Applied Motion 7080 User Manual

9/17/99

7080.ai

User's Manual

7080

Step Motor Driver

Applied Motion Products, Inc.

404 Westridge Drive Watsonville, CA 95076

Tel [phone] [phone] Fax [phone]

motors • drives • controls

Technical Specifications

Amplifiers

Inputs

Output

Microstepping

Self Test

Dual, MOSFET H-bridge, 3 state, pulse width modulated
switching at 25 kHz. 18 - 80 VDC input. 0.8 - 7.0 amps/phase
output current, switch selectable in 0.2 amp increments. 550
watts maximum output power. Overcurrent and overtemperature
protection. Automatic idle current reduction (defeatable),
reduces current to 50% of setting after one second.

Step, direction and enable, optically isolated, 5-12V logic. 2
mA/V/signal, sink requirement. (24V logic can be used with
current limiting resistors.) Motor steps on rising edge of step
signal current. 0.25 µsec minimum pulse width, 2 MHz max
step rate. 2 µsec minimum set up time for direction signal.

Fault output, optically isolated, becomes active if an over
temperature or overcurrent (short circuit) fault occurs.

16 switch selectable resolutions. Steps per revolution with 1.8
motor: 200, 400, 1000, 2000, 5000, 10000, 12800, 18000,
20000, 21600, 25000, 25400, 25600, 36000, 50000, 50800.
Waveform: pure sine standard. Other waveforms available upon
request. Other resolutions available upon request.

Switch selectable self test rotates motor slowly in alternating
direction, for testing drive & motor without input signals.

Physical

Connectors

Fuse

CE Mark

Mounted on 1/4 inch thick black anodized aluminum
heatsink/chassis. 2 x 3 x 6 inches overall. Power on and fault
indicators. See drawing on page 14 for more information.
Maximum chassis temperature: 70 C.

Screw terminal blocks.
Motor: 4 position, accepts AWG 12-28 wire
DC Input: 2 position, accepts AWG 12-28 wire
Signal Input: 8 position, accepts AWG 16-28 wire

Wickman 6.3 amp time lag, TR-5 style. Order from Digikey
(1-800-DIGIKEY) part number WK4066.

Complies with EN55011A and EN50082-1(1992).

-15--2-

Mechanical Outline

0.150"

5.70"

2.45"

6.00"

6x Ø.170

2.00"

5.70"

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 [phone] or you can reach us by fax at (831) 761–6544.

Features

• Drives NEMA sizes 14 through 42 step motors

• MOSFET pulse width modulation switching amplifiers (3 state)

• Phase current from 0.8 to 7.0 amps/phase (switch selectable, 32 settings)

• Step, direction and amplifier enable inputs, optically isolated

• Microstepping from full step through 1/ 254 (switch selectable, 16 settings)

• Over temperature and over current (short circuit) protection

• Idle current reduction (50% or 0%, switch selectable)

• Fault output, optically isolated

Block Diagram

18-80VDC

3.00"

0.25"

.720"

1.345"

0.15"

1
2

43

step
direction

enable

fault output

overcurrent

light

overtemp

light

6.3A fuse

resolution

selector

Optical

Isolation

Fault

Monitor

power

light

Voltage

Regulator

Microstep

Sequencer

Self Test

-3--14-

motor phase A

PWM Power

Amplifier

PWM Clock

25 kHz

motor phase B

PWM Power

Amplifier

current

34567

selector

1

idle

current

reduction

2

Getting Started

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

a 18-80 volt DC power supply for the motor. Please read the section entitled

•

Choosing a Power Supply

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

•
a small flat blade screwdriver (3/32" or 2.5 mm) for tightening the connectors

•

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

for help in choosing the right power supply.

Choosing a Power Supply

We recommend using an Applied Motion Products power supply with this drive.
Two models are available: the PS430 (30 volts DC at 4 amps) and the PS1050 (50
volts DC at 10 amps). The PS430 can also provide 500 mA of well regulated 5 volt
power for your logic circuits. If you do not choose an A.M.P. supply, please follow
the recommendations below.

Voltage

Chopper drives like the 7080 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

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 48 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.

voltage

connector

motor

connector

switches for

selecting
microstep
resolution

power indicator

(red LED)

overcurrent

indicator

(yellow LED)

power

overtemperature

indicator

(yellow LED)

Always use the blue & white Applied

Motion screwdriver with this

connector. Larger screwdrivers may

remove the plastic dimples that

prevent the screws from falling out.

-4-

mounting

hole (1 of 6)

connector

STEP
DIRECTION
ENABLE
FAULT

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 7080 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 48 volt
supply can be expected to draw only half the supply current that it would with a 24
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.

-13-

Fault Protection

The 7080 provides protection against reversed power supply polarity, motor short
circuits and excessive drive temperature. Under normal operation, you should see
one red light, the power light.

Connecting the Power Supply

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

Power Supply

located in the back of this manual.

