Applied Motion 2035 User Manual

Mechanical Outline

3/5/99

2035.ai
JK

0.125"

3.75"

User's Manual

2.50"

4x Ø.125

1.50"

2x Ø.125

2035

4.00"

3.70"

2035 O

3362

3362

Step Motor Drivers

3.00"

0.25"

0.25"

0.15"

.875"

Copyright 1999

Applied Motion Products, Inc.

404 Westridge Drive Watsonville, CA 95076

Tel [phone] [phone] Fax [phone]

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motors • drives • controls

Introduction

Technical Specifications

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) 525­1609 or you can reach us by fax at (831) 761–6544.

Is This the Right Manual?

This manual is for 2035 and 2035 O drives of revision level E. Earlier drives had
fewer features and different connections that revision E, so they require a different
User's Manual.

If this is the manual that was shipped with your drive, it's almost certainly the right
one. How can you tell for sure?

Hold the drive so that the words "Step Motor Driver" are at the bottom. On the right,
you'll see a blue screw terminal connector. How many terminals does it have?

3 terminals - old 2035 or 2035 O. This is the wrong manual.
4 terminals - new 2035. This is the right manual.
9 terminals - new 2035 O. Right manual.

If this is the wrong manual, call the factory and request the "old" 2035 manual.

Amplifiers

Oscillator
(2035 O)

Inputs

Tach Output
(O suffix)

Physical

Connectors

Dual, bipolar H-bridge, pulse width modulated switching at 20kHz.
12-35 VDC input. 0.125 - 2.0 amps/phase output current, switch
selectable in 0.125 A increments. 70 watts maximum output power.
Automatic idle current reduction, reduces current to 50% of setting
after one second.

0 to 5000 steps per second. Linear acceleration and deceleration,
individually adjustable from 5 to 900 msec.

Step, direction and enable, optically isolated, 5-24V logic. 2200
ohms input impedance. Motor steps when STEP input turns off.
10 µsec minimum low pulse. 50 µsec minimum set up time for
direction signal. Step input is run/stop in oscillator mode. (0 =run,
1 = stop.)

Optically isolated. Uncommitted (open collector, open emitter)
phototransistor, 24V max, 20 mA max. One pulse per step.

Mounted on 1/4 inch thick black anodized aluminum heat transfer
chassis. 1.5 x 3.0 x 4.0 inches overall. Power on LED. See
drawing on back cover for more information. Maximum chassis
temperature: 70˚C. Weight: 9 ounces (250 g).
Ambient temp range (operating): 0 - 70˚C.

European style screw terminal blocks.
Power Supply: 2 position.
Motor: 4 position.
Signal Input: 4 position (2035), 9 position (2035 O)
Max wire size: AWG 16.

-15--2-

Mounting the Drive

Features

You can mount your drive on the wide or the narrow side of the chassis. If you
mount the drive on the wide side, use #4 screws through the four corner holes. For
narrow side mounting applications, you can use #4 screws in the two side holes.

smooth flat surface

#4 screws

wide side mount narrow side mount

The amplifiers in the drive generate heat. Unless you are running at 1 amp or below,
you may need a heat sink. To operate the drive continuously at maximum power
you must properly mount it on a heat sinking surface with a thermal constant of no
more than 4°C/watt. Applied Motion Products can provide a compatible heat sink.
Often, the metal chassis or enclosure of your system will work as an effective heat
sink.

Never use your drive in a space where there is no air flow or where
other devices cause the surrounding air to be more than 70˚C. Never
put the drive where it can get wet or where metal particles can get on
it.

Recommended Motors

Motor Size Winding Max Torque Current

Number inches Connection oz-in Amps

5014-842 1.38 x 1.38 x 1.57 4 lead 19 1.0
HT17-068 1.65 x 1.65 x 1.30 parallel 23 1.0
HT17-071 1.65 x 1.65 x 1.54 parallel 30 1.25
HT17-075 1.65 x 1.65 x 1.85 parallel 40 1.75

5023-127 2.22 x 2.22 x 2.25 4 leads 110 2.0

5023-149 2.22 x 2.22 x 3.25 parallel 140 2.0
HT23-393 2.22 x 2.22 x 1.54 parallel 75 1.4
HT23-396 2.22 x 2.22 x 2.13 parallel 175 1.4
HT23-399 2.22 x 2.22 x 2.99 parallel 260 1.4

5034-324 3.38 x 3.38 x 2.50 series 190 2.0

•Drives sizes 14 through 23 step motors. Can also be used in some cases to drive
size 34 motors. See page 14 for a list of recommended motors.

