Applied Motion PDO3540 User Manual

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Page 1

Hardware Manual

PDO 3540

Step Motor Driver w/ Oscillator

DIR+

DIR– STEP+ STEP–

EN+ EN–

SPEED+

SPEED-

TACH+ TACH–

CW WPR CCW

JOYSTICK

EXT SPEED

50% IDLE

SELF TEST

0.1

0.2

0.4

0.8

1.6

123456 123456

Step Motor Driver

CURRENT

(BASE = 0.4 A)

STEPS/REV

OSC BYPASS

POWER

ACCEL

HIGH SPEED LOW SPEED

B-

B+

A-

MOTOR

PDO 3540

A+

POWER

-1-

motors • drives • controls

Page 2

-2-

Page 3

T able of Contents

Introduction --------------------------------------------------------------------- 4 Features-------------------------------------------------------------------------- 4 Getting Started ------------------------------------------------------------------ 5 Connecting the AC Line --------------------------------------------------------- 6 Connecting the Motor ----------------------------------------------------------- 8 Modes of Operation ------------------------------------------------------------ 10 Setting Up for Pulse & Direction Mode ---------------------------------------- 11 Microstepping ------------------------------------------------------------------ 12 Selecting Microstepping Resolution -------------------------------------------- 13 Joystick Mode ------------------------------------------------------------------ 14 Oscillator Mode ---------------------------------------------------------------- 15 Speed Control from 0 to 5 Volt Analog Signal --------------------------------- 17 Connecting Digital Inputs ------------------------------------------------------ 18 Enable Input -------------------------------------------------------------------- 19 Setting Phase Current ---------------------------------------------------------- 20 Current Set Table --------------------------------------------------------------- 21 Mounting the Drive------------------------------------------------------------- 22 Recommended Motors---------------------------------------------------------- 23 Block Diagram------------------------------------------------------------------ 23 Technical Specifications -------------------------------------------------------- 24

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Page 4

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.

Features

• Powerful, precise and efficient mosfet driver providing up to 3.5 amps per phase and microstepping to 50,800 steps per revolution.

• Reliable, efficient, low noise 40 VDC linear, toroidal power supply.

• Automatic idle current reduction reduces motor and drive heating, saves power.

• Inputs and outputs are optically isolated, differential (sourcing or sinking). Speed

& Enable 5 - 24 VDC, Step & Direction 5 - 12 VDC.

• Digital oscillator provides smooth accel/decel ramps and precise speed control.

• Easy to configure with on-board switches and potentiometers for all settings.

• Oscillator Mode operates from internal pots, external pots, 0 - 5 V analog signal,

or analog joystick.

• Two speed ranges, can be selected “on the fly” by a digital signal with automatic ramping between speeds.

• Tach Out signal allows easy measurement of speed.

• Built-in self test for troubleshooting.

• Accepts 110 or 220 volt AC power (factory preset for 110 volts).

• Sturdy 2.25 x 7.8 x 5 inch metal chassis.

• Pluggable screw terminal connectors for motor, AC power and I/O signals makes

wiring easy.

• CE and TUV Compliant

-4-

Page 5

Getting Started

To use your PDO 3540 motor control, you will need the following:

✔ a power cable (line cord) ✔ 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.

For pulse & direction mode:

✔ a source of step pulses (usually an indexer is used)

For oscillator mode:

✔ an instrument for measuring motor speed (tachometer, freq. counter or o-scope)

For joystick mode:

✔ an analog joystick (see page 25 for recommended joystick) The sketch below shows where to find the important connection and adjustment

points. Please examine it now.

Power LED

Motor Connector

All mating connectors are included.

DIR+

DIR– STEP+ STEP–

EN+ EN–

SPEED+

SPEED-

TACH+ TACH–

CW WPR CCW

JOYSTICK

EXT SPEED

50% IDLE

0.1

0.2

0.4

0.8

1.6

(BASE = 0.4 A)

OSC BYPASS

SELF TEST

ACCEL HIGH SPEED

LOW SPEED

B-

B+

A-

A+

123456 123456

Step Motor Driver

CURRENT

STEPS/REV

POWER

MOTOR

PDO 3540

Connector*

step & direction enable speed tachometer out ext potentiometer

Dip Switches

oscillator mode current setting microstep resolution idle current

Trim Pots

oscillator speed, accel & decel

AC Power Connector

POWER

-5-

*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.

