with the test remember to couple the load and motor if you uncoupled them before the test 40 ADVANCED MICRO CONTROLS INC APPENDIX A CHOOSING YOUR MOTOR Sizing Your Motor Your motor choice is based on the output torque you need the mounting space you have and your budgetary cons
60. parate from the indexer and input wiring in order to lessen the possibility of coupling transient noise into the low power cabling 2 If a conduit containing the indexer cabling or other input wiring must cross conduit that contains power wiring they must cross at right angles 3 Whenever possible conduit that contains low power cabling must be kept 1 foot 30 cm away from 120Vac conductors 2 feet 61 cm from 240Vac conductors and 3 feet 91 cm from 480 Vac conductors Surge EMI Suppression All inductive devices in the system such as motor starters contactors relays and solenoids must have surge suppression devices installed across their coils This limits the amount of electrical noise that may be coupled into any low power cabling near the inductive devices In the case of the SD17040 s indexer cabling this low ers the chances that electrical noise will appear as directional pulses to the drive This includes all devices that share an AC power connection with the SD17040 and its indexer have wiring in the enclosure that houses the SD17040 or indexer or wiring that is run in the same conduit as indexer wiring DC loads are typically suppressed with a flyback diode while AC loads are typically suppressed with a RC network or varistor gt RC Networks are the preferred suppressor for AC loads The figure below show where surge suppression devices should be placed in the circuit Acceptable Connection Inductive ac
61. puts If your indexer is sending pulses in the CW CCW format and the drive is config ured for the Step amp Direction format the motor will rotate counter clock wise when the drive receives CW pulses and it will not rotate at all when the drive receives CCW pulses If the indexer is sending pulses in the Step amp Direction format and the drive is configured for the CW CCW for mat the motor will only rotate clockwise even when the indexer is com manding a counter clockwise move The motor runs backwards CW instead of CCW and or CCW instead of CW 1 One of the motor phases may be reversed This is most commonly the problem with converting from a SD3520 to a SD17040 because the sense of the B phase is reversed between the two drives 2 There may be a problem with the directional inputs Either they are wired incorrectly or the format is wrong Check wiring and see the previous problem for more information on problems with format 20 Gear Drive Plymouth Ind Park Terryville CT 06786 49 Tel 860 585 1254 Fax 860 584 1973 http www amci com TROUBLESHOOTING Indexer Problems Symptom Solution My indexer PLC reports a fault Your logic maybe reversed On the SD17040 the Fault Output is on from the SD17040 when every conducts current when the drive is working correctly and turns off thing seems fine stops current flow when there is a fault with the drive Therefore losing power to the drive appear
62. r sourcing and you must use the 3 9KQ resistor as shown in figure 6 4 With the directional pulses being in the STEP DIR format the SD17040 s Pulse Train DIP switch SB1 2 should be set to one when using the MicroLogix 1500 Open Collector Sourcing Output 5 to 24V 2 5017040 Input DIR CCW Rum Output STEP CW hn D 21 A foe ed DIR CCW OR 4 STEP CW I Shielded Twisted Vpc RLIMIT Pair Cable 5 Volts Te 12 Volts Open Collector Sinking Output 15 5 10 24 24 Volts DIR CCW pu A STEP CW a DS DIRICCW ji PE EE S y oo STEPICH 4 Indexer Shielded Twisted Output E Pair Cable PEE Figure 6 4 Single Ended Input Connections Disable Input Wiring The Disable Input on the SD17040 will shut off motor current when active The circuitry of this input is identical to the directional pulse inputs Refer to figures 6 3 and 6 4 when wiring this input A momentary or toggle switch can be used in place of the open collector output shown in figure 6 4 Do not activate the Disable Input while the motor is running When the Disable Input CAUTION is active the current to the motor is removed and the motor is free to rotate No hold ing torque is available while the Disable Input is active The SD17040 does not accept directional pulses while the Disable Input is active Therefore when the Dis