•Pulse width modulation switching amplifiers

•Phase current from 0.125 to 2.0 amps (switch selected, 16 settings)

•Step and direction and enable inputs, optically isolated, 5-24V.

•Inputs can be sourcing (PNP) or sinking (NPN) type

•Full and half step (switch selected)

•Automatic 50% idle current reduction (switch selected)

•Built in ramping pulse generator with adjustable speed, accel, decel (2035 O)

•0 - 5000 Hz oscillator speed range (2035 O)

•Optically isolated Tach output for monitoring speed (2035 O)

•Speed can be set from on-board trimpot or external pot (2035 O)

•Compact size: 1.5 x 3 x 4 inches.

Block Diagram

com
step

dir

enable

tach+

tach-

12-35VDC

cw

wiper

ccw

Isolation

step

Optical

Oscillator

extspeed

STEP/SLEW JUMPER

Step

Sequencer

full step/
half step

accel

decel

speed adj

Amplifier

50% idle

+5V

Regulator

current setting

A+
A-

to

B+

motor

B-

power

LED

(red)

2035 O only

-3--14-

Getting Started

Choosing a Power Supply

To use your Applied Motion Products motor control, you will need the following:

a 12-35 volt DC power supply for the motor. Please read the section entitled

•

Choosing a Power Supply

5 to 24 volts DC, to activate the optoisolation circuits (if you are using an

•

for help in choosing the right power supply.

O

drive and don't have 5 - 24V available, see page 12.)
a source of step pulses capable of sinking at least 5 mA

•
if your application calls for bidirectional rotation, you'll also need a direction

•
signal, capable of sinking 5 mA
a compatible step motor (see page 14)

•
a small flat blade screwdriver for tightening the connectors and adjusting the

•
oscillator

The sketch below shows where to find the important connection and adjustment
points. Please examine it now.

power

connector

motor

connector

switches for

selecting current,

idle current,

full or half stepping,

speed pot (2035 O)

LED - indicates

DC power

trimpots for adjusting

oscillator speed, accel and

decel rates

(2035 O only)

jumper for selecting

oscillator mode

(2035 O only)

mounting

hole (1 of 6)

logic

connector

STEP, DIR, EN

connector for external

speed pot/signal

& tach output
(2035 O only)

Voltage

Chopper drives 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
atleast five times that of the motor. Depending on how fast you want to run the
motor, you may need even more voltage than that. More is better, the only upper
limit being the maximum voltage rating of the drive itself: 35 volts. If you choose
an unregulated power supply, do not exceed 24 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.

Current

The maximum supply current you will 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 2035 and 2035
O use 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.

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 foldback. 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 “foldback” to a lower voltage. With many foldback schemes the
voltage returns to normal only after the first motor step and is fine thereafter. In that
sense, unregulated power supplies are better. They are also less expensive.

-4-

-13-

Using Mechanical Switches with 2035 O Drive

The 2035 O was designed to be used with active logic and for that reason has
optically isolated inputs. To activate the optoisolators a small, but not insignificant
amount of current at 5 to 24 volts DC is required.

In some applications, step motors and drives are used with mechanical switches
only and there is no readily available source of 5 - 24 volts.

In these instances, the motor power supply can be used if it does not exceed 24
VDC. The recommended wiring diagram is shown below.

Connecting the Power Supply

If you need information about choosing a power supply, please read

Power Supply

on page 13 of this manual.

Choosing a

If you're power supply does not have a fuse on the output or some kind of short
circuit current limiting feature you need to put a 3 amp slow blow fuse between the
drive and power supply. Install the fuse on the + power supply lead.

Connect the motor power supply + terminal to the driver terminal labeled "+VDC".
Connect power supply – to the drive terminal labeled "-". Use no smaller than 20
gauge wire. Be careful not to reverse the wires. Reverse connection will
destroy your driver, void your warranty and generally wreck your day.

Check your wiring carefully before turning on the power supply!

