User Manual
Contents
1. 15 Mounting the Optional MMI 2 15 Recommended Motors 4 17 Mechanical Outline 17 Technical Specifications 18 Mechanical Outline Optional MMI 19 2 Introduction Thank you for selecting an Applied Motion Products motor control We hope our dedication to performance quality and economy will make your motion control project successful If there s anything we can do to improve our products or help you use them better please call or fax We d like to hear from you Our phone number is 800 525 1609 or you can reach us by fax at 831 761 6544 Features e Powerful precise and efficient MOSFET driver providing up to 3 5 amps per phase and microstepping to 50 800 steps per revolution e Reliable efficient low noise 40 VDC linear toroidal power supply e Powerful flexible easy to use indexer e Connects by a simple cable to your PC for programming cable included e Microsoft Windows based software for easy setup and programming e Eight inputs for interacting with the user and other equipment e Three outputs for coordinating external equipment Accepts 110 or 220 volt AC power factory preset for 110 volts e External2. 3 4 1 2 2200 TLP621 or L NEC PS2501 Wiring a Mechanical Limit Switch You can use normally open or normally closed limit switches Either way wire them as shown here Fa 5 24 VDC SUPPLY Wiring a Limit Sensor Some systems use active limit sensors that produce a voltage output rather than a switch or relay closure These devices must be wired differently than switches CW LIMIT CCW LIMIT o CW LIMIT o CCW LIMIT I I I I Si3540 I I I I I I If your sensor has an open collector output or a sinking output wire it like this CWLIMIT i3540 I CW LIMIT output Sensor Wiring for Sinking or Open Collector Output If the sensor output goes low at the limit select the option closed If the output is open or high voltage choose open Other sensors have sourcing outputs That means that current can flow out of the sensor output but not into it In that case wire the sensor this way ey ay ek Yee output Proximity Sensor Wiring for Sourcing Output If the sensor output goes high at the limit choose the program option closed if the output is low at the limit select open 10 Wiring Inputs CCM gt inside Si i i The Si3540 input circuits can be used with oan is eer te lt gt 5 04 sourcing or sinking signals
3. 5 to 24 volts 20 AW 1s a i Go VDC This allows connection to TTL circuits il i 2 ei power PLCs relays and mechanical switches l 20 AYA on ae Because the input circuits are isolated they i a Supply require a source of power If you are con NO E A a O necting to a TTL circuit or to a PLC you ______ Connecting an Input to the Si 1 Motion Output should be able to get power from the PLC or CHO 2200 Ayar Set Si 1 motion signal to in position Si 1 will trigger Si3540 at end of each move TTL power supply If you are using relays or A meee ee en PE De mechanical switches you will need a 5 24 WIOG i TER i ES power supply This also applies if you are w Se 2 2 or R connecting the Si3540 inputs to another Si CWJ0 ai R Ss OM oh e S product from Applied Motion like the Si 1 1S 2 RI power and Si 100 indexers or the Si5580 7080i ts arene eae AA Supply and MC8400 indexer drives ID O Note If current is flowing into or out of an Si3540 input the logic state of that Connecting a 3540i Si5580 7080i or MC8400 input is low If no current is flowing or the input is not connected the logic state When output closes Si3540 input goes low is high The diagrams on the following pages show how to connect Si3540 inputs to various devices The maximum voltage that can be applied to an input terminal is Fom 24 volts DC Never apply AC voltage to an input terminal al DEEDEE ee hee a Connecting an NPN T
4. As with six lead motors series operation gives you more torque at low speeds and less torque at high speeds In series operation the motor should be operated at 30 less than the rated current to prevent overheating The wiring diagrams for eight lead motors are shown below Ay Orange A Orange BIk Wht Org Wht 8 8 lead lead BIk Wht Org motor motor Wit Black Black Yel Red low Red Red lyel Yellow Yel e By Wht wht B B wht Red Wht B 8 Leads Series Connected 8 Leads Parallel Connected Connecting to the PC eLocate your computer within 6 feet of the Si3540 Your Si3540 was shipped with a black adapter plug It has a telephone style jack at one end and a larger 9 pin connector at the other Plug the large end into the COM1 serial port of your PC Secure the adapter with the screws on the sides If the COM1 port on your PC is already used by something else you may use the COM2 port for the Si3540 On some PCs COM2 will have a 25 pin connector that does not fit the black adapter plug If this is the case and you must use COM2 you may have to purchase a 25 to 9 pin serial adapter at your local computer store Your Si3540 was also shipped with a 7 foot telephone line cord Plug one end into the adapter we just attached to your PC and the other end into the PC MMI jack on your Si3540 Never connect the Si3540 to a telephone circuit It uses the same connectors and cords as telephones and modems but the v
5. S Tel 831 761 6555 800 525 1609 Fax 831 761 6544 x http www applied motion com Copyright 1999 19