63. rque on the motor If you have less then you expected the most common causes are improper motor current switch settings or having the Idle Current Reduction turned on Have your indexer make a slow move in the clockwise direction for one turn While the turn is in progress the STEP LED should blink Verify that the motor rotated in the correct direction for one complete turn If you are using an optical encoder or other position feedback verify that the indexer or controller is reading it properly Repeat step 4 4 with a move in the counter clockwise direction Again verify that the motor rotated in the correct direction for one turn NOTE gt Any problems at steps 4 4 and 4 5 are usually caused by not setting the Pulse Train Input 4 6 4 7 4 8 4 9 switch correctly or programming the wrong number of pulses in the indexer profile The sec ond problem is most commonly seen when replacing an SD8055 with the SD17040 The SD8055 was a microstepping drive so profiles written for the SD8055 will most likely need to be modified before working with the SD17040 If you are using the Disable Input verify its operation with the motor stopped Note that the motor will have no holding torque while this input is active and the motor s shaft will be free to rotate If you are using the Fault Output verify that it is On conducting Remove power from the SD17040 disconnect the motor and re apply power The STEP FAULT LED shold be red and t
64. s the Disable Input and the Fault Ouput 2 Signals attached to Indexer Connector are of low voltage and low power Indexer Cabling can be installed in conduit along with other low power cabling such as communication cables and low power ac dc lines It cannot be installed in conduit with ac power lines stepper motor cabling or other high power ac dc lines HIGH POWER CONDUIT 3 Each cable must be shielded and grounded only at the ACIDE Outputand Rewer Cabling device that is generating the signals If you must splice the cable it must be done in a grounded junction box When splicing treat shield as signal carrying conductor Do not connect the shield to earth ground at the junction box SYSTEM EQUIPMENT ENCLOSURE GROUNDING ELECTRODE SDI7040 Mounted to Back of Enclosure ADVANCED MICRO CONTROLS INC 20 sj GENERAL INSTALLATION GUIDELINES Wiring continued gt Motor Wiring High Power AC amp DC 1 Motor Wiring must be kept separate from the indexer cabling and other low power I O wiring in order to lessen the possibility of coupling transient noise into the low power cabling 2 If a conduit containing the indexer cabling or other low power wiring must cross conduit that contains motor wiring they must cross at right angles gt AC Power Wiring High Power AC amp DC 1 Power Wiring must be kept se
65. s as a fault If you re expecting the fault output to turn on and conduct current when there is a fault then your logic is reversed The motor is running faster slower Most likely a problem with the 50170405 Step Resolution setting or the than expected and or the distance indexer s programming If the motor is running too fast the Step Resolu traveled is father shorter than tion on the SD17040 is set to Full Step and the indexer s programmer expected assumed it would be set to Half Step If the motor is running slow the Step Resolution is set to Half Step or the indexer programmer assumed it would be set to Full Step Drive Problems Symptom Solution Both LED s are off and the Fault The AC line voltage may be too low It must be greater than 85Vac for Output is active Not conducting the SD17040 to operate properly Power is applied to the drive One or both of the 5A fuses may be blown These fuses will not blow under normal circimstances so call AMCI for assistance Blown fuses may be a sign of serious installation problems Both LEDs are green the Fault The Disable input may be active If this input is receiving power the Output is inactive conducting but motor current is removed but the drive does not go into a fault condi the motor is not powered tion Idle Current Reduction may be enabled When the Idle Current Reduction is turned on current is removed from the motor if a direc tional pulse is not received
66. s it was designed for and other products available from AMCI you can use to complete your system Stepper Motor Systems When you must control rotational position or velocity stepper motors have several advantages over servo control systems The first is cost Opposed to closed loop servo systems that require position feedback to the drive stepper systems operate open loop accurately controlling position and velocity without feedback Eliminating the feedback loop can result in a great cost savings The stepper motor itself is also tough easy to install and offers high output torque for its size As shown in figure 1 1 there are three basic components to a stepper system Step Pulses SD17040 Fault Diagnostics Motor Currents Position Feedback _ optional Figure 1 1 Block Diagram of a Stepper System gt The Indexer The indexer sometimes called the controller generates directional pulses that control the position velocity and rotational direction of the stepper motor Indexers can take on many forms from a plug in card card for a PLC to a black box that runs a fixed profile whenever the operator presses a button gt The Drive The drive converts the directional pulses from the indexer into the current waveforms needed to drive the stepper motor The SD17040 accepts differential signals from the indexer and out puts 170Vdc digitized waveforms to t