Run/Stop switch (closed=run)

+

Motor

STEP COM DIR

2035 O

Power

Supply

12-24

VDC

-

Direction

switch

+VDC-

Idle Current Reduction

The 2035 and 2035 O drives include a feature that automatically reduces the motor
current by 50% when the motor is not moving. This is known as idle current
reduction.

For qualifying OEMs, we can change the amount of current reduction during the
manufacturng process.

If you want full current all the time, move the switch away from the
50% IDLE label.

50% IDLE

50% Idle Current

2

50% IDLE

No Idle Current Reduction

2

motor

fuse

supply

12-35 VDC+–

+VDC-

Connecting the Motor

Warning: When connecting the motor to the driver, be sure that the
motor power supply is off. Secure any unused motor leads so that they
can't short out to anything. Never disconnect the motor while the drive
is powered up. 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

A+

A-

Red

Blue

Yellow

4

lead

motor

White

B+ B-

produce more torque at low speeds, but
cannot run as fast as in the center tap

4 Leads

configuration. In series operation, the motor
should be operated at 30% less than the rated current to prevent overheating.
Winding diagrams for both connection methods are shown on the next page

-12- -5-

A-

NC

A+

NC = not
connected

Grn/Wht

White

Green

Red

B-

motor

Black

6

lead

NC

B+

Red/

Wht

A-

A+

NC

NC = not
connected

Grn/Wht

White

Green

Red

motor

Black

6

lead

B+B-

Red/

Wht

NC

Using a Remote Speed Control Potentiometer

The 2035 O step motor driver includes an analog signal input connector that can be
used to control the oscillator speed externally. Normally, an on board potentiometer
controls the speed.

You will need:

• a 10k to 100kΩ linear potentiometer. A multiturn type is recommended.

• a shielded, three wire cable

6 Leads Series Connected 6 Leads Center Tap Connected

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 over heating. The wiring diagrams for eight
lead motors are shown below.

Orange

A+

Org/Wht

8

lead

Blk/Wht

A-

Black

Red

8 Leads Series Connected

motor

Red/

B+ B-

Wht

Yel/
Wht

Blk/Wht

A-

Yellow

Orange

A+

8

lead

Org/

Wht

Black

Red

B+

8 Leads Parallel Connected

Yel/
Wht

motor

Red/Wht

Yel
low

B-

Step Table

(full stepping)

Step A+ A- B+ B-

0+–+–

To install the external pot:

• move switch #1 toward the EXTSPEED label. That disconnects the on board pot.

• wire your pot to the 2035 O:

➤ the potentiometer wiper connects to the WPR terminal
➤ the potentiometer CW terminal connects to the CW terminal
➤ the third pot terminal connects to the CCW terminal
➤ the cable shield connects to the CCW terminal

With this arrangement, speed will increase as you turn the external pot clockwise.
The frequency range will be 0 to 5000 steps per second.
The on board trimpots will still control acceleration and declerations times. Turning
the pots clockwise makes the acceleration and deceleration faster (i.e. reduces the
time to or from speed).

2035 O

CW

WPR

CCW

cw

external

pot

DIR=1

cw

1–++–
2–+–+

3+– –+
4+–+–

Step 3 is the Power Up State

DIR=0

ccw

-11--6-

Using the Oscillator

Drives with an O suffix are equipped with internal
pulse generators that you can use to drive the motor.
To set the drive to oscillator mode, simply find the
jumper located near the center of the printed circuit
board and move it to the SLEW setting. The figure at the right shows the proper
setting of the jumper.

The oscillator is activated by driving the
pulses will increase linearly, accelerating the motor until it reaches a preset speed.
The motor will remain at this speed until the
pulse frequency then decreases linearly, decelerating the motor and load to rest.

To change the slew speed, locate the trimpot labeled
screw you can raise or lower the speed within a range of 0 to 5000 steps per second.
Turning the screw clockwise makes the motor run faster.

The acceleration and deceleration rates can also be adjusted using the trimpots
labeled

ACCEL

and

DECEL

. The range of accel and decel time is 5 to 900
milliseconds. Turning the pot clockwise makes the motor accelerate or decelerate
faster.

The ACCEL and DECEL pots are single turn, so don't try to turn

them too far.

