Page 1
Hardware Manual
1240i-485
Intelligent Step Motor Driver
with Multi-drop RS-485 Interface
920-0033 A 7/6/2010
motors • drives • controls
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Table of Contents
Introduction..................................................................................................................4
Features .......................................................................................................................4
Block Diagram..............................................................................................................4
Getting Started .............................................................................................................5
Connecting the Power Supply ......................................................................................6
Choosing a Power Supply ............................................................................................7
Connecting the Motor ..................................................................................................8
Connecting to the Host Computer ................................................................................9
Jogging ......................................................................................................................11
Limit Switches............................................................................................................11
Wiring a Mechanical Limit Switch ..............................................................................12
Wiring a Limit Sensor ................................................................................................12
Wiring Inputs .............................................................................................................13
Wiring Outputs ...........................................................................................................15
Mounting the Drive ....................................................................................................16
Recommended Motors ...............................................................................................17
Mechanical Outline ....................................................................................................18
Technical Specifications .............................................................................................19
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Introduction
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 host computer
CW LIMIT
CCW LIMIT
OUT1
OUT2
OUT3
RS485
Optical
Isolation
Optical
Isoation
Si™
Microstepping
Indexer
Sequencer
eeprom
Optical
Isolation
Internal
Power
Supply
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
• Precise pulse width modulation switching amplifier 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 to host computer by RS-485 multi-drop interface, allowing up to 32
drives to be commanded in real time from one port.
• Microsoft WindowsTM-based software for easy setup
• 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.
• 3.0 x 4.0 x 0.5 inch overall dimensions.
• CE Compliant
Block Diagram
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Page 5
Getting Started
mounting hole (1 of 4)
DC power & motor
connector
power LED
i/o connector
inputs 1,2,3,4
jog cw
jog ccw
cw limit
ccw limit
out 1,2,3
RS-485 connector
to host computer
To use your 1240i-485 motor control, you will need the following :
• a power supply (see page 7 for help choosing one).
• a compatible step motor (see page 17 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 or NT with an RS-485 serial
port or adapter (486 or better with 8 MB ram recommended)
• SCL Setup Utility software that came with your 1240i
• SCL 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.
Always use the blue & white Applied Motion screwdriver with the connectors. Larger screwdrivers may remove the plastic dimples that
prevent the screws from falling out.
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-7-
Connecting the Power Supply
1240i
1A fuse
-
V +
DC Power
Supply
12 - 42 V
+
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.
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Page 7
Choosing a Power Supply
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 you may encounter a problem with current fold back. When you first power
up your drive, the full current of both motor phases will be drawn for a few milliseconds while the stator field is being established. After that the amplifiers start
chopping and much less current is drawn from the power supply. If your power
supply thinks this initial surge is a short circuit it may “fold back” to a lower voltage.
Because of that, unregulated power supplies are better. They are also less expensive.
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Connecting the Motor
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
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.
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Page 9
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
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.
Connecting to the Host Computer
•The 1240i-485 includes a multi-drop RS-485 communcation interface that must be
connected to the RS-485 port of a host computer. Up to 32 drives can be connected
to one host and individually commanded in real time. Each drive is “addressed” by a
special character, unique to each drive, included at the beginning of each command.
To assign an address character to each drive in your system, you’ll first need to connect each drive individually to the host. A Windows PC and the SCL Setup Utility is
the easist way to do this.
The RS-485 standard allows both 2 wire and 4 wire configurations. The 1240i
supports the four wire type. Consider yourself lucky, as four wire RS-485 does not
require the host to disable its transmitter after each command is sent, and with four
wires you can send commands and receive data back at the same time.
If you plan to use a Windows PC as your host, then you’ll need to purchase an RS-232
to RS-485 adaptor. We’ve had excellent results with the model 117701 adaptor, sold
by Jameco (800-831-4242). If your RS232 port is like most, it has only 9 pins, so
you’ll need a “9 pin to 25 pin serial cable”. That’s also available from Jameco: model
31721.
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Configure the Jameco adapter as follows:
+TX- +RX- GND +TX- +RX- GND +TX- +RX- GND
to PC RX+
to PC RX-
to PC TX+
to PC TX-
to PC GND
Drive #1 Drive #2 Drive #3
• Set the switches for “DCE” and “TxON,RxON”
• Connect adapter pin 1 to drive terminal RX+
• Connect adapter pin 2 to drive terminal RX-
• Connect adapter pin 3 to drive terminal TX-
• Connect adapter pin 4 to drive terminal TX+
Another source of RS-485 adapters is B&B Electronics (815-433-5100 or www.bbelec.com). If your PC does not have an RS-232 serial port, B&B can supply you with
a USB to RS-485 converter.
If you plan to use more than one drive in your system, then connect the drives to each
other as follows:
• RX+ to RX+
• RX- to RX-
• TX+ to TX+
• TX- to TX-
• GND to GND
We recommend Category 5 wire, commonly used for ethernet networks. Maximum
distance from the host to any drive is 4000 feet. Because our drives transmit data at a
modest 9600 bits per second, no termination resistors are required.
The 1240i-485 will not work with the Si Programmer™ software. You need a standard
1240i for that. The only software on the Si™ CD that works with this drive is the SCL
Setup Utility.
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Jogging
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
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.
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.
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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
+
–
You can use normally open or normally closed limit switches. Either way, wire them
as shown here. If the switch closes at the limit, select the option “closed”. If the
switch is open, or high voltage, choose “open”.
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:
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”.
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Wiring Inputs
2200
2200
2200
2200
2200
2200
inside Si3540
COM
COM
COM
IN1
IN2
IN3
IN4
CWJOG
CCWJOG
1240i
switch or relay
(closed=logic low)
IN
COM
5-24
VDC
Power
Supply
-
+
The 1240i input circuits can be used with
sourcing or sinking signals, 5 to 24 volts.
This allows connection to TTL circuits,
PLCs, relays and mechanical switches.
Because the input circuits are isolated, they
require a source of power. If you are connecting to a 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-1
and Si-100 indexers or the 3540i, Si3540,
Si5580, 7080i and BL series drives.
Note: If current is flowing into or out of a 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.
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.
Use normally open momentary switch to trigger 1240i using Wait Input instruction.
Use single throw switch if using the If Input instruction for program branching.
Connecting an Input to a Switch or Relay
Use normally open momentary switch for jogging.
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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, BL7080i or BLSi7080
(When output closes, 1240i input goes low).
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 sensor activates, 1240i input goes low).
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Page 15
Wiring Outputs
330
+5V
OUT1–
OUT1+
1240i
Controller Chip
inside 1240i
PLC
COMMON
INPUT
1240i
OUTPUT-
OUTPUT+
5-24 VDC
Power Supply
+–
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.
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.
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.
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Mounting the Drive
Four .156" mounting holes
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.
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Page 17
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 1.2
HT23-396 1.2
HT23-399
parallel
parallel
parallel
parallel
parallel
parallel
series
series
series
22
32
52
45
115
170
7
10
19
1.2
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Mechanical Outline
3.70
2.70
.50
max
.062
0.15
4x Ø.156
4.00
3.00
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Page 19
Technical Specifications
Ampliers
Power Supply
Inputs
Outputs
Microstepping
Motion Update
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 typical max. load.
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.
Physical
Connectors
Agency
Approvals
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.
RS-485 communcations: 5 position, AWG 16-28.
CE compliant to EN55011A, EN50082-1(1997)
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Page 20
920-0033 A 7/6/10
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 2002
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