Applied Motion 7080i User Manual

6/1/99

Hardware Manual

7080i

Programmable

Step Motor Driver

Copyright 1999

Applied Motion Products, Inc.

404 Westridge Drive Watsonville, CA 95076

Tel [phone] [phone] Fax [phone]

Motor
Connections

AB

+

-

-

+

Power
Supply

VDC

+

-

Mechanical Outline - Optional MMI

➝

1.975

➝
➝

YES NO

0.960

0.963

➝

0.425

1.38

4.90

2.988

0.13

3.875
CENTERED

SPACE BKSP ENTER

123

456

.0

789

+

-

CWLIM

GND

GND

GND

IN1

IN2

IN3

IN4

CW JOG

CCW JOG

01+

01-

02+

02-

03+

03-

+

-

+

-

FAULTCCWLIM

3.875
CENTERED

4.90

-2-

-19-

Technical Specifications

Amplifiers

Power Supply

Inputs

Outputs

Microstepping

Dual, MOSFET H-bridge, 3 state, pulse width modulated
switching at 20 kHz. 0.8 - 7.0 amps/phase output current,
software selectable. 560 watts maximum output power.
Overcurrent and overtemperature protection. Automatic idle
current reduction (software programmable), reduces current to
motor when idle. Minimum motor inductance is 0.8 mH.

Accepts 24 - 80 VDC power supply. 7 amps typical max load.
14A maximum power on surge.

IN 1-4, CW JOG, CCW JOG: 5V logic. Internally pulled up to
+5V with 10k resistor. Filtered.
CW LIMIT, CCW LIMIT: 5 - 24V, optically isolated. 680 ohms
internal resistance. No additional resistance is needed for 5 - 12
volts. For 24 volt logic, add 1000 ohms in series.

Optically isolated. 24V, 100 mA max.

13 software selectable resolutions. Steps per revolution with

1.8º motor: 2000, 5000, 10000, 12800, 18000, 20000, 21600,
25000, 25400, 25600, 36000, 50000, 50800. Waveform: pure
sine.

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

• Powerful, precise and efficient mosfet driver providing up to 7 amps per
phase and microstepping to 50,800 steps per revolution.

• Accepts 24 - 80 VDC power supply.

• Powerful, flexible, easy to use indexer.

• Connects by a simple cable to your PC for programming (cable included).

• Microsoft Windows-based software for easy set up and programming.

• Eight inputs for interacting with the user and other equipment.

• Four outputs for coordinating external equipment.

• Sturdy 2 x 3 x 6 inch metal chassis with integral heat sink.

• Screw terminal connectors for motor and DC power. Cage clamp connector for
I/O signals.

• Three LEDs indicating power, drive and indexer status.

• Overcurrent (short circuit) and over temperature protection.

• Optional man machine interface (MMI) allows operator to enter distances,
speeds, loop counts and more.

Motion Update

Physical

Connectors

Fuse

CE Mark

12800 Hz.

Constructed on black anodized aluminum chassis/heat sink.
2 x 3 x 6 inches overall. 21 oz. 70ºC max. heat sink
temperature. Power,overtemp and overcurrent LEDs. See page
17 for detailed drawing .

Power, motor: screw terminal block. Wire size: AWG 12 - 28.
I/O Signals: Wago cage clamp block. Wire size: AWG 20 - 28.

Wickman TR-5 style, 6.3A fast acting. Order from Digikey (1­800-DIGIKEY), P/N WK3066.

Complies with EN55011A and EN50082-1(1992).

-18-

Block Diagram

24 - 80 VDC

fuse

INPUT1
INPUT2
INPUT3
INPUT4

CW JOG/IN5

CCW JOG/IN6

CW LIMIT

CCW LIMIT

to PC/MMI

FAULT OUT

Filters

Optical

Isolation

RS232

Optical

Isolation

Internal

Logic

Supply

Microstepping

Sequencer

eeprom

Si™

Indexer

Fault

Monitor

-3-

overtemp LEDovercurrent LED

MOSFET

3 State

PWM

Power

Amplifier

Optical

Isolation

motor phase A

motor phase B

OUT1
OUT2
OUT3

Getting Started

Recommended Motors

To use your 7080i motor control, you will need the following:

✔ a power supply (see page 5 for help in choosing one).
✔ a compatible step motor
✔ 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 or Windows 95 with a 9 pin serial

port (486 or better with 8 MB ram recommended)

✔ the Si Programmer software that came with your 7080i
✔ the programming cable that came with your 7080i
✔ Si Programmer manual

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

connector

motor
power supply

Motor Winding Max Torque Max Power Current Setting
Number Connection oz-in Watts Amps/phase