67. stem take steps to ensure that the earth ground of the motor and the earth ground of the SD17040 are at the same potential Ideally the motor and drive will be connected to the same ground bus Information on grounding the motor and SD17040 is given in the Grounding section chapter 5 on page 26 along with the Mounting the Motor and Step 5 Grounding and Powering the System sections of this chapter on pages 34 and 39 respectively Step 1 Installing the Drive Selecting a Location Like most stepper drives the SD17040 needs to be installed in a NEMA enclosure to protect it from the fac tory environment Most installations place the drive in the same cabinet as the indexer or other control logic and run long cables to the motor However this type of installation can suffer from three problems 1 The motors cable will carry a significant amount of current and the longer the cable the more power will be lost to cable resistance This will decrease the available torque from the motor 2 The motor current is switched at 22KHz which will generate a significant amount of electrical noise Therefore EMI is a potential problem especially if the motor cable is not properly installed 3 In order to detect motor faults the earth ground connections of the motor and the SD17040 must be tied together A long cable run between the indexer and motor increases the likelihood of a ground loop To limit these problems consider mounting the SD17040 in
68. sure the wiring is correct slide the boot over the connector to cover the screw heads MC 1 Motor Connector Rubber Boot not shown 110Vac present on terminals when drive is powered Rubber Boot should be installed to reduce the risk POWER O of electric shock S boxe Green Chassis Ground 115Vac Neutra 95 132 Vac S AC POWER 50 60 Hz S Black 115Vac Line a eu N NI Both the Neutral and Hot Lines are internally fused Grounding Wire in the SD17040 Min 8 Gauge Stranded or 1 2 Braided Wire GROUND BUS Q Q o Figure 6 10 Power and Grounding Connections WARNINGS 1 Input power must be 95 to 132 Vac 50 60 HZ and able to supply 5APK for proper oper ation 2 Never attempt to power the drive with 230Vac Doing so will damage the drive and void its warranty If you are converting from an SD3520 to the SD17040 verify that the 03520 was operating at 120Vac before applying power to the SD17040 If your instal lation only has 230 Vac you must install a step down transformer to power the SD17040 The transformer must be rated for a minimum of 750Va Both the Neutral and the Line power connections are internally fused in the SD17040 External fuses or cir cuit breakers can also be used They must be rated for at least 5 amps 20 Gear Drive Plymouth Ind
69. t correctly the SD17040 must be mounted with the heat sink fins vertical as shown in figure 6 2 A large amount of heat can also be dissipated through the back panel if the drive is securely mounted to a metal panel The ambient temperature around the drive must not exceed 120 F 50 C If mounting the drive in an enclosure you must make provisions for proper air flow The clearance dimensions given in figure 6 2 should be sufficient for most applications but a small cooling fan mounted below the drive may be needed if the ambient temperature is high or the enclosure is not venti lated Never block the fins of the heat sink Never expose the SD17040 to liquids including condensing humidity Never expose the 5017040 to metal particles If the 5017040 is mounted in a ventilated enclosure the ventilation fans should have dust covers gt Never open the drive Opening the drive will void the factory warranty gt Never probe the drive Hazardous voltages are present within the drive and digital ground is isolated from earth ground 20 Gear Drive Plymouth Ind Park Terryville CT 06786 31 Tel 860 58 5 1254 Fax 860 584 1973 http www amci com INSTALLING THE 6017040 Step 2 Connecting the Indexer NOTE 5 1 All of the Indexer I O connections are low power low voltage signals All cabling must be done with twisted pair wires with an overall shield Belden 8761 instrumentation cable or Belden 9729 communication c