Page 6

Connecting the AC Line

The PDO 3540 is set for 110 VAC operation at the factory. If you use 110 VAC power, all you need to do is install a power cord and plug it in. If you plan to use 220 VAC power, follow the instructions below.

PDO 3540 to AC power, consult a qualified electrician and observe all building and electrical codes. AC power can be dangerous.

220 VAC Instructions

In order to use 220 volts, you’ll need to change a fuse and a switch setting inside

the case.

• Remove all mating connectors from the drive.

• Set the drive on it’s widest side, so that you can read PDO 3540 Step Motor

Driver properly.

• Remove the four (4) phillips head screws that mount the chassis sheet metal to the chassis heat sink. See page 17 for a mechanical outline of the drive.

• The 110/220 switch is located near the position of the AC power connector, next to the toroidal transformer (see sketch below).

• For 220 VAC operation slide the switch towards the bottom of the drive, or towards the transformer end of the drive. The position of the switch is labeled on the PC board also, “230” being for 200-240 VAC operation, and “115” for 100-120 VAC operation.

• Replace the fuse next to the switch with the 220 VAC fuse that came with the drive. See technical specifications on page 25 to order more fuses.

• Replace the drive’s cover and assembly screws.

Note: If you plan to hard wire the

110/220 VAC Switch

Fuse

SW1

CN1

230 115

Switch set for 110 VAC

PC Board

AC Power Connector

-6-

SW1

CN1

230 115

Switch set for 220 VAC

Page 7

Installing an AC Line Cord

Remove about 5 mm (3/16 inces) of insulation from each of the three wires of your line cord. (That’s right, three wires. For safety, always use a three wire power cord on anything with a metal case). Depending on where you got your power cord, it may have black, white and green wires, or brown, white and green wires.

The AC power plug that was shipped with your PDO 3540 might be one of two types. The “old style” is shown below, on the left. The “new style” , which comes with an insulating rubber boot, is shown below, on the right.

Make sure you follow the proper sketch for you connector style.

To Earth Ground

To Neutral

To Line (Hot)

To Earth Ground

To Neutral

To Line (Hot)

"Old Style"

AC Power Plug

"New Style"

AC Power Plug

Always unplug the line cord from the wall before attaching

it to the PDO 3540.

•Connect the black or brown wire to the PDO 3540 “L” terminal of the AC power connector. That is the line, or “hot” connection.

•Connect the white or blue wire to neutral, the “N” terminal.

•Finally, and most importantly, connect the green wire to the “GND” terminal. That

connects the PDO 3540 metal enclosure and DC power supply ground to earth ground.

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Page 8

Connecting the Motor

Secure any unused motor leads, insulate exposed conductors. Never connect motor leads to ground or to a power supply .

Never connect or disconnect the motor to the driver when the AC power is on.

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

lead

motor

Yellow

B+ B–

4 Leads

White

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.

A–

A+

Grn/Wht

White

Green

Red

B–

lead

motor

Black

Red/

Wht

B+

A–

A+

Grn/Wht

White

Green

Red

lead

motor

Black

Red/

Wht

B+B–

6 Leads Series Connected 6 Leads Center Tap Connected

-8-

Page 9

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.

A+

Org/Wht

Orange

Blk/Wht

A+

Orange

lead

Blk/Wht

A–

Black

Red

8 Leads Series Connected 8 Leads Parallel Connected

motor

Red/

Wht

B+ B–

Yel/ Wht

Yellow

A–

Org/

Wht

Black

Red

B+

motor

Yel/ Wht

lead

Red/Wht

Yel low

B–

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Page 10

Modes of Operation

The PDO 3540 has four modes of operation, selected by three dip switches. Self Test Mode is used for trouble shooting. If you are unsure about the motor or

signal connections to the drive, or if the PDO 3540 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 revolution backward. The pattern repeats until you slide the switch away from the TEST label. The PDO 3540 always uses half step mode during the self test, no matter how you set the steps/rev switches. The self test ignores the STEP and DIRECTION inputs while operating. The ENABLE input continues to function normally.