Tach Output

The Tach Out signal is provided for measuring the motor speed. It generates one
pulse per motor step. The schematic diagram of the Tach Out optoisolation circuit
is shown below.

Do not connect the Tach output to more than 24VDC.
The current into the Tach+ terminal must not exceed 20 mA.

+5V

330Ω

internal

tach

signal

Internal Tach Circuit

inside 2035 O

Optoisolator

NEC PS2501 or equiv.

TACH+
TACH–

STEP

input low. The frequency of step

STEP

input is driven high. The step

SPEED

. By turning the brass

4700Ω

TACH+

2035 O

TACH–

Connecting Tach Output

to a Frequency Counter

IN

GND

+
–

5 - 24V

DC
Power
Supply

Freq

Counter

Connecting Logic

The 2035 and 2035 O drives contain optical isolation circuitry to prevent the
electrical noise inherent in switching amplifiers from interfering with your circuits.
Optical isolation is accomplished by powering the motor driver from a different
supply than your circuits. There is no electrical connection between the two: signal
communication is achieved by infrared light. When your circuit turns on or turns off
an infrared LED (built into the drive) it signals a logic state to the phototransistors
that are wired to the brains of the drive.

A schematic diagram of the input circuit is shown below. Connect your logic
circuitry to the signal connector as shown in the sketch at the right. Even though the
drive provides it's own 5 volt logic power, you must supply 5-24 volts DC to
activate the LEDs on the input side of the
optoisolators. Most CMOS and open collector
TTL devices are directly compatible with this
drive. If you are using open collector outputs,
no pull up resistor is necessary.

Most step motor indexers and PLCs can also
connect directly to the 2035 and 2035 O drives.

The driver will step on the positive going edge
of the step pulse. Minimum pulsewidth is 10
µsec.

+5 VDC

STEP+

Si-100

STEP–

DIR+
DIR–

Connecting the 2035 to an Applied Motion Si-100 Indexer

(leave Si-100 STEP+ and DIR+ outputs unconnected)

+5 VDC

Si-1

STEP

DIR

Connecting the 2035 to an Applied Motion Si-1 Indexer

-7--10-

COM

STEP

DIR

COM

STEP

DIR

COM

STEP

DIR

EN

Inside 2035

2200

2200

2035

2035

Selecting Between Full and Half Step Operation

Current Setting Table

Locate the bank of switches near the motor
connector. One switch is labeled on the circuit
board as

Sliding the switch toward the

HALF STEP

.

HALF STEP

label
sets the driver for that mode of operation. The
opposite position is full step. When set to full

HALF STEP

125
250

500

1000

step, the driver always uses "two phases on" mode
to provide maximum motor torque.

Setting Phase Current

Before you turn on the power supply the first time, you need to set the driver for the
proper motor phase current. The rated current is usually printed on the motor label.

The 2035 drive current is easy to set. If you wish, you can learn a simple formula
for setting current and never need the manual again. Or you can skip to the table on

the next page, find the current setting you want, and set the DIP switches according
to the picture.

Current Setting Formula

Locate the bank of tiny switches near the motor connector. Four of the switches
have a value of current printed next to them, such as 500 and 1000. Each switch

controls the amount of current, in milliamperes (mA), that it's label indicates. There
is always a base of current of 125 mA. To add to that, slide the appropriate switches

toward their labels. You may need your small screwdriver for this.

Example

Suppose you want to set the driver for 1.25 amps
per phase (1250 mA). You need the 125 mA base

current plus another 1000 and 125 mA.

1250 = 125 + 1000 +125

Slide the 125 and 1000 mA switches toward the labels
as shown in the figure.

-8- -9-

HALF STEP

125
250

500

1000

.125

AMPS/PHASE

.25

AMPS/PHASE

.375

AMPS/PHASE

.5

AMPS/PHASE

.625

AMPS/PHASE

.75

AMPS/PHASE

.875

AMPS/PHASE

1

AMPS/PHASE

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

1.125

AMPS/PHASE

1.25

AMPS/PHASE

1.375

AMPS/PHASE

1.5

AMPS/PHASE

1.625

AMPS/PHASE

1.75

AMPS/PHASE

1.875

AMPS/PHASE

2

AMPS/PHASE

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

CURRENT

BASE =

125mA

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000

125
250
500

1000