70. terminals are not connected Pulse Train Input Switch selectable to CW CCW or Step Direc tion Motor Current Switch selectable from 0 9 to 4 0Apk in 0 1 Amp steps Idle Current Reduction Switch selectable to Not reduced or To 0 Motor current is reduced to selected level if a step pulse is not received for one second Current restored to full value on next pulse Resolution Switch selectable to Full Step or Half Step 200 or 400 Steps per Turn Internal Power Fuses 5 Amp Slow Blow Both Line and Neutral are fused Fuses are not field replaceable Environmental Specifications Input Power 95 to 132Vac 50 60 Hz 5 0 Apk max Drive will retain control of motor down to 85Vac at reduced torque Operating Temp 32 to 122 F 0 to 50 C Storage Temp 40 to 185 F 40 to 85 C Humidity 0 to 95 non condensing Motor Specifications Type 2 phase hybrid 4 6 or 8 lead motor Insulation Minimum 500Vdc phase to phase and phase to case Inductance 1 mH minimum 2 5 to 45 mH recommended 20 Gear Drive Plymouth Ind Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com SPECIFICATIONS 5017040 Connector Placement Figure 3 1 shows the placement of the three connectors and the grounding lug on
71. that they are unaltered from the version posted by Advanced Micro Controls Inc on our official website www amci com You may incorporate portions of this documents in other literature for your own personal use provided that you include the notice Portions of this document copyright 2001 by Advanced Micro Controls Inc You may not alter the contents of this document or charge a fee for reproducing or distributing it Standard Warranty ADVANCED MICRO CONTROLS INC warrants that all equipment manufactured by it will be free from defects under normal use in materials and workmanship for a period of 1 year Within this warranty period shall at its option repair or replace free of charge any equipment covered by this warranty which is returned shipping charges prepaid within one year from date of invoice and which upon examina tion proves to be defective in material or workmanship and not caused by accident misuse neglect alteration improper installation or improper testing The provisions of the STANDARD WARRANTY are the sole obligations of AMCI and excludes all other warranties expressed or implied In no event shall be liable for incidental or consequential damages or for delay in performance of this warranty Returns Policy All equipment being returned to AMCI for repair or replacement regardless of warranty status must have Return Merchandise Authorization number issued by AMCI Call 860 585 1254 w
72. the SD17040 Detailed connector pinouts are given Oz later in the chapter EE 5017040 Indicator LED s sad T Figure 3 1 also shows the placement of the drive s two indicator LED s The Power LED is just that It s on when power is applied to the drive The Step Fault LED is green when drive is operational NEN S red when there is a fault condition and blinking green when the drive 0 is receiving pulses from the indexer Note that this LED will appear to iii be on dimly when the drive is receiving pulses at a high frequency and 1 E a 1 384 Ha E SD17040 Features Overview the 3 The following section gives brief descriptions of the 51217040 settings SD1 a1 They are presented so that you can familiarize yourself with the drive or More in depth descriptions are given in the Chapter 4 SWITCH SET 0 0 TINGS starting on page 21 95 132 Vac 50 60 Hz Step Resolution GJ bel Vie POWER The Step Resolution feature sets the number of steps needed to com Sa f CONNECTOR plete one rotation Standard stepper motors have an inherent resolu A tion of 1 8 per step or 200 steps per turn The SD17040 can drive a V motor at this resolution which is commonly called Full Step or can drive a motor at 400 steps per turn which is commonly called Half Figure 3 1 Connector Placement
73. the motor on a large metal surface you may need to install a fan to force cooling air over the motor 34 ADVANCED MICRO CONTROLS INC INSTALLING THE 6017040 A 9 Step 3 Installing the Stepper Motor continued Mounting the Motor continued Motors should be mounted using the heaviest hardware possible AMCI motors can produce high torgues and accelerations that may weaken and shear inadeguate mounting hardware 1 The motor case must be grounded for proper operation This is usually accomplished through its mounting hardware If you suspect a problem with your installation such as mounting the motor to a painted surface then run a bonding wire from the motor to a solid earth ground point near it Use a minimum 8 gauge stranded wire or 1 2 wire braid as the grounding wire 2 Do not disassemble any stepper motor A significant reduction in motor performance will result 3 Consult with AMCI before machining motor shafts AMCI has machining capability that may allow you to order the motor as a custom product Damaging a motor by improperly modifying a motor s shaft will void its warranty Connecting the Load Care must be exercised when connecting your load to the stepper motor Even small shaft misalignments can cause large loading effects on the bearings of the motor and load The use of a flexible coupler is strongly rec ommended whenever possible Extending the Motor Cable CAUTION The shield of the motor cable is co