SELF TEST

Self Test Mode

OSC BYPASS

SELF TEST

Pulse & Direction Mode - the PDO 3540 receives step pulses from an indexer such as the Applied Motion Si-1 or Si-100. Steps/revolution are set by switches 3 - 6 (see page 13).

Joystick mode - speed and direction are determined by an external analog voltage. STEP and DIR inputs can be used for limit switches. SPEED input selects speed range. LO SPEED and HI SPEED pots adjust the 2 speed ranges.

Oscillator mode - speed can be controlled by onboard potentiometers and/or by an external analog voltage. STEP input starts and stops the motor. DIR input controls direction of rotation. SPEED input selects the speed range.

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Pulse & Direction Mode

JOYSTICK

OSC BYPASS

SELF TEST

Joystick Mode

JOYSTICK

OSC BYPASS

SELF TEST

Oscillator Mode

Page 11

Setting up for Pulse & Direction Mode

To operate the drive in Pulse & Direction mode, you must:

✔ Connect an indexer/controller to the STEP and DIR inputs. ✔ Set the microstep resolution (steps/rev). ✔ Turn off the SELF TEST switch and turn on the OSC BYPASS switch.

Differential Logic

If your controller has STEP+, STEP-, DIR+ and DIR- outputs, which many indexers do, the connections are simple. Just connect STEP+ to STEP+, STEP- to STEP- and so forth, as shown below.

DIR+ DIR+

Indexer

Controller

with

Differential

Outputs

DIR- DIR-

STEP+ STEP+

STEP- STEP-

ENABLE+ ENABLE+ ENABLE- ENABLE-

= optional signal

PDO 3540

Drive

Sinking Logic

If your controller has STEP, DIR and +5V outputs, like the Applied Motion Products Si-1 indexer, connect STEP+ and DIR+ to +5V. Connect STEP- to STEP. Connect DIR- to DIR.

Indexer

+5V OUT

DIR DIR-

DIR+

Controller

with

Sinking

Outputs

STEP STEP-

ENABLE- ENABLE-

STEP+

ENABLE+

PDO 3540

Drive

= optional signal

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Page 12

Sourcing Logic

If your controller has STEP, DIR and GND (ground or common) outputs, connect STEP- and DIR- to GND. Connect STEP+ to STEP. Connect DIR+ to DIR.

DIR DIR+

Indexer

Controller

with

Sourcing

Outputs

STEP STEP+

ENABLE ENABLE+

GROUND ENABLE-

= optional signal

DIR-

STEP-

PDO 3540

Drive

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 PDO 3540 precisely control the amount of current in each phase at each step position as a means of electronically subdividing the steps even further. The PDO 3540 offers a choice of 16 step resolutions in pulse & direction mode. The highest setting divides each full step into 254 microsteps, providing 50,800 steps per revolution when using a 1.8° motor.

Note: In oscillator/joystick mode the microstep resolution is fixed at 12800 steps/rev, regardless of the dip switch settings.

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 provded 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 0.2 pitch lead screw, you get 0.0001 inches/step.

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Page 13

Selecting Microstep Resolution

5kΩ

joystick

joystick "fire" button

fwd

rev

PDO 3540

SPEED+

DIR-

STEP-

SPEED-

CCW

WPR

5-12 VDC

SUPPLY

DIR+

STEP+

rev limit switch

fwd limit switch

200

(FULL)

400

(HALF)

1000

(1/5)

2000

(1/10)

5000

(1/25)

STEPS/REV

6543

20000

(1/100)

6543

21600

(1 arc min)

6543

25000

(1/125)

6543

25400

(1/127)

6543

25600

(1/128)

6543

STEPS/REV

6543

STEPS/REV

6543

STEPS/REV

6543

STEPS/REV

6543

STEPS/REV

10000

(1/50)

12800

(1/64)

18000

(.02o)

STEPS/REV

6543

36000

(.01o)

6543

50000

(1/250)

6543

50800

(1/254)

-13-

6543

STEPS/REV

6543

STEPS/REV

6543

STEPS/REV

Page 14

Joystick Mode

5kΩ

joystick

joystick "fire" button

fwd

rev

PDO 3540

SPEED+

DIR-

STEP-

SPEED-

CCW

WPR

5-12 VDC

SUPPLY

DIR+

STEP+

rev limit switch

fwd limit switch

In this mode, speed and direction are determined by the voltage applied to the WPR (wiper) terminal. 2.5 volts is “stopped” (no speed). Increasing the WPR voltage toward 5 volts results in forward motion: speed increases with voltage. Decreasing the WPR voltage from 2.5 toward 0 results in reverse motion, with speed increasing as voltage decreases. In joystick mode, the PDO 3540 operates at 12800 steps/rev.