6. trigger I O is optically isolated 5 24V sinking or sourcing signals PC MMI port is RS 232 e Sturdy 2 25 x 7 8 x 5 inch metal chassis e Pluggable screw terminal connectors for motor AC power and I O signals e Optional man machine interface MMI allows operator to enter distances speeds cycle counts and more e CE and TUV Compliant Block Diagram x LED power fuse i 110 1 d 9 220 VAC 3 INPUT1 g INPUT2 z INPUT3 A INPUT4 gt CW JOG IN5 CCW JOG IN6 jr 3 CW LIMIT IN7 Mi al i icrostepping 5 COW LIMIT IN8 Indexer Sequencer 2 Ww to PC MMI Getting Started To use your Si3540 motor control you will need the following V apower cable line cord V acompatible step motor V asmall flat blade screwdriver for tightening the connectors an Applied Motion Products screwdriver suitable for this purpose is included with your drive V apersonal computer running Windows 3 1 95 98 or NT with a9 pin serial port 486 or better with 8 MB ram recommended V the Si Programmer software that came with your Si3540 V the programming cable that came with your Si3540 VY Si Programmer software manual The sketch below shows where to find the important connection and adjustment points Please examine it now All Mating connectors included Always use the blue amp white Applied Motion screwdriver with the above 1 0 connectors Larger screwdrivers may remove the pla
7. 25000 Mechanical Outline 25400 25600 36000 50000 50800 Waveform pure sine f U J 8 JU szaf 5 Motion Update 12800 Hz QA me ao INPUTS o al S nsew E 8 o z 2 Physical Constructed with black anodized aluminum heat sink and heavy g Lo H 8 gauge steel housing 2 25 x 5 40 x 7 80 inches overall 4 0 lbs 0 to om 8 50 C ambient operating temperature See page 17 for detailed Eoo aal B drawing go oe UA e o z ae Connectors European style pluggable screw terminal blocks Motor 4 position e A A B B Signal Input Output 18 position 8 input 6 output E A 4 limit AC input 3 position L N G D Be E Ar d ese Agency CE complies with EN55011A EN50082 1 1997 EN50178 1997 r Approvals and TUV Ap a ia Fuses Wickman TR 5 style Order from Digikey 1 800 DIGIKEY m i f 110V P N WK4250BK ND T 1 25 A IEC 1 125 k 0 750 0 750 220V P N WK4243BK ND T 0 63 A IEC lt lt 2 25 kk 5 00 gt 5 40 gt 17 18 Mechanical Outline Optional MMI 11 2 99 A 0 960 A 0 963 A 1 975 0 425 A 1 38 0 13 lt gt 4 90 3 875 CENTERED Neo o ls of al Applied Motion Products Inc ao 404 Westridge Drive Watsonville CA 95076 p
8. Hardware Manual SI3540 Programmable Step Motor Driver INPUT COM IN 5 JOG CW IN 6 JOG CCW o gt Q ba Q 2 1 2 w amp amp S kas Ks Qa Q Tt O e Applied Motion Products motors drives controls Table of Contents Introduction 44 744 7 4 7447 44 3 Features 4 44 44 44 7474 74 74 7417 nee nen ne nee 3 Block Diagram 4 4 3 Getting Started 4 Connecting the AC Line 5 Connecting the Motor 7 Connecting to the PC 8 Jogg ng 4 4 4 4 4 44 4 9 Limit Switches 2 2 22 2222 22 44 4 eee 9 Wiring a Mechanical Limit Switch 10 Wiring a Limit Sensor 2 22222 22222 2 2 eee eee eee 10 Wiring Inputs 22 22 2222 eee nee nee ne cece ne 11 Wiring Outputs 2 2 2 2e essence ene 4 4 4 4 13 Microstepping n ene sence cree nee ee cere nee nee ne neces tence ne cees 14 Mounting the Drive
9. OUTI Si3540_ l i Optoisolator Controller Chip l NEC PS2502 l i or equiv l Schematic Diagram of Si3540 Output Circuit Since there is no electrical conneciton to the Si3540 you must provide the source of current and voltage typically from a power supply You must also limit the current to less than 100 mA so that the output transistor is not damaged You would normally use a resistor for this but some loads such as PLC inputs limit the current automatically The diagram below shows how to connect an Si3540 output to an optically isolated PLC input 12 24 VDC Power Supply O 13 Microstepping Most step motor drives offer a choice between full step and half step resolutions In full steo mode both motor phases are used all the time Half stepping divides each step into two smaller steps by alternating between both phases on and one phase on Microstepping drives like the Si3540 precisely control the amount of current in each phase at each step position as a means of electronically subdividing the steps even further The Si3540 offers a choice of 13 step resolutions The highest setting divides each full step into 254 microsteps providing 50 800 steps per revolution when using a 1 8 motor In addition to providing precise positioning and smooth motion microstep drives can be used for motion conversion between different units The 25 400 step rev setting is provded as a means of convert