74. tion you need to do your job Chapier Title Intended Audience Anyone new to the SD17040 This chapter gives a basic overview of INTRODUCING THE SD17040 the features available on the unit typical applications and comple mentary equipment QUICK START Anyone already experienced in installing or using similar products and wants generalized information to get up and running quickly SPECIFICATIONS Anyone that needs detailed information on the drive itself SWITCH SETTINGS Anyone that must determine switch settings when installing the SD17040 GENERAL INSTALLATION GUIDELINES Anyone new to installing electronic controls in an industrial environ ment The chapter includes general information on grounding wir ing and surge suppression that is applicable to any controls installation INSTALLING THE SD17040 Anyone that must install a SD17040 on a machine Includes infor mation on mounting grounding and wiring specific to the unit The chapter also gives guidelines for testing the system once it s installed CHOOSING YOUR MOTOR Anyone that must choose a motor for an application UPGRADING TO THE SD17040 Anyone that is upgrading to the SD17040 from AMCI s SD3520 TROUBLESHOOTING ADVANCED MICRO CONTROLS INC INTRODUCING THE 5017040 This chapter is written for anyone that wants to familiarize themselves with the features of the 5017040 the type of application
75. tional codes Background AMCI has extensively tested the SD17040 both in the lab and in the field under a wide range of conditions to see how the unit reacts to an adverse environment This includes testing the unit after intentionally installing it incorrectly The results of our testing is the following list of areas that must be addressed when engineering your system The order of the list shows the areas that have the largest impact on system operation first 1 Grounding 2 Wiring 3 Surge Suppression This list also shows the first areas that should be investigated if your installation experiences problems 20 Gear Drive Plymouth Ind Park Terryville CT 06786 25 Tel 860 585 1254 Fax 860 584 1973 http www amci com 15 GENERAL INSTALLATION GUIDELINES Grounding Proper grounding is the single most important consideration for a safe installation Proper grounding also ensures that unwanted electrical currents such as those induced by electromagnetic noise will be quickly shunted to ground instead of flowing throughout the machine gt All ground connections must be permanent and continuous to GROUND BUS provide a low impedance path to earth ground for induced 1 noise currents Enclosure and ALL of its Eguipment gt The chassis of the SD17040 must be connected to chassis ground through its mounting in the enclosure and with a bonding wire connected to the grounding lug This wire must be a minimum of 8
76. tor offers more torque than a Center Tap Connected motor at low speeds but usually offers lower torque at high speeds However the operating temperature of a center tap connected motor is always higher than a series connected motor Note that the A CTAP and B CTAP pins on the motor connector are not powered and are for wiring convenience only A Center Tap Connection is equivalent to a unipolar connection because only half of the winding is used Six Lead Series Connected Motor Case INTERLOCK 0 6 Motor Connections shown BCTAP BLK LEAD for CW rotation 0 WHT RED MOTOR Facing mounting flange NS ee a Shields For CCW rotation reverse Hd 0 WHT GRN Stepper Drive B and B B GRN connections Ae D g 7 0 p INTERLOCK Q Wht Red and Wht Gm S I 0 are white wires with colored tracers Integral six conductor cable Six Lead Center Tap Connected Motor Case a INTERLOCK 6 Motor Connections shown WHT RED LEAD for CW rotation Bs PLK 1 MOTOR Facing mounting flange d i ed Shields UH For CCW rotation reverse Stepper Drive B 10 GRN connections lt WHT GRN HH p INTERLOCK Q Wht Red and Wht Gm 6 are white wires with colored tracers Integral six conductor cable