The maximum speed is determined by two things: the state of the SPEED input and the HI SPEED and LO SPEED trimpots. When the SPEED input is ON, the speed range of the joystick can be adjusted with the LO SPEED pot, up to 5 rev/sec (300 rpm). When the SPEED input is OFF (or open), the joystick speed range is adjusted with the HI SPEED pot, up to 25 rev/sec (1500 rpm). Turning the pots clockwise increases the speed.

In joystick mode, limit switches can be connected to the PDO 3540 to prevent motion outside of defined limits. The forward limit should be connected to the STEP input and the reverse limit should be connected to the DIR input. When the forward limit is ON, the motor will not move forward (that is, when the joystick voltage is between 2.5 and 5 volts). When the reverse limit is ON, the motor will not move when the joystick is in the 0 to 2.5 volt range. If you don’t need limits, you can leave the STEP and DIR inputs unconnected.

T ypical Wiring for Joystick Mode

-14-

Page 15

25 20 15 10

5 0

-5

-10

speed (rev/sec)

-15

-20

-25 012345

volts volts

Speed vs. Input Voltage

Joystick Mode, SPEED input off (open)

HI SPEED pot at maximum

Oscillator Mode

In oscillator mode, the PDO 3540 uses the direction set by the DIR input. Off, or open, gives clockwise motion, if the motor is wired according to pages 8 and 9. Motor speed and the function of the STEP input can be determined from the following table. In oscillator mode, the PDO 3540 operates at 12800 steps/rev.

SPEED

input

OFF/open

switches

joystick

ext speed

joystick

ext speed

joystick

ext speed

joystick

ext speed

7 & 8

speed setbywhen STEP

LO SPEED

78 78 7878

HI SPEED

WPR input

trimmed by

HI SPEED

-15-

accel to speed

accel to speed accel to speed

accel to speed

goes ON

when STEP

goes OFF

instant stop

decel to stop

Page 16

There are two speed ranges in oscillator mode. One is the low speed range, which is activated when the SPEED input is on. The low speed can be set from 0 to 5 rev/ sec (0 - 300 rpm) by adjusting the LO SPEED pot. Turning the pot clockwise increases the speed.

The high speed setting is used when the SPEED input is off, or open. If switch #7 is toward the words EXT SPEED, then the high speed is proportional to the voltage applied to the WPR terminal, and is trimmed by the HI SPEED pot. You can connect an external 1K - 5K pot to the WPR, CW and CCW terminals, or you can apply a 0 to 5 volt analog signal to the WPR terminal (ground your analog signal to the CCW terminal). The high speed range is 0 - 25 rev/sec (0 - 1500 rpm). You can reduce the range by turning down the HI SPEED pot. For example, if you want the motor to go 750 rpm when the external pot is on maximum, turn the HI SPEED pot down about half way.

When switch #7 is away from the EXT SPEED label, the high speed is set by the HI SPEED pot and the WPR input does nothing.

Never apply more than 5 volts DC or less than 0 volts to the

WPR pin.

In joystick and oscillator modes, the accel/decel rate is set by the ACCEL pot.

The acceleration range is 1 to 250 rev/sec/sec. Turning the pot clockwise makes the motor start and stop faster, but if you set it too high the motor may run out of torque and stall.

In nearly all cases, the accel/decel rate you set is respected by the PDO 3540. For example, if you switch the SPEED input while the motor is moving, the drive will change speeds smoothly. If you are operating in EXT SPEED mode and make a sudden change in the voltage to the WPR terminal, the drive accelerates (or decelerates) to the new speed smoothly, according to the accel pot setting.

