Page 1
Hardware Manual
1240i
Programmable Step Motor Driver
motors • drives • controls
-2-
Page 2
Table of Contents
MOSFET
3 State
PWM
Power
Amplifier
motor phase A
motor phase B
12 - 42 VDC
INPUT1
INPUT2
INPUT3
INPUT4
CW JOG/IN5
CCW JOG/IN6
to PC/MMI
CW LIMIT
CCW LIMIT
OUT1
OUT2
OUT3
RS232
Optical
Isolation
Optical
Isoation
Si™
Microstepping
Indexer
Sequencer
eeprom
Optical
Isolation
Internal
Power
Supply
AIN/+5/GND
Connector
only for SCL
Applications
Introduction -----------------------------------------------------------------------4
Features ---------------------------------------------------------------------------4
Block Diagram --------------------------------------------------------------------4
Getting Started --------------------------------------------------------------------5
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.
Connecting the Power Supply-----------------------------------------------------6
Power LED Diagnostics -----------------------------------------------------------6
Choosing a Power Supply -------------------------------------------------------- 7
Connecting the Motor -------------------------------------------------------------8
Connecting to the PC -------------------------------------------------------------9
Jogging ------------------------------------------------------------------------- 10
Limit Switches ------------------------------------------------------------------ 10
Wiring a Mechanical Limit Switch ---------------------------------------------- 11
Wiring a Limit Sensor ----------------------------------------------------------- 11
Wiring Inputs ------------------------------------------------------------------- 12
Wiring Outputs ------------------------------------------------------------------ 14
Microstepping ------------------------------------------------------------------ 15
Mounting the Drive ------------------------------------------------------------- 16
Mounting the Optional MMI ---------------------------------------------------- 17
Recommended Motors ---------------------------------------------------------- 19
Mechanical Outline ------------------------------------------------------------- 20
Technical Specifications -------------------------------------------------------- 21
Mechanical Outline - Optional MMI--------------------------------------------- 22
Features
• Precise pulse width modulation switching amplifiers providing up to 1.2 amps per
phase and microstepping to 50,800 steps per revolution.
• Accepts 12 - 42 VDC power supply.
• Powerful, flexible, easy to use indexer.
• Connects by a simple cable to your PC for programming (cable included).
• Microsoft WindowsTM-based software for easy setup and programming
• Eight inputs for interacting with the user and other equipment.
• Three outputs for coordinating external equipment.
• External trigger I/O is optically isolated, 5-24V, sinking or sourcing signals.
• PC/ MMI port is RS-232.
• 3.0 x 4.0 x 0.65 inch overall dimensions.
• Optional man machine interface (MMI) allows operator to enter distances,
speeds, cycle counts and more.
• CE Compliant
Block Diagram
-3-
-4-
Page 3
Getting Started
1240i
1A fuse
-
V +
DC Power
Supply
12 - 42 V
+
i/o connector
inputs 1,2,3,4
jog cw
jog ccw
cw limit
ccw limit
out 1,2,3
power/motor
connector
DC power supply
motor
power LED
mounting hole (1 of 4)
pc/mmi
connector
* Always use the blue & white
Applied Motion screwdriver
with these connectors.
Larger screwdrivers may remove
the plastic dimples that prevent
the screws from falling out.
To use your 1240i motor control, you will need the following :
• a power supply (see page7 for help choosing one).
• a compatible step motor (see page 19 for recommended motors).
• a small flat blade screwdriver for tightening the connectors - an Applied Motion
Products screwdriver suitable for this purpose is included with your drive.
• a personal computer running Windows 3.1, 95, 98, NT, W2K, XP, Vista or Vista64
or Windows7 with a 9 pin serial port (486 or better with 8 MB ram recommended)
• the Si ProgrammerTM software that came with your 1240i
• the programming cable that came with your 1240i
• Si ProgrammerTM software manual - on the CD that came with your 1240i
The sketch below shows where to find the important connection and adjustment
points. Please examine it now.
There are two versions of the 1240i, one has an added 3-pin connector CN7.
All Mating connectors included.
Connecting the Power Supply
If you need information about choosing a power supply, please read Choosing a
Power Supply on the next page.
If your power supply does not have a fuse on the output or some kind of short circuit
current limiting feature, you need to put a 1 amp fast acting fuse between the drive
and the power supply. Install the fuse on the + power supply lead.
Connect the motor power supply as shown below. Use no smaller than 18 gauge
wire. Be careful not to reverse the wires. Reverse connection may destroy your
driver, void your warranty and generally wreck your day.
Power LED Diagnostics
The power LED is also used as a status indicator for alarm codes for the drive.