5023-122 parallel 75 60 2.0
5023-123 parallel 120 93 2.5
5023-124 parallel 177 110 3.5
HT23-393 parallel 59 54 1.4
HT23-398 series 145 111 2.1
HT23-400 parallel 240 169 2.8
5034-348 parallel 185 133 4.8
5034-349 parallel 300 151 5.0
5034-350 parallel 390 213 5.5
5042-022 parallel 595 300 5.5

Mechanical Outline - 7080i

0.150"

2.45"

6x Ø.170

2.00"

RS232 connector

pc
mmi

over current fault

LEDs

power

over temp fault

-4-

I/O connector

cw limit
ccw limit
cw jog
ccw jog
inputs 1 - 4
outputs 1 - 3

5.70"

3.00"

6.00"

0.25"

-17-

5.70"

.720"

0.15"

1.345"

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 thin part.

When you flush mount the MMI in a
panel, only the thin section will stick

MMI
(rear section)

MMI
(front section
and gasket)

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 your box for
this purpose.

If you want the MMI to be dust proof and
watertight, you must place the black rubber

1

23

45
789

6

.0

SPACE BKS

➝

➝

YES NO

P

ENTER

➝

➝

panel

gasket between the thin part of the MMI and
your panel. Assemble the two halves using the
eight small screws.

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.

Then cut a hole in your panel for the cable
that runs between the MMI and the 7080i.
The hole must be at least 5/8" in

gasket
(included)

sealant (not included)

panel

diameter for the connector to fit
through. You will also need 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.

When you mount the MMI to your
panel, you will need to use some kind
of sealant to keep dust and liquid out.

1

23

456
789

.0

SPACE BKSP ENTER

➝

➝

YES NO

➝

➝

MMI

Silicone or latex caulking is okay, or you
can make your own gasket from a sheet of
compliant material like rubber or RTV.

-16-

Connecting the Power Supply

If you need information about choosing a power supply, please read Choosing a
Power Supply below.

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

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 7080i 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 57 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.

-5-

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.

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 7080i 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 7080i 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.

narrow side

mounting holes

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 7080i with the programming
cable. You will not, however, need the adapter plug. The MMI has the same
telephone style connector as the 7080i.

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 7080i, you can use any telephone line cord as a
programming cable. They are available at most supermarkets and discount stores.
Please be careful not to lose the adapter plug that connects the telephone cord to
the COM port of your PC. The adapter is a custom made part and is only available
from Applied Motion.

-6- -15-

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 7080i precisely control the amount of current in each
phase at each step position as a means of electronically subdividing the steps even
further. The 7080i 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 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.

Connecting the Motor

Never connect the motor to the driver when the power is on.

!

Secure any unused motor leads.
Never disconnect the motor while the 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.

Four lead motors can only be connected
one way. Please follow the sketch at the
right.

A+

A–

Red

Blue

Yellow

4 Leads

4

lead

motor

White

B+ B–

The microstep resolution of the 7080i is set by the Si Programmer software.

Fault Protection

The 7080i provides protection against motor short circuits and excessive drive
temperature.

If the OVERTEMP light is on the 7080i has detected a thermal problem and shut
down the amplifiers. The first thing you should do is to unplug the drive from the
power source. Next, touch the heat sink with your fingers. If it is very hot, the drive
has probably overheated. Usually this means you need more air flow around the
drive.

If the OVERCURRENT light is on the 7080i has detected a short circuit and has
shut down the amplifiers. Unplug the drive from the power source. 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 to ground.

-14-

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 below.

Note: NC means not connected to anything.

Grn/Wht

A–

White

NC

Green

A+

Red

B–

6 Leads Series Connected 6 Leads Center Tap Connected

lead

motor

Black

NC

6

Red/

Wht

B+

A–

A+

NC

Grn/Wht

White

Green

Red

lead

motor

Black

6

Red/

Wht

NC

B+B–

-7-

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.

Orange

A+

Org/Wht

8

Blk/Wht

lead

Blk/Wht

A–

Black

Red

8 Leads Series Connected 8 Leads Parallel Connected

motor

Red/

B+ B–

Wht

Yel/
Wht

A–

Yellow

A+

Org/

Wht

Orange

Black

Red

B+

Yel/
Wht

8

lead

motor

Red/Wht

Yel
low

B–

Connecting to the PC

Wiring Outputs

Before we discuss the output conditions, we need to talk about the circuitry. All
three 7080i 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.

At power-up, the 7080i 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 7080i output terminals.
Maximum current is 100 mA per output.

+5V

330Ω

OUT1+

OUT1–

Optoisolator

NEC PS2502

or equiv.

inside 7080i

7080i

Controller Chip

• Locate your computer within 6 feet of the 7080i.