10. elephone cord to the COM port of your PC The adapter is a custom made part and is only available from Applied Motion 15 Flush Mounting When you remove the MMI from the shipping carton you will notice that it has two parts The first is a fairly thin section that contains the keypad display and some circuit boards The other part is thicker and contains the telephone jack and a cable that connects to the keypad assembly MMI rear section iw MMI front section When you flush mount the MMI in a SS gasket panel only the thin section will stick out from your panel the large portion mounts behind your panel You ll need to cut a precise section from your panel There is a cardboard template in the MMI s shipping box for this purpose If you want the MMI to be dust proof and watertight you must place the black rubber gasket between the thin part of the MMI and your panel Assemble the two halves using the eight small screws provided Surface Mounting An easier way to mount the MMI is to bolt the two halves together ahead of time using the eight small screws If you want the MMI to be dust proof and watertight put the black rubber gasket between the two halves before screwing them together gasket Then cut a hole in your panel for the cable included that runs between the MMI and the Si3540 The hole must be at least 5 8 in diameter for the connector to fit thorugh You will also need
11. ing motion from metric to english there are 25 4 mm in an inch Other settings provide step angles that are decimal degrees 36 000 steps rev makes the motor take 0 01 steps Some settings are used with lead screws When the drive is set to 2000 steps rev and used with a 0 2 pitch lead screw you get 0 0001 inches step The microstep resolution of the Si3540 is set by the Si Programmer software 14 Mounting the Drive You can mount your drive on the wide or the narrow side of the chassis Use for NARROW SIDE Use for WIDE SIDE mounting mounting Never use your drive in a space where there is no air flow or where the ambient temperature exceeds 50C 120F Never put the drive where it can get wet Never allow metal particles near the drive Mounting the Optional MMI There are two ways to mount the MMI in your application No matter which method you choose you ll need to connect the MMI to your Si3540 with the programming cable You will not however need the adapter plug The MMI has the same telephone style connector as the Si3540 Depending on how you mount the MMI and cable in your application you may find that it is difficult to remove the cable from the back of the MMI If this is the case and you need to reprogram the Si3540 you can use any telephone line cord as a programming cable They are available at most supermarkets and discount stores Pleae be careful not to lose the adapter plug that connects the t
12. oltages are not compatible Programming Note Always apply power to the Si3540 after the Si Programmer software is running on your PC 8 Jogging Two of the Si3540 input terminals are provided for jogging the motor The inputs are labeled JOG CW and JOG CCW Activating one of the inputs commands the drive to move the motor at a pre designated speed until the contact is opened A relay or mechanical switch can be used to activate the jog inputs 5 24 volt cir cuitry can be used The schematic diagram of the input circuit is shown below If you re using a switch or relay wire one end to the JOG input and the other to the power supply negative terminal Then connect the COM input to the power supply positive terminals Limit Switches The Si3540 has two limit switch inputs LIMIT CW and LIMIT CCW By connect ing switches or sensors that are triggered by the motion of the motor or load you can force the Si3540 to operate within certain limits This is useful if a program error could cause damage to your system by traveling too far The limit inputs are optically isolated This allows you to choose a voltage for your limit circuits of 5 to 24 volts DC This also allows you to have long wires on limit sensors that may be far from the Si3540 with less risk of intoducing noise to the Si3540 The schematic diagram of the limit switch input circuit is shown below Si3540 Controller Chip
13. onnector That is the line or hot connection Connect the wite or blue wire to neutral the N terminal Finally and most importantly connect the green wire to the GND terminal That connects the Si3540 metal enclosure and DC power supply ground to earth ground 6 Connecting the Motor Never connect or disconnect the motor to the driver when the AC power is on Secure any unused motor leads Never disconnect the motor while the AC power is on Never connect motor leads to ground or to a power supply You must now decide how to connect your motor to the drive Red A i 4 lead Four lead motors can only be connected motor one way Please follow the sketch at the aa Blue right Yellow White B B 4 Leads Six lead motors can be connected in series or center tap In series mode motors produce more torque at low speeds but cannot run as fast as in the center tap configuration In series operation the motor should be operated at 30 less than the rated current to prevent overheating Wiring diagrams for both connection methods are shown below Note NC means not connected to anything A Grn Wht A Gtn Wht 6 3 6 White White NC lead At lead motor motor Green A NC Red oooh Red Wht aa Red Blach Red Black B NC B B B NC 6 Leads Series Connected 6 Leads Center Tap Connected 7 Eight lead motors can also be connected in two ways series and parallel