Choosing a

If you see no lights either the fuse is blown or you do not have power applied to
the drive. If the fuse blows, the + and – leads to the power supply may be reversed.
Check to see if the wires connecting the power supply to the drive are reversed.

If you see a yellow "short" light the 7080 has detected an overcurrent
condition and shut down the amplifiers. The first thing you should do is switch the
power supply off. Check the motor wiring carefully. Make sure that the connections
to the drive are secure and that any unused motor leads are insulated from the drive
and power supply and from each other. Check the motor leads for shorts between
phases or shorts to ground.

If you see a yellow "temp" light the 7080 has overheated. This means you
need more air flow around the drive or additional heat sinking.

Mounting the Drive

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 #6 screws through the four corner holes. For
narrow side mounting applications, you can use #6 screws in the two side holes.

The 7080 drive will dissipate heat better if you mount it on the narrow
side. Please use narrow side mounting whenever possible.

wide side

mounting holes

The amplifiers in the 7080 generate heat. To operate the drive continuously at
maximum power you may need additional heat sinking or forced air cooling. 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 50 C. Never put the drive where it can get wet or
where metal particles can get on it.

-12- -5-

narrow side

mounting holes

Connect the motor power supply + terminal to the driver terminal labeled "+V".
Connect power supply – to the drive terminal labeled "V–." Use 18 gauge wire. Be

careful not to reverse the wires.

7080 Drive

DC Power Supply

Connecting the Motor

When connecting the motor to the driver, be sure that the
motor power supply is off. Secure any unused motor leads

!

You must now decide how to connect your
motor to the drive. The lead colors shown
are for Applied Motion Products motors.

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. Winding diagrams for both connection
methods are shown on the next page.

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!

Red

A+

4

lead

AÐ

Blue

Yellow

4 Leads

motor

White

B+ BÐ

Grn/Wht

AÐ

motor

Black

*

6

lead

NC

Red/

Wht

B+

White

NC

*

Green

A+

Red

BÐ

6 Leads Series Connected 6 Leads Center Tap Connected

Grn/Wht

AÐ

6

lead

A+

White

motor

NC

*

Green

Red

Black

B+BÐ

Red/

Wht

NC

*

* NC = not connected to anything.

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

Blk/Wht

lead

Blk/Wht

AÐ

Black

Red

8 Leads Series Connected 8 Leads Parallel Connected

motor

Red/

Yel/

Wht

B+ BÐ

Wht

AÐ

Yellow

A+

Org/

Wht

Orange

Black

Red

B+

Yel/
Wht

8

lead

motor

Red/Wht

Yel
low

BÐ

Step Table

(full stepping)

Step A+ A- B+ B-

0+–+–

Selecting Microstep Resolution

1

200

STEPS/REV

(FULL)

400

STEPS/REV

(HALF)

1000

STEPS/REV

(1/5)

2000

STEPS/REV

(1/10)

5000

STEPS/REV

(1/25)

10000

STEPS/REV

(1/50)

12800

STEPS/REV

(1/64)

STEP

MODE

STEP

MODE

STEP

MODE

STEP

MODE

STEP

MODE

STEP

MODE

STEP

MODE

2

43

1
2

43

1
2

43

1
2

43

1
2

43

1
2

43

1
2

43

20000

STEPS/REV

(1/100)

21600

STEPS/REV

(1 arc min)

25000

STEPS/REV

(1/125)

25400

STEPS/REV

(1/127)

25600

STEPS/REV

(1/128)

36000

STEPS/REV

(.01 )

50000

STEPS/REV

(1/250)

STEP

MODE

STEP

MODE

STEP

MODE

STEP

MODE

STEP

MODE

STEP

MODE

STEP

MODE

1
2

43

1
2

43

1
2

43

1
2

43

1
2

43

1
2

43

1
2

43

DIR=1

(5V)

cw

1–++–
2–+–+

3+– –+
4+–+–

Step 3 is the Power Up State

DIR=0

(0V)

ccw

18000

STEPS/REV

(1/90)

STEP

MODE

1
2

43

50800

STEPS/REV

(1/254)

STEP

MODE

1
2

43

-11--6-

Idle Current Reduction

Your drive is equipped with a feature that automatically reduces the motor current by 50%
anytime the motor is not moving. This reduces drive heating by about 50% and lowers
motor heating by 75%. This feature can be disabled if desired so that full current is
maintained at all times. This is useful when a high holding torque is required. To minimize
motor and drive heating we highly recommend that you enable the idle current reduction
feature unless your application strictly forbids it. Idle current reduction is enabled by
sliding switch #2 toward the 50% IDLE label, as shown in the sketch below. Sliding the
switch away from the 50% IDLE label disables the reduction feature.

50% IDLE

2

50% IDLE

2

Connecting Logic

The 7080 contains 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 at the right.