Alarm codes are shown below:
Code: Message:
2 red, 1 green ccw limit
2 red, 2 green cw limit
1 red, 3 green subroutine stack overflow
2 red, 3 green subroutine stack underflow
4 red, 3 green bad instruction in Si program (memory or software error)
7 red, 1 green serial communication error
solid red firmware re-flash mode. Si Firmware Downloader can be
used to recover drive, contact technical support.
-5-
-6-
Page 4
Choosing a Power Supply
A+
A–
B+ B–
4
lead
motor
Red
Blue
Yellow
White
4 Leads
A+
A–
NC
B+
B–
NC
6
lead
motor
Red
Black
Red/
Wht
Green
Grn/Wht
White
A+
A–
NC
B+B–
NC
6
lead
motor
Grn/Wht
White
Green
Red
Red/
Wht
Black
6 Leads Series Connected 6 Leads Center Tap Connected
Please follow the recommendations below for choosing a power supply:
Voltage
Chopper drives like the 1240i work by switching the voltage to the motor terminals
on and off while monitoring current to achieve a precise level of phase current. To
do this efficiently and silently, you’ll want to have a power supply with a voltage
rating at least five times that of the motor. Depending on how fast you want to run
the motor, you may need even more voltage than that. If you choose an unregulated
power supply, do not exceed 28 volts. This is because unregulated supplies are
rated at full load current. At lesser loads, like when the motor’s not moving, the
actual voltage can be up to 1.4 times the rated voltage. For smooth, quiet operation,
a lower voltage is better.
Current
The maximum supply current you could ever need is the sum of the two phase currents. However, you will generally need a lot less than that, depending on the motor
type, voltage, speed, and load conditions. That’s because the 1240i uses switching
amplifiers, converting a high voltage and low current into lower voltage and higher
current. The more the power supply voltage exceeds the motor voltage, the less current you’ll need from the power supply. A motor running from a 24 volt supply can
be expected to draw only half the supply current that it would with a 12 volt supply.
We recommend the following selection procedure:
1) If you plan to use only a few drives, get a power supply with at least twice the
rated phase current of the motor.
2) If you are designing for mass production and must minimize cost, get one power
supply with more than twice the rated current of the motor. Install the motor in the
application and monitor the current coming out of the power supply and into the
drive at various motor loads. This will tell you how much current you really need so
you can design in a lower cost power supply. If you plan to use a regulated power
supply our PS50A24 is a good choice.
-7-
Connecting the Motor
Never connect or disconnect the motor to the driver when the
power is on.
Insulate unused motor leads separately, and then secure.
Never connect motor leads to ground or to a power supply.
You must now decide how to connect your
motor to the drive.
Four lead motors can only be connected
one way. Please follow the sketch at the
right.
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.
-8-
Page 5
A+
A–
B+ B–
8
lead
motor
8 Leads Series Connected 8 Leads Parallel Connected
A+
A–
B+
B–
8
lead
motor
Orange
Org/Wht
Blk/Wht
Black
Red
Red/
Wht
Yel/
Wht
Yellow
Orange
Org/
Wht
Blk/Wht
Black
Red
Red/Wht
Yel/
Wht
Yel
low
Eight lead motors can also be connected in two ways: series and parallel. As
2200
2200
inside 1240i
COM
JOG CW
JOG CCW
+
5-24
VDC
SUPPLY
-
1240i
Controller
Chip
2200
10K
+5V +5V
3
4
1
2
CW LIMIT+
CW LIMIT–
CCW LIMIT+
CCW LIMIT–
inside 1240i
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.
Jogging
Two of the 1240i input terminals are provided for jogging the motor. The inputs are
labeled “JOG CW” and “JOG CCW”. Activating one of the inputs commands the
drive to move the motor at a pre-designated speed until the contact is opened. A
relay or mechanical switch can be used to activate the jog inputs. 5-24 volt circuitry
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 (+) terminal.
Limit Switches
The 1240i has two limit switch inputs, LIMIT CW and LIMIT CCW. By connecting
switches or sensors that are triggered by the motion of the motor or load, you can
force the 1240i to operate within certain limits. This is useful if a program error
could cause damage to your system by traveling too far.
Connecting to the PC
•Locate your computer within 6 feet of the 1240i. Connect the drive to your PC using
the programming cable supplied.
Programming Note: Always apply power to the 1240i after the Si
software is running on your PC.
Never connect the 1240i to a telephone circuit. It uses the
same connectors and cords as telephones and modems, but the
voltages are not compatible.
-9-
TM
Programmer
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 1240i with less risk of intoducing noise to the
1240i. The schematic diagram of the limit switch input circuit is shown below.