77. traints Torque curves for all of AMCI s motors are available on the following pages There are a few things to remember when choosing your motor based on torque curves 1 The torque curves in this manual are for the SD17040 You cannot use these curves to accurately determine the amount of torque from an AMCI motor when it is attached to a different drive Nor can you accurately determine the amount of torque from a motor when attached to an SD17040 if its torque curves were generated using a different drive In general a motor s high speed torque is directly related to the output bus voltage of the drive If a drive s output bus is lower than the 170 Vdc available on the SD17040 then the available torque from its motor will drop off faster as speed increases 2 Torque curves are shown with 200 steps turn full step resolution selected Half step resolution result in a 10 deviation in the torque curves 3 Make sure the motor can provide the needed torque over the entire speed range of your application ae torque drops as speed increases so evaluate the motors torque at its highest operating speed 4 As you can see from the torque curves attaching a motors windings to the drive in parallel has the advantage of more torque from the motor at high speeds The disadvantage is that the motor will always run hotter when connected in parallel so additional cooling may be needed A simple guideline is to use the largest motor your mount SM23 90
78. u see a phase to case short make sure you don t have a stray wire from the B or A ter minals hitting the Earth Ground terminal on the connector ADVANCED MICRO CONTROLS INC TROUBLESHOOTING Notes 20 Gear Drive Plymouth Ind Park Terryville CT 06786 51 Tel 860 585 1254 Fax 860 584 1973 http www amci com ADVANCED MICRO CONTROLS INC 20 GEAR DRIVE TERRYVILLE CT 06786 T 860 585 1254 F 860 584 1973 WWW AMCI COM LEADERS IN ADVANCED CONTROL PRODUCTS
79. y AMCI but no longer sold as a new unit The SD17040 has several advantages over the SD3520 With its higher bus voltage the SD17040 generates more torque at high speeds its larger motor connector simplifies wiring it has short circuit and overcurrent protection and its fault output allows you to monitor the drive s status NOTE 5 Before replacing 6123520 verify that the motor s insulation has a high enough rating for the SD17040 Minimum phase to phase and phase to ground voltage rating is 500Vdc AMCI motors meet this specification DIP Switch Settings gt Step Resolution SB1 1 There is a switch on the front of the SD3520 labeled HALF STEP If the switch is pushed towards this label then the drive is set for half step resolu tion and SB1 1 on 5017040 should be set Off If the switch on the 5103520 is pushed away from the label then it is set for full step resolution and SB1 1 on the SD17040 should be set to gt Pulse Train Input SB1 2 Set this switch to its position which selects Step amp Direction The 03520 does not have a programmable pulse train input type gt Idle Current SB1 3 Set this switch to its position which select the No Reduction setting By default the SD3520 reduces the motor current by 5096 when a directional pulse is not received for one second but this feature can be defeated by changing a jumper in the unit Because the SD17040 reduces the current
80. y lowering its operating temperature 20 Gear Drive Plymouth Ind Park Terryville CT 06786 45 Tel 860 585 1254 Fax 860 584 1973 http www amci com UPGRADING TO THE 5017040 Replacing a SD3520 continued Physical Installation 5017040 is not a drop in replacement for the 503520 You will have to rework your mounting dimen sions Refer to chapter 6 INSTALLING THE SD17040 which starts on page 29 for mounting dimensions and suggested clearances Indexer Connector Wiring Changes gt Step and Direction Can be brought over directly to the 5017040 gt Enable Input Can be brought over to the SD17040 s Disable Input Any current limiting resistors used because the input voltage exceeds 5 Vdc must be replaced 12 to 15 Vdc systems that used a 1KQ resistor with the 03520 must replace them with 2 resistors 24 Vdc systems need to replace the 2 KQ resistor with a 3 9 KQ resistor gt Fault Output Does not exist on 503520 Can either be left open can be wired into your sys tem for fault monitoring See Fault Output on page 15 and Detectable Faults on page 18 for information on how the fault output works Fault Output Wiring on page 34 details how to wire the output Motor Connector Wiring Changes gt Interlock Pins Not available on the 5123520 Must be connected with a short jumper on the 5017040 for normal operation gt CTap Pins Not available on the 503520 You do not need to

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