Impulse PCW-5181 User Manual

Industrial Devices Corporation

The Only Microstepping Drive with:

Open Loop Stall Detect

Multi-Stepping Dynamic Smoothing Xtreme Smoothness

(OLSD™)

Motion Node

User’s Manual

P/N PCW-5181 Version 1.0

Revision History

Version: 1.0

April 2001

Industrial Devices Corporation (IDC) strives to maintain effective communication with all users and potential users of our products. If you have any questions or concerns regarding this technical manual or the product it covers, please contact:

Industrial Devices Corporation

3925 Cypress Dri ve

Petaluma, CA 94954

TEL: (800) 747-0064

FAX: (707) 789-0175

FROM OUTSIDE THE U.S. CALL (707) 789-1000

WEB SITE: www.idcmotion.com

EMAIL: info@idcmotion.com

Table of Contents

CHAPTER 1 - IMPULSE OVERVIEW ...............................................................................................1-1

CHAPTER 2 - SHIPPING CONTENTS .............................................................................................2-1

CHAPTER 3 - CONNECTING AND INSTALLING YOUR IMPULSE ...............................................3-1

ONNECTING A MOTOR TO THE IMPULSE

A. C B. S

ERIAL COMMUNICATION CONNECTIONS

.................................... ...... ....... ...... ....... ...... ....... ...... ...3-3

...................................................................................3-4

Making RS-232/RS-485 Connections ...................................................................................3-4

Daisy-Chaining Impulse Drives ............. ...... ....... ...................................................................3-5

Multi-Dropping with RS-485 ..................................................................................................3-5

Troubleshooting RS-232C Communication Problems ...........................................................3-6

ONNECTING AN

C. C

IDC K

EYPAD

..................................... .................................................... .........3-7

Using a Keypad with Impulse RS232C .................................................................................3-7

Using a Keypad with Impulse RS485 ....................................................................................3-7

ONNECTING

D. C E. LED DIAGNOSTIC F. CONNECTING

OUNTING THE IMPULSE DRIVE

G. M

OWER

AC P

NPUTS AND OUTPUTS

...................................... ................................................... ................3-8

NDICATIONS

................................................................................................. 3-8

.........................................................................................3-9

................................... .......................... .......................... ....... 3-10

Environmental and Installation Requirements .....................................................................3-10

Mounting Arrangements ......................................................................................................3-10

Impulse Dimensions ........................................... .................................................................3-11

Inserting and Removing Mounting Brackets from the Impulse ............................................3-12

Impulse DIN-Rail Mounting ................................ ...... ...........................................................3-13

CHAPTER 4 - CONFIGURING IMPULSE WITH APPLICATION DEVELOPER™ ..........................4-1

NSTALLING APPLICATION DEVELOPER ON WINDOWS

SING APPLICATION DEVELOPER

U F

INE-TUNING YOUR APPLICATION

XIS SETUP

OTOR

M M

ECHANICS

OMMAND

MOOTHNESS

X-S A

DVANCED

I/O S I/O D S

TORED MOVE SETUP

ILE MENU DIT MENU

E S

ETUP MENU

OMMUNICATIONS MENU UN MENU

R V

IEW MENU

PDATING YOUR IMPULSE OPERATING SYSTEM

...................................... ...... ....... ...... ....... ...... ...... ....... ...... ........................................4-10

.......................................................................................................................................4-11

...................................... ...................................... ....................................... ..............4-12

................................. ................................................................. .................................4-13

TREME SMOOTHING

DVANCED TUNING

ETUP

................................. ............................................. .............................................. .......4-18

ESCRIPTIONS

.................................. ................................ ................................. .................... 4-18

- E

..................................................................................................................................4-23

....................................... ...... ....... ...... ....... ...... ...... ....... ...... ........................................4-23

..............................................................................................................................4-23

.............................................................................................................4-24

....................................... ................................................... ........................................4-25

...................................... ................................ ................................ ...........................4-26

...................................................................................................4-2

...................................... .......................... .......................... ....... 4-10

™) ...................................................................................4-15

) ....................................... .................................................... .......4-17

DITING STORED MOVES

95/98/2000/ME/NT ................. ...... ....... ...... ...4-1

........................................................................4-21

: ................................... ........................................ 4-27

CHAPTER 5 - CONFIGURING IMPULSE WITH AN IDC KEYPAD .................................................5-1

Table of Contents

ECTION

S S

ECTION

NTRODUCTION TO THE

1 - I

ONFIGURING IMPULSE WITH AN

2 - C

FP100 I

MPULSE KEYPAD

EYPAD

IDC K

....................................... .................... 5-11

................................... ...... ....... ...... ...5-1

Configuring Impulse with the Keypad ..................................................................................5-12

Open a File ..........................................................................................................................5-12

Using the EDIT > SETUP Menus to Configure the Impulse ................................................5-12