• Your 7080i 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 7080i. 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
will have to purchase a 25 to 9 pin serial adapter at your local computer store.

• Your 7080i 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 RS232 jack
on your 7080i.

Never connect the 7080i to a telephone circuit. It uses the same
connectors and cords as telephones and modems, but the voltages are
not compatible.

Programming Note: Always apply power to 7080i after the Si™
Programmer software is running on your PC.

Schematic Diagram of 7080i Output Circuit

Since there is no electrical connection to the 7080i, 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 7080i output to an optically isolated
PLC input.

12-24 VDC

Power Supply

+ –

OUTPUT+

COMMON

PLC

7080i

OUTPUT-

-13--8-

INPUT

Wiring Inputs

Each input has a pull up resistor to the internal 5 volt power supply and an RC filter.
Because of the pull up resistor, if nothing is connected to an input, it defaults to the
"high" state. One way to control an input is by connecting a switch between the
input and ground. When the switch is closed, the input state is "low." When the
switch is open, it's "high." You can connect a relay the same way.

You can also connect an active signal to an 7080i input, as long as it's from a 0 - 5
VDC, or "TTL compatible" circuit. Open collector circuits are okay, too.

+5V

10K

INPUT

Schematic Diagram of Inputs 1 - 4, cw jog and ccw jog)

inside 7080i

1K

100pF

7080i

Controller Chip

The maximum voltage that can be applied to an input terminal is 5
volts DC. Never apply AC voltage to an input terminal.

Connecting a Proximity Sensor to an Input

The best type of proximity switch to use is "NPN normally open." You will need an
external power supply to operate the sensor. Connect the power supply and
proximity switch terminals as shown in the diagram.

Jogging

Two of the 7080i input terminals are provided for jogging the motor. The inputs are
labeled "JOG CW" and "JOG CCW". Connecting one of the inputs to ground
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
volt circuitry can also 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 one
of the GND inputs. For active circuitry, connect the signal to JOG and the circuit
ground to GND.

If the 7080i is connected to a PC with the programming software running, the jog
inputs will function under two conditions:

1) if the program is not executing

2) if the program is executing a Wait Input command.

If the 7080i is operating in stand alone mode (i.e. without a computer attached) then
the jog inputs work when the program is executing the Wait Input instruction.

To set the Jog Speed and Jog Accel/decel rate, adjust the scroll bars in the main
programming window.

You may be concerned about wiring a proximity sensor to a 5 volt input when the
sensor is powered by 12 or 24 volts. Fear not: even though the sensor is powered
by a higher voltage, NPN type proximity sensors do not apply any voltage to the
output. They either switch the output terminal to ground, or leave it open circuit.
This is referred to as an "open collector" output. Thus, the 7080i input never sees
more than 5 volts.

If you are uncertain about the output voltage of your sensor, hook it up to your
power supply, but not the 7080i. Measure the voltage with a DC voltmeter at the
output terminal in both sensor states and make sure it does not exceed 5 volts. If
the sensor is truly open collector, the voltage will measure 0 in both states.

+

DC

Power

Supply

–

+

Proximity

Sensor

–

output

IN

7080i

GND

-12-

JOG CW

JOG CCW

GND

+5V

+5V

10K

10K

inside 7080i

1K

100pF

7080i

Controller Chip

1K

100pF

-9-

Limit Switches

Limit Sensors

The 7080i 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 7080i 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. It also allows you to have long wires on limit
sensors that may be far from the 7080i with less risk of introducing noise to the
7080i. The schematic diagram of the limit input circuit is shown below.

If you want to operate the limit switch circuits at 24 volts, you must
add 1000 ohms in series with each limit switch. For 5 - 12V operation,
no external resistance is required.

+5V +5V

4.7K

7080i

Controller

Chip

CW LIMIT+

CW LIMIT–
CCW LIMIT+
CCW LIMIT–

inside 7080i

1K

NEC PS2501

3
4
1
2

TLP621 or

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:

CW LIMIT+

+

DC

Power

Supply

–

+

Limit

Sensor

–

output

CW LIMIT-

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:

7080i

Wiring a Limit Switch

You can use normally open or normally closed limit switches. Either way, wire
them as shown here.

CW LIMIT+

+
5-12
VDC

SUPPLY

-

CCW LIMIT+

CW LIMIT-

7080i

CCW LIMIT-

-10-

+

DC

Power

Supply

–

+

Proximity

Sensor

–

output

LIMIT+

7080i

LIMIT-

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."

The current through the 7080i limit switch inputs must not exceed 20
mA. If your limit sensor power supply voltage is between 12 and 24
volts DC, add a 1000 ohm resistor in series with the sensor output. Do
not use voltages higher than 24 VDC.

-11-