-10-
Page 6
Wiring a Mechanical Limit Switch
1240i
CCW LIMIT+
CCW LIMIT-
CW LIMIT-
+
5-24
VDC
SUPPLY
-
CW LIMIT+
1240i
CW LIMIT-
+
DC
Power
Supply
–
Limit
Sensor
CW LIMIT+
Wiring for Sinking or Open Collector Output
output
+
–
1240i
LIMIT-
+
DC
Power
Supply
–
Proximity
Sensor
LIMIT+
Wiring for Sourcing Output
output
+
–
2200
2200
2200
2200
2200
2200
inside 1240i
COM
COM
IN1
IN2
IN3
IN4
JOG CW
JOG CCW
1240i
switch or relay
(closed=logic low)
IN
COM
5-24
VDC
Power
Supply
-
+
You can use normally open or normally closed limit switches. Either way, wire them
as shown here.
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.
If your sensor has an open collector output or a sinking output, wire it like this:
Wiring Inputs
The 1240i input circuits can be used with
sourcing or sinking signals, 5 to 24 volts.
This allows connection to many TTL circuits,
PLCs, relays and mechanical switches.
Because the input circuits are isolated, they
require a source of power. If you are connecting to an open collector TTL circuit or
to a PLC, you should be able to get power
from the PLC or TTL power supply. If you
are using relays or mechanical switches,
you will need a 5-24 V power supply. This
also applies if you are connecting the 1240i
inputs to another Si product from Applied
Motion, like the Si-100 indexers or the
3540i, Si3540, Si5580, 7080i and Si4500
indexer-drives.
Note: If current is flowing into or out of an 1240i input, the logic state of that input is
low. If no current is flowing, or the input is not connected, the logic state is high.
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:
If the sensor output goes high at the limit, choose the program option “closed”. if
the output is low at the limit, select “open”.
-11-
The diagrams on the following pages show how to connect 1240i inputs to various
devices.
The maximum voltage that can be applied to an input terminal
is 24 volts DC. Never apply AC voltage to an input terminal.
Connecting an Input to a Switch or Relay
Use normally open momentary switch to trigger 1240i using Wait Input instruction.
Use single throw switch for parameter selection using If Input instruction.
Use normally open momentary switch for jogging.
-12-
Page 7
330
+5V
OUT1–
OUT1+
1240i
Controller Chip
inside 1240i
PLC
COMMON
INPUT
1240i
OUTPUT-
OUTPUT+
5-24 VDC
Power Supply
+–
Connecting an Input to the Si-1 Motion Output
1240i
IN
IN/JOG COM
SI-1 indexer
MOTION+
MOTION–
5-24
VDC
Power
Supply
-
+
1240i
IN
COM
3540i, Si3540, 7080i,
Si5580, Si4500
or Si-100
OUT+
OUT–
5-24
VDC
Power
Supply
-
+
1240i
NPN
Proximity
Sensor
IN
COM
output
+
–
5-24
VDC
Power
Supply
-
+
NPN
Proximity
Sensor
IN
COM
output
+
–
5-24
VDC
Power
Supply
-
+
1240i
PNP
Proximity
Sensor
IN
output
+
–
COM
5-24
VDC
Power
Supply
-
PNP
Proximity
Sensor
IN
output
+
–
COM
5-24
VDC
Power
Supply
-
+
(Set Si-1 motion signal to “in position”. Si-1 will trigger 1240i at end of each move).
Connecting a 3540i, Si3540, Si5580, 7080i or Si4500
(When output closes, 1240i input goes low).
Wiring Outputs
Before we discuss the output conditions, we need to talk about the circuitry. All three
1240i 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 1240i 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 1240i
output terminals. Maximum current is 100 mA per output.
Connecting an NPN Type Proximity Sensor to a 1240i input
(When prox sensor activates, 1240i input goes low).
Connecting a PNP Type Proximity Sensor to a 1240i input
(When prox sensor activates, 1240i input goes low).
-13-
Schematic Diagram of 1240i Output Circuit
Since there is no electrical connection to the 1240i, 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 1240i output to an optically isolated
PLC input.
-14-
Page 8
mounting holes
0.156 inch Diameter
0.156 inch Diameter
mounting holes
Microstepping
Most step motor drives offer a choice between full step and half step resolutions. In
full step mode, both motor phases are used all the time. Half stepping divides each
step into two smaller steps by alternating between both phases on and one phase on.
Microstepping drives like the 1240i precisely control the amount of current in each
phase at each step position as a means of electronically subdividing the steps even
further. The 1240i offers a choice of 13 step resolutions. The highest setting divides
each full step into 254 microsteps, providing 50,800 steps per revolution when us-
ing a 1.8
In addition to providing precise positioning and smooth motion, microstep drives
can be used for motion conversion between different units. The 25,400 step/rev
setting is provided as a means of converting motion from metric to english (there are
25.4 mm in an inch). Other settings provide step angles that are decimal degrees
(36,000 steps/rev makes the motor take 0.01
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 1240i is set by the Si ProgrammerTM software.