The only time the drive makes an instant change is when the SPEED input is on and the STEP input goes off. That is done so that you can stop instantly (and exactly) from a low speed.

-16-

Page 17

0 - 5V speed signal

signal return

PDO 3540

STEP+

STEP-

CCW

WPR

5-12 VDC

SUPPLY

run/stop switch

(closed=run)

direction switch

STEP+

DIR+

SPEED+

STEP-

DIR-

PDO 3540

speed switch (closed=lo speed)

5kΩ

pot

ccw

SPEED-

CW WPR CCW

Typical Wiring for Oscillator Mode Using External Speed Control Pot

Speed Control from a 0 to 5 V olt Analog Signal

In oscillator mode, the PDO 3540 can rotate the motor at a speed proportional to an analog voltage. The voltage must be applied to the WPR terminal. The direction of rotation is controlled by the digital DIR input and the motor can be stopped either by setting the analog input voltage to 0 or by turning the digital STEP signal off.

To use the PDO 3540 in this mode, set switch #8 away from the JOYSTICK label, and set switch #7 toward the EXT SPEED label.

The HI SPEED pot sets the maximum speed (the motor speed when the analog signal is at 5 volt DC). The range is 0 - 25 rev/sec. Wiring diagrams and a plot of speed v. voltage are shown below and on the next page.

Wiring for Speed Control by 0 - 5 V Analog Signal (with Dir Control)

+ 5-12 VDC

SUPPLY

0 - 5V speed signal

signal return

run/stop switch

(closed=run)

direction switch

STEP+

DIR+

STEP-

DIR-

WPR CCW

-17-

PDO 3540

Page 18

Wiring for Speed Control by 0 - 5 Volt Analog Signal (Unidirectional)

0 - 5V speed signal

signal return

PDO 3540

STEP+

STEP-

CCW

WPR

25 20 15 10

speed (rev/sec)

012345

Speed vs Input Voltage

EXT SPEED mode, HI SPEED pot at maximum

Connecting Digital Inputs

The PDO 3540 contains optical isolation circuitry to prevent the electrical noise inherent in switching amplifiers from interfering with your circuits. This arrangement also allows a wide range of input voltages to be used and gives you the option of using sinking or sourcing inputs.

A schematic diagram of the input circuit is shown on the next page. You must supply 5 - 12 volts DC to supply current to the LEDs on the input side of

the optoisolators. 5 - 24 VDC is acceptable for the SPEED and ENABLE inputs. You can operate the STEP and DIR inputs at 24 VDC if you add a 1000 ohm resistor to each input. Most CMOS and open collector TTL devices are directly compatible with this drive, as are typical PLC and proximity sensor outputs.

-18-

Page 19

STEP+

50% IDLE 50% IDLE

STEP-

PDO 3540 Input circuit

Sinking Circuits (NPN)

If your output devices sink current, then connect the “+” terminals to your positive power supply, and the “-” terminals to your signals (i.e. STEP-, DIR-, etc.). If you are using a TTL circuit to drive the PDO 3540, connect the “+” terminals to your 5 volt bus. No ground connection is needed. If you are using a PLC or proximity sensor, you’ll need a power supply.

Sourcing Circuits (PNP)

If your output devices can only source current (some PLC outputs are this way), connect the “-” terminals to the ground of the DC power supply that powers your output circuits. Then connect your signals to the “+” terminals (STEP+, DIR+, etc.).

Note: We refer to an input as being ON when current is flowing through the input. A signal is OFF when no current is flowing. An input is OFF when COM and the input terminal are at the same voltage, or when the input is left unconnected (open).

Tach Output

The Tach Out signal is provided for measuring the motor speed. It generates 100 pulses per revolution, so if you connect a frequency counter, the speed reads out in revs/second with two decimal places.

Do not connect the Tach output to more than 24 VDC.

The current into the T ach+ terminal must not exceed 20 mA.

Enable Input

ENABLE allows the user to turn off the current to the motor by setting this signal to logic 0. The logic circuitry continues to operate, so the drive “remembers” the step postion 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.

need to connect anything to the ENABLE input.

If you have no need to disable the amplifiers, you don’t

-19-

Page 20

Setting Phase Current

50% IDLE 50% IDLE

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 PDO 3540 is the peak current, not RMS.