14. rive or towards the transformer end of the drive The position of the switch is labeled on the PC board also 230 being for 200 240 VAC operation and 115 for 100 120 VAC operation e Replace the fuse next to the switch with the 220 VAC fuse that came with the drive See technical specifications on page 18 to order more fuses e Replace the drive s cover and assembly screws PC Board 110 220 VAC Switch X AC Power Fuse Connector Switch set for 110 VAC Switch set for 220 VAC 5 Installing an AC Line Cord Remove about 5 mm 3 16 inces of insulation from each of the three wires of your line cord That s right three wires For safety always use a three wire power cord on anything with a metal case depending on where you got your power cord it may have black white and green wires or brown white and green wires The AC power plug that was shipped with your Si3540 might be one of two types The old style is shown below on the left The new style which comes with an insulating rubber boot is shown below on the right Make sure you follow the proper sketch for your connector style gt To Earth Ground gt To Neutral gt To Line Hot Old Style AC Power Plug New Style AC Power Plug Always unplug the line cord from the wall before attaching it to the Si3540 Connect the black or brown wire to the Si3540 L terminal of the AC power c
15. stic dimples that prevent the screws from falling out RS232 connector 3 IN soacom JE 1 0 connector a fosco NE inputs 1 4 x INPUT 1 Q INPUT 2 Jog CW CCW INPUT 3 tf o INPUT 4 p IN5 JOGCW p SO AN 1 0 connector Q pee ee a B 2 3 Joe 1 0 connector TS outputs 1 3 Power LED HEE T D e a Q SF lg ae r Motor connector AC power connector Connecting the AC Line The Si3540 is set for 110 VAC operation at the factory If you use 110 VAC power all you need to do is install a power cord and plug it in If you plan to use 220 VAC power follow the instructions below Note lf you plan to hard wire the Si3540 to AC power consult a qualified electri cian and observe all building and electrical codes AC power can be dangerous 220 VAC Instructions In order to use 220 volts you ll need to change a fuse and a switch setting inside the case e Remove all mating connectors from the drive e Set the drive on its widest side so that you can read Si3540 Programmable Step Motor Driver properly e Remove the four 4 phillips head screws that mount the chassis sheet metal to the chassis heat sink See page 17 for a mechanical outline of the drive e The 110 220 switch is located near the position of the AC power connector next to the toroidal transformer see sketch below e For 220 VAC operation slide the switch towards the bottom of the d
16. two holes that line up with the big mounting holes in the MMI The mechanical outline on page 19 shows the location of the big mounting holes sealant not included panel When you mount the MMI to your panel you will need to use some kind of sealant to keep dust and liquid out Silicone or latex caulking is okay or you can make your own gasket from a sheet of compliant material like rubber or RTV 16 Recommended Motors Technical Specifications fet Max Torque Amplifiers Dual MOSFET H bridge 3 state pulse width modulated PWM Number Connection A switching at 20 kHz 0 2 3 5 amps phase output current software 40 selectable 122 watts maximum output power Automatic idle current aa reduction software programmable reduces current to motor when idle Minimum motor inductance is 0 8 mH Power Supply Linear toroidal transformer based for high reliability and low noise 5023 122 2 22x2 22x20 paalld 6o 20 100 120 or 200 240 VAC input switch selectable 50 60 Hz DC voltage at nominal line voltage 35 VDC full load 40 VDC no load HT23 394 2 22x2 22x154 paalld 60 28 Inputs 5 24 VDC optically isolated 2200 ohms internal resistance Can be configured for sinking NPN or sourcing PNP signals Outputs Optically isolated 12 24 VDC 100 mA max Microstepping 13 software selectable resolutions Steps per revolution with 1 8 motor 2000 5000 10000 12800 18000 20000 21600
17. ype Proximity Sensor to an Si3540 input COM When prox sensor activates Si3540 input goes low 524 VDC switch or relay Si3540 n M e i Power closed logic low l i l 5 24 Ce amp A PNP res TEVA T Power an Si3540 Connecting an Input to a Switch or Relay Su p ply i l Use normally open momentary switch to trigger Si3540 using Wait Input instruction es ee i bens Se 1 Use single throw switch for parameter selection using If Input instruction Use normally open momentary switch for jogging Connecting a PNP Type Proximity Sensor to an Si3540 input When prox sensor activates Si3540 input goes low 11 12 Wiring Outputs Before we discuss the output conditions we need to talk about the circuitry All three Si3540 outputs are optically isolated That means that there is no electrical connection between the indexer drive and the output terminals The signal is transmitted to the output as light What you see is a transistor NPN type that closes or conducts current when the output is low When the output is high the transistor is open Note At power up the Si3540 sets all three programmable outputs high open circuit The maximum voltage between any pair of and output terminals is 24 volts DC Never connect AC voltages to the Si3540 output terminals Maximum current is 100 mA per output meats i OS ey ee ee I 5V inside Si3540 l 330 OUTI i
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