° motor.
° steps). Some settings are used with
Mounting the Drive.
The 1240i has four 0.156 inch diameter holes in the circuit board for mounting.
Always use standoffs or spacers to support the 1240i: a 1240i with power connected
will be damaged if you set it on a conductive surface without supports. The standoffs
or spacers can be up to 0.25 inch in outer diameter. You can use #4 or #6 screws to
fasten the 1240i.
-15-
-16-
Page 9
123
Ý
Ý
456
Ý
Ý
789
YES NO
.0
SPACE BKSP ENTER
panel
MMI
(front section
and gasket)
MMI
(rear section)
123
Ý
Ý
456
Ý
Ý
789
YES NO
.0
SPACE BKSP ENTER
panel
sealant (not included)
MMI
gasket
(included)
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 1240i with the MMI cable. The
MMI has the same telephone style connector as the 1240i.
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.
When you flush mount the MMI in a panel,
only the thin section will stick out from
your panel - the large portion mounts
behind your panel. You’ll need to cut a
precise section from your panel. There is a
cardboard template in 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.
-17-
Then cut a hole in your panel for the cable
that runs between the MMI and the 1240i.
The hole must be at least 5/8” in diameter for the connector to fit thorugh. You
will also need two holes that line up with
the big mounting holes in the MMI. The
mechanical outline on page 22 shows the
location of the big mounting holes.
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.
-18-
Page 10
IN2
IN1
COM
COM
COM
3.00 IN.
4 HOLES, 0.156 DIA.
2.85 IN.
0.15 IN.
0.65 IN.
4.00 IN.
3.85 IN.
0.15 IN.
CCW CW
LIM
- + - +
JOG
CW
CCW
IN4
IN3
- + - + - +
OUT3 OUT2 OUT1
- B + - A + - V +
+5V AIN GND
Recommended Motors
Motor
Number
Winding
Connection
Max Torque
oz-in
Current Setting
Amps/phase
HT17-068
HT17-072
HT17-076
HT11-012 1.0
HT11-013 1.0
5014-842 1.0
1.2
1.1
1.1
HT23-393/593 1.2
HT23-396/596 1.2
HT23-399/599
parallel
parallel
parallel
parallel
parallel
parallel
series
series
series
22
32
52
45
115
170
7
10
19
1.2
Mechanical Outline
-19-
-20-
Page 11
4.90
4.90
1.38
0.13
3.875
CENTERED
3.875
CENTERED
1 2 3
4 5 6
7 8 9
YES NO
. 0
SPACE BKSP ENTER
2.988
1.975
0.425
0.963
0.960
Technical Specifications
Mechanical Outline - Optional MMI
Ampliers
Power Supply
Inputs
Outputs
Microstepping
Motion Update
Physical
Connectors
Dual H-bridge, 3 state, pulse width modulated (PWM) switching at 25
kHz. 0.1 - 1.2 amps/phase output current, software selectable. 48 watts
maximum output power. Automatic idle current reduction (software
programmable) reduces current to motor when idle. Minimum motor
inductance is 0.8 mH.
Accepts 12 - 42 VDC power supply. 1.2 amps or greater at 24VDC.
5 - 24 VDC, optically isolated. 2200 ohms internal resistance. Can be
configured for sinking (NPN) or sourcing (PNP) signals.
Analog Input - not currently supported by Si Programmer, may be read
in SCL mode using “RA or “IA” commands.
Optically isolated. 5-24 VDC, 100 mA max.
13 software selectable resolutions. Steps per revolution with 1.8° motor: 2000, 5000, 10000, 12800, 18000, 20000, 21600, 25000, 25400,
25600, 36000, 50000, 50800. Waveform: pure sine.
12800 Hz.
Constructed on 0.063 inch thick printed circuit board. Four mounting
holes, 0.156 inch diameter. Overall size : 3.00 x 4.00 x 0.65 inches.
0.15 lb. 0 to 50°C ambient operating temperature. See page 20 for
detailed drawing.
European style screw terminal blocks. Power Supply and Motor: 6
position. Wire size: AWG 16 - 28. Signal input/output: 19 position.
Wire size: AWG 16 - 28.
Agency
Approvals
CE compliant to EN55011A, EN50082-1(1997)
-21-
-22-
Page 12
Notes
920-0038B 1240i.indd 7/7/2010
-23-
Applied Motion Products, Inc.
404 Westridge Drive Watsonville, CA 95076
Tel (831) 761-6555 (800) 525-1609 Fax (831)-761-6544
http://www.applied-motion.com
Copyright 2000
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