The PDO 3540 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 eight switches. Five of the switches have a value of current printed next to them, such as 0.2 and 1.6. Each switch controls the amount of current, in amperes (A), that it’s label indicates. There is always a base current of

0.4 A. 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 2.2 amps per phase. You need the 0.4 A base current plus another 1.8 A.

2.2 (TOTAL) = 0.4 (BASE) + 1.6 + 0.2

Slide the 1.6 and 0.2 A switches toward the labels as shown in the figure.

CURRENT

(BASE = 0.4 A)

0.1

0.2

0.4

0.8

1.6

5 4321

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 use the idle current reduction feature unless your application strictly forbids it. Idle current reduction is enabled by sliding switch #6 toward the 50% IDLE label, as shown in the sketch below. Sliding the switch away from the 50% IDLE label disables the reduction feature.

Idle Current Reduction Idle Current Reduction

Enabled Disabled

-20-

Page 21

Current Set T able

0.4

AMPS/ PHASE

0.5

AMPS/ PHASE

0.6

AMPS/ PHASE

0.7

AMPS/ PHASE

0.8

AMPS/ PHASE

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

5 4321

1.2

AMPS/ PHASE

1.3

AMPS/ PHASE

1.4

AMPS/ PHASE

1.5

AMPS/ PHASE

1.6

AMPS/ PHASE

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

5432154321

54321

54321543215432154321

2.0

AMPS/ PHASE

2.1

AMPS/ PHASE

2.2

AMPS/ PHASE

2.3

AMPS/ PHASE

2.4

AMPS/ PHASE

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

543215432154321

54321

AMPS/ PHASE

2.8

AMPS/ PHASE

2.9

AMPS/ PHASE

3.0

AMPS/ PHASE

3.1

3.2

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

5432154321543215432154321543215432154321

0.9

AMPS/ PHASE

1.0

AMPS/ PHASE

1.1

AMPS/ PHASE

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

5 4321

1.7

AMPS/ PHASE

1.8

AMPS/ PHASE

1.9

AMPS/ PHASE

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

2.5

AMPS/ PHASE

2.6

AMPS/ PHASE

2.7

AMPS/ PHASE

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

3.3

3.4

3.5

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

AMPS/ PHASE

54321 54321 54321 54321

AMPS/ PHASE

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Page 22

Mounting the Drive.

You can mount your drive on the wide or the narrow side of the chassis.

Use for NARROW-SIDE mounting.

Use for WIDE-SIDE mounting.

DIR+

DIR-

STEP+

STEP-

Never use your drive in a space where there is no air flow or

where the ambient temperature exceeds 50 oC (120 oF). Never put the drive where it can get wet. Never allow metal particles near the drive.

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Page 23

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 1.4 HT17-071 1.65 x 1.65 x 1.54 parallel 30 1.7 HT17-075 1.65 x 1.65 x 1.85 parallel 40 1.7

5023-122 2.22 x 2.22 x 2.0 parallel 60 2.0

5023-123 2.22 x 2.22 x 3.0 parallel 100 2.5

5023-124 2.22 x 2.22 x 4.0 parallel 150 3.5 HT23-394 2.22 x 2.22 x 1.54 parallel 60 2.8 HT23-397 2.22 x 2.22 x 2.13 parallel 140 2.8 HT23-400 2.22 x 2.22 x 2.99 parallel 180 2.8

5034-348 3.38 x 3.38 x 2.50 parallel 130 3.5

Block Diagram

110 or

220 VAC

STEP

DIRECTION

ENABLE

HI/LO SPEED

TACH

EXT

joystick

ext speed

SPEED INPUT

Digital Oscillator

Joystick Interface

speed

Optical

Isolation

speed

osc bypass

fuse

accel

self test

Internal

Power Supply

Microstep Sequencer

-23-

steps/rev

power LED

MOSFET

Amplifier

3 State

PWM

Power

current

0.4 to 3.5 A/phase

50% idle

motor phase A

motor phase B

Page 24

T echnical Specifications

Amplifiers

Power Supply

Inputs

Dual, MOSFET H-bridge, 3 state, pulse width modulated (PWM) switching at 20 kHz. 0.4 - 3.5 amps/phase output current, dip switch selectable. 122 watts maximum output power. Automatic idle current reduction (defeatable) reduces motor current to 50% of setting after one second. Minimum motor inductance is 0.8 mH.

Linear, toroidal transformer based for high reliability and low noise. 100-120 or 200-240 VAC input, switch selectable. 50/ 60 Hz. DC voltage at nominal line voltage: 35 VDC full load, 40 VDC no load.

Speed, Enable: optically isolated, differential 5 - 24 VDC logic. 2200 ohms internal resistor.

Step, Direction: optically isolated, differential 5 - 12 VDC logic, 680 ohms internal resistance. (24 VDC with external 1000 ohm resistance).

Wiper: 0 - 5 VDC analog signal. Maximum recommended pot/ joystick impedance: 1K - 5K ohms. Joystick dead zone: +/- 80 mV. Potentiometer/analog signal dead zone: 40 mV.

Tach Output

Microstepping

In pulse & direction mode, motor steps on rising edge of STEP+ input (falling edge of STEP-). 0.25 µsec minimum pulse, 2 MHz maximum step rate. 1 µsec minimum set up time, 50 µsec minimum hold time for direction signal.

Optically isolated, uncommitted (open collector, open emitter) photo transistor. 30 VDC, 20 mA max. 100 pulses per motor revolution, 50% duty cycle (square wave).

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. 12800 steps/rev in OSC/JOY mode.

-24-

Page 25

T echnical Specifications (cont’d.)

7.80"

2.25"

1.125"

0.750"

5.00"

5.40"

0.200" (x6)

123456 123456

MOTOR

A+

A-

B+

B-

PDO 3540

Step Motor Driver

50% IDLE

JOYSTICK

OSC BYPASS

STEPS/REV

SELF TEST

ACCEL

EXT SPEED

0.1

0.2

0.4

0.8

1.6

CURRENT

HIGH SPEED LOW SPEED

(BASE = 0.4 A)

POWER

DIR+

DIR– STEP+ STEP–

EN+ EN–

SPEED+

SPEED-

TACH+ TACH–

CW WPR CCW

POWER

Recommended Joystick

Speed Ranges

Physical

Connectors

CE Marks

Fuses

Maurey Instrument Corp., Chicago, IL (773) 581-4555 JS31462S5T3 (2 axis) or SAJ2515-F-502 (1 axis)

LO speed range: 0 - 5 rev/sec HI speed range: 0 - 25 rev/sec Accel/decel range: 1 to 250 rev/sec/sec

Constructed with black anodized aluminum heat sink and heavy gauge steel housing. 2.25 x 5.4 x 7.8 inches overall. 4.0 lbs. Ambient temperature range: 0 - 50 oC. See page 26 for detailed drawing.

European style, pluggable screw termminal blocks. Motor: 4 position. Wire size: AWG 12 - 26 Signal Input/Output: 13 position. Wire size: AWG 16 - 28 AC Input: 3 position. Wire size: AWG 12 - 20

Complies with EN55011a, EN50082-1(1997), EN50178(1997) Wickman TR-5 style. Order from Digikey (1-800-DIGIKEY)

110V: P/N WK4250BK-ND (T 1.25 A IEC) 220V: P/N WK4243BK-ND (T 0.63 A IEC)

-25-

Page 26

Mechanical Outline

7.80"

2.25"

1.125"

0.750"

5.00"

5.40"

0.200" (x6)

123456 123456

MOTOR

A+

A-

B+

B-

PDO 3540

Step Motor Driver

50% IDLE

JOYSTICK

OSC BYPASS

STEPS/REV

SELF TEST

ACCEL

EXT SPEED

0.1

0.2

0.4

0.8

1.6

CURRENT

HIGH SPEED LOW SPEED

(BASE = 0.4 A)

POWER

DIR+

DIR– STEP+ STEP–

EN+ EN–

SPEED+

SPEED-

TACH+ TACH–

CW WPR CCW

POWER

-26-

Page 27

Notes

-27-

Page 28

11/2/99

Applied Motion Products, Inc.

404 Westridge Drive Watsonville, CA 95076

(800) 525-1609 Tel (831) 761-6555 Fax (831) 761-6544

http://www.applied-motion.com

-28-