STEP+

STEP–

Drive Input Circuit

inside 7080

330½

Idle Current Reduction Selected

No Current Reduction

Self Test

The 7080 includes a self test feature. This is used for trouble shooting. If you are unsure
about the motor or signal connections to the drive, or if the 7080 isn't responding to your
step pulses, you can turn on the self test.
To activate the self test, slide switch #1 toward the TEST label. The drive will slowly rotate
the motor, 1/2 revolution forward, then 1/2 rev backward. The pattern repeats until you
slide the switch away from the TEST label. The 7080 always uses half step mode during
the self test, no matter how you set switches 2 and 3. The self test ignores the STEP and
DIRECTION inputs while operating. The ENABLE input continues to function normally.

TEST

Self Test ON

1

TEST

Self Test OFF

1

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 7080 precisely control the amount of current in each phase at each step
position as a means of electronically subdividing the steps even further. The 7080 offers a
choice of full and half step as well as 14 other 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
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 steps.) Some settings are used with lead screws. When the
drive is set to 2000 steps/rev and used with a 5 pitch lead screw, you get .0001
inches/step.

-10- -7-

Indexer

with

Sinking

Outputs

Connecting to Indexer with Sinking Outputs

+5V OUT

DIR DIR-

STEP STEP-

DIR+

STEP+

7080

Drive

(includes Applied Motion SI-1 Indexer)

PLC

with
Sinking
Outputs

Connecting to PLC with Sinking Outputs

+24V

DIR DIR-

2200
1/4W

STEP STEP-

DIR+

STEP+

7080
Drive

(Most PLC's use 24 volt logic)

Indexer

with

Differential

Outputs

Connecting to Indexer with Differential Outputs

DIR+

DIR- DIR-

STEP+
STEP-

DIR+

STEP+
STEP-

7080
Drive

(Many High Speed Indexers have Differential Outputs)

The ENABLE input allows the user to turn off the current to the motor by providing a
positive voltage between EN+ and EN-. The logic circuitry continues to operate, so the drive
"remembers" the step position even when the amplifiers are disabled. However, the motor
may move slightly when the current is removed depending on the exact motor and load
characteristics. If you have no need to disable the amplifiers, you don't need to

connect anything to the

ENABLE

input.

Using the Fault Output

The 7080 has a fault output to tell you if the drive has overheated or if a short circuit
has occured at the motor outputs. The fault output is optically isolated for noise
immunity. This makes it more flexible and more reliable, but also harder to hook
up. To connect to 5 volt logic, follow the sketch below. For other connections,
consult the factory.
The photo transistor turns on when there is a fault. In circuit below, the signal will
be high (near 5 volts) when there is no fault. The signal will go low (0 volts) if a
fault occurs.

7080

FAULT+

1k

FAULT–

Resistor

10k

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 current you set on the 7080 is the peak current, not RMS.

The 7080 drive current is easy to set. If you wish, you can learn a simple formula
for setting current and never need the current table 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. Five of the switches
have a value of current printed next to them, such as 0.4 and 1.6. Each switch

controls the amount of current, in amperes (A), that its label indicates. There is
always a base of current of 0.8A. 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 5 amps
per phase. You need the 0.8 A base

current plus another 0.2, 0.8 and 3.2 A.

5.0 = 0.2 + 0.8 + 3.2 + 0.8 (base)

Slide the 0.2, 0.8 and 3.2 A switches toward the labels
as shown in the figure.

+5 VDC

1/4W

TTL or CMOS input

SELF TEST

50% IDLE

0.2

0.4

0.8

1.6

CURRENT

BASE = 0.8

3.2

1234567

Current Setting Table

34567 34567 34567 34567 34567 34567 34567 34567

2.4

AMPS/
PHASE

2.6

AMPS/
PHASE

2.8

AMPS/
PHASE

3.0

AMPS/
PHASE

3.2

AMPS/
PHASE

3.4

AMPS/
PHASE

3.6

AMPS/
PHASE

3.8

AMPS/
PHASE

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.8

AMPS/
PHASE

1.0

AMPS/
PHASE

1.2

AMPS/
PHASE

1.4

AMPS/
PHASE

1.6

AMPS/
PHASE

1.8

AMPS/
PHASE

2.0

AMPS/
PHASE

2.2

AMPS/
PHASE

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

34567 34567 34567 34567 34567 34567 34567 34567

4.0

AMPS/
PHASE

4.2

AMPS/
PHASE

4.4

AMPS/
PHASE

4.6

AMPS/
PHASE

4.8

AMPS/
PHASE

5.0

AMPS/
PHASE

5.2

AMPS/
PHASE

5.4

AMPS/
PHASE

-9--8-

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

34567 34567 34567 34567 34567 34567 34567 34567

5.6

AMPS/
PHASE

5.8

AMPS/
PHASE

6.0

AMPS/
PHASE

6.2

AMPS/
PHASE

6.4

AMPS/
PHASE

6.6

AMPS/
PHASE

6.8

AMPS/
PHASE

7.0

AMPS/
PHASE

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

0.2

0.4

0.8

1.6

3.2

34567 34567 34567 34567 34567 34567 34567 34567