MOTOR SETUP ..................................................................................................................5-12

COMMAND SETUP ............................................................................................................5-13

MECHANICAL SETUP ........................................................................................................5-15

MOTOR TUNING SETUP (X-Smoothness) ........................................................................5-16

ADVAN CED SE TUP ...................... ....... ...... ....... ...... ...... ....... ...... ....... ...... ....... ...... ....... .......5-17

I/O SETUP ..........................................................................................................................5-20

Move Menus - Using Stored Moves ......................... ...... ....... ..............................................5 -2 2

UNIT# ....................................... ............................................. ..............................................5-24

CHAPTER 6 - HARDWARE REFERENCE .......................................................................................6-1

MPULSE SPECIFICATIONS

EMOTE MOUNTING YOUR KEYPAD

XTENDING THE CABLE LENGTH TO YOUR KEYPAD EYPAD MOUNTING TEMPLATE

K I

MPULSE

PTIONAL ACCESSORIES FOR YOUR IMPULSE

MPULSE-APPLICABLE

I/O S

CHEMATICS

..............................................................................................................6-1

................................... ............. ............. ............. ............. .........6-2

...................................... ................... ................6-2

.................................... ............ ............. ............. ............. ............. ...6-3

.................................... .......................... .......................... ...................... 6-4

................................. ............. ............. ............. .........6-7

IDC M

OTORS

............................................................................................... 6-9

CHAPTER 7 - TROUBLESHOOTING THE IMPULSE ......................................................................7-1

ROUBLESHOOTING TABLE

IMITS TABLES

..............................................................................................................................7-3

................................... .......................... .......................... ...................... 7-1

CHAPTER 8 - PRODUCT SUPPORT ............................................................................................... 8-2

ARRANTY

& R

EPAIRS

.................................. ....................................................................... .........8-3

APPENDIX A: RECOMMENDED WIRING PRACTICES FOR IDC CONTROLS ............................ A-1

APPENDIX B - IMPULSE ADVANCED PROGRAMMING ..............................................................B-1

APPENDIX C - USING NON-IDC MOTORS WITH THE IMPULSE .................................................C-1

USTOM OR USER-DEFINED MOTORS

........................................................................................... C-2

INDEX........................................................................................................................END OF MANUAL

Chapter 1 - Impulse Overview

The Impulse is the latest microstepping drive from Industrial Devices Corporation and this innovative drive will move your appli cati ons with a combi nation of features previously unheard of in the motion control industry.

The Impulse is a self-contained microstepping drive designed to operate permanent-magnet linear and rotary hybrid step-motors. Its internal control hardware is based on a digital signal processor (DSP) operating a pair of IGBT power amplifiers. The Impulse is fully protected against shortcircuits and overheating.

Responding to users who demand the ultimate in value and reliability, the Impulse employs the following features and performance enhancements:

Feature Function

Open Loop Stall Detect Dynamic Smoothing Multi-Stepping Motion Node

Xtreme Smoothing

IDeal Performance Probe Automatic fine-tuning of the Impulse for optimum performance with the con-

I/O Capabilities 4 configurable inputs and one configurable output provide the user with

Configurable I/O Polarity I/O polarity can be set to Active High or Active Low ensuring compatibility

Diagnostic LED Green for power ON/ENABLED, flashing green for DISABLED, red for ON/

Ultra-Compact Packaging Top-notch performance, while consuming a minimal amount of space Resolution Up to 100,000 steps/rev FLASH Firmware Downloadable software facilitates quick upgrades over the internet Current Reduction Modes Enable Stop (current reduced to 75% of drive setting if no motion occurs

Anti-Resonance Provides optimum torque and nulls mid-range instability Integrate d C ooling Tunnel For maximum performance and multiple drive mounting capability Regenerative Circuit Dumps excessive power during deceleration

Allows a motor to run without an encoder and still be able to detect a stall Move profiles are smoothed to minimize jerk For full-stepping with the smoothness of microstepping 7 simple moves can be stored in the Impulse and activated via inputs or

serial port. This feature is optional. 6 component “gain” settings for low-speed smoothness, reduced vibration,

and more usable torque

figured motor

flexibility

with a wide range of controls

UNCONFIGURED, flashing red for FAULTS

during a user-programmed amount of time) Enable Idle (user-defined current reduction percentage if no motion occurs during a user-programmed amount of time)

Chapter 1 - Impulse Overview

This manual will enable you to 1) quickly setup and verify that your Impulse is operational, 2) configure and program the Impulse for your specific application, and 3) successfully troubleshoot possible performance problems.

1-1

Chapter 1 - Overview

This page intentionally left blank

1-2

Chapter 2 - Shipping Contents

Your Impulse will arrive equipped as listed in section #1. If any parts or accessories are missing, please call IDC Custome r Support at: (800) 747-0064. Sections 2 and 3 are provided as reference material.

- What You Will Receive if You Ordered the Following:

Chapter 2 - Shipping Contents

Impulse + FP100

(or FP220) Keypad

1. Impulse Microstepping Drive 1. Impulse Microstepping Drive 1. Impulse Microstepping Drive

2. AC power cord for Impulse 2. Motor Connector 2. AC power cord for Impulse

3. Motor Connector 3. AC power cord for Impulse 3. Motor Connector

4. FP100 (or FP220) Keypad 4. IDCMotion Software 4. FP100 (or FP220) -RS48 5 Keypad

5. Remote cable for Keypad 5. Impulse Quick Setup/Ref. Guide 5. Keypad Power Supply

6. Keypad mounting gasket 6. Impulse User’s Manual 6. Remote cable for Keypad

7. Keypad mounting template 7. Keypad mounting gasket

8. IDCMotion Software 8. Keypad mounting template

9. Impulse Quick Setup/Ref. Guide 9. IDCMotion Software

10.

Impulse User’s Manua

- Ordering and Identifying an Impulse

Using the tables below, fill in the boxes and you will be able to order or identify your Impulse:

IMPULSE Input Power Capability Drive Type Communication Accessories

Impulse Only

Impulse + FP100-RS485

(or FP220-RS485) Keypad

10. Impulse Quick Setup/Ref. Guide

11.

Impulse User’s Manua

IM L T4

Input Power Drive Type Accessories (order separately)

L Line Voltage 120 VAC T4 Stepper Drive, 4 A *FP_ _ _-_ _ Keypad Configuration

DB25BO 25 pin D-Shell Breakout Board

Capability Communication SS-IO 25 pin I/O Cable - 2 ft.

M Motion Node Version 2 RS232 SS-IO-6 25 pin I/O Cable - 6 ft. D Drive Version 4 RS485 SS-RS232 Serial Comm. Cable

PCS-5004 Keypad to PC Cable PCS-5110 Screw-Mounting Bracket PCS-5111 DIN Rail Mounting Bracket *FP100, FP220, FP100- R S485, or FP220-RS485

- Accessories Currently Available for the Impulse

SS-RS232 Impulse to PC Cable

DB25BO Screw Terminal Breakout Board

SS-IO (2ft. cable) SS-IO-6 (6ft. cable)

PCS-5004 Keypad to PC Cable

PCS-5110 Screw-Mount Bracket

PCS-5111 DIN Rail Mounting Bracket

2-1

Chapter 2 - Shipping Contents

This page intentionally left blank

2-2

Chapter 3 - Connecting and Installing Your Impulse

The purpose of this chapter is to provide information that will help you connect and install your Impulse drive in its intended application.

The Impulse drive easily interfaces with a PC, PLC, Step & Direction Motion Controller, or IDC keypad. Block diagrams of several Impulse-based applications are shown below.

Typical Impulse Applications

Keypad

PLC

I/O TX RX

RS232C

1 - 7 Stored Moves

961/962 Indexer

Single or Multi-Axis

Unit #1

RS232C

RS485

Digital Inputs (4)

Digital Output (1)

Fault Output

Step/Dir/Shutdown

Impulse

Unit #99

PLC

I/O

RS485

Unit #1

Unit #32

3-1

Chapter 3 - Connecting and Installing Your Impulse

Read This Page Bef ore Your Begin!

Always use cau ti on

• driven cylinders are capable of exerting trem endous force agai ns t an obstruction.

Always en sure that power to yo u r system is OFF

• mainten ance activity, or making any con nections or adjus t m ents.

Do not insert objects into the Impulse drive

• sonal injury, and equipment could be damaged beyond repair.

when working with mechanica l syste ms. Ge a rs an d s crew-

CAUTION!

before performing any

. High volt ages could cause per-

Do not open the Impulse drive.

• is opened.

The factory warranty will be voided if the drive

3-2

A. Connecting a Motor to the Impulse

Connecting an IDC Motor

The A+, A-, B+, and B- phase outputs power the motor windings.

Connect motor wires to the motor connector (supplied) and plug the wir ed con nector into the dr ive. Drawings below provide color codes for IDC motors.

GND is internally connected to the earth pin on the power connector. This provides a convenient terminal for grounding the motor frame and a motor cable shield. Note: If the motor is mounted on a machine that is grounded, do not connect the motor to GND.

The two INTLK pins must be jumpered together on the motor connector to allow power to the motor.

CAUTION! Do not remove the motor connector from the Impulse drive while power is applied. Removing the connector while power is applied could damage the connector pins.

Do not extend the interlock jumper wire to provide protection for anot her connector interface. The

interlock circuit is susceptible to trips caused by noise-pickup in cables (20 kHz switching).

Chapter 3 - Connecting and Installing Your Impulse

Note: This is a high-impedance safety-interlock circuit. If the interlock wire breaks, or the connector is removed, the current to the motor is immediately stopped, the drive faults (latches) and the LED on the front panel of the Impulse will flash five times (see LED Diagnostics on p. 3-8).

IDC Motor Wiring/Color Codes

Series Parallel Parallel

YELLOW

WHT/YEL

WHT/RED

RED

SHIELD

BLACK

WHT/BLK WHT/ORG

ORANGE

WHT/YEL

SHIELD

WHT/BLK

Connecting a Non-IDC Motor

YELLOW

WHT/RED

RED

BLACK

WHT/ORG

ORANGE

Motor Connector

GREEN/YEL

P31/32/33S12/21/23/32/33 P21/22, S21/23

YELLOW

WHT/RED

RED

WHT/YEL

BLACK

WHT/ORG

ORANGE

WHT/BLK

Quick Disconnect Cable Wire Color

A+ Red

A- Red/Yellow

*GND Green

B+ Red/White

B- Red/Black

*Gray-colored Quick Disc. cables are shielded - connect shield to GND.

One of the Impulse drive’s more advanced features, Open Loop Stall DetectTM, is guaranteed only when matched with one of IDC’s S or P-series motors.

IDC’ s S and P series motors have cust om windi ngs to pro vide optimu m dynami c performan ce with the Impulse. If you use another manufacturer’s motor, refer to Non-IDC Motors in Chapter 6, Hardware Reference, for more information.

3-3

Chapter 3 - Connecting and Installing Your Impulse

B. Serial Communication Connections

Making RS-232/RS-485 Connections

The standard Impulse drive uses a 3-wire implementation of RS-232C. The RX, TX, and COM lines are the serial signals supported. No hardware handshaking is required. Note that some RS-232C devices require handshaking, such as R TS and C TS. It is the respons ibility of the user to disable this handshaking via software or hard ware (see Troubleshooti ng RS -232C Com munica tion P roblems on page 3-6 for more information).

If you will be using RS-485 communication, the typical 5-wire interface connection to a “host” is shown below. See “Multi-Dropping Impulse Drives with RS-485” on the next page for information on using termination resi stors. Note: the maximum cable length for RS-485 communication is 4,000 feet.

Make your RS-232C connecti on as shown below . The PC Cable (IDC P/N SS-RS 232) shown below, is an ideal choice for making trouble-free RS-232C connections to the Impulse.

IDC P/N

SS-RS232

Comm Port Settings

RS-232C/RS-485 Baud Rate 19200 (fi xed) Stop Bits 1 Data Bits 8 Parity None XON/XOFF Yes

9-Pin

Connector

RS-485 Host

3 (TX) 2 (RX) 5 (COM)

TX-

TX+

RX-

RX+

COM

COM PORT

RS-232C

COM PORT

RS-485

3-4

Daisy-Chaining Impulse Drives

Your Impulse also supports daisy chaining. The unit address (range 1-99) can be set via the keypad or in Application Developer.

Rules for Daisy Chain Operation

1. Units on a daisy chain must be “d evice add ressed ’ (nu mber ed) in o rder for commu nications to work properly. A unit’s address should increment upward as you move down the daisy chain from the PC (see illustration below).

2. Do not duplicate unit addresses.

3. Any loose RS-232C connections or miswiring along the daisy chain will cause communications to fail. Please double check wiring if communication problems arise.

4. Please call IDC if you need to daisy chain more than 99 drives.

5. The hardware diagram below shows how to connect the daisy chain.

Chapter 3 - Connecting and Installing Your Impulse

PC/Host

RS-232C

Device

COM

Multi-Dropping with RS-485

If you will be “multi-dropping” Impulse drives with RS485, add 120-ohm termination resistors across RX and TX connections of the last unit as shown below:

RS-485

Host

Impulse

Unit 1

RX TX COM

Impulse

Unit 2

RX TX COM

Impulse

Unit 3

RX TX COM

Add resistors as shown here:

3-5

Chapter 3 - Connecting and Installing Your Impulse

Troubleshooting RS-232C Communication Problems

If communications between computer and Impulse are unsuccessful, one or more of the following procedures will usually solve the problem:

1. Host transmit (TX) must be con nected to receive (RX) of the dr ive unit, and receive ( RX) of the host must be connected to transmit (TX) of the drive. If communication fails, try switching connections on either the host or the drive.

2. Some serial ports may require handshaking. Jumper R TS to C TS, and DSR to DTR (s ee tab le).

3. Check your ground connections. The COM

Jumpers 9 pin D 25 pin D

RTS to CTS 7 to 8 4 to 5

DSR to DTR 4 to 6 6 to 20

terminal should be isolated from earth gro und. Use DC common or signal ground as your reference - do not use earth ground or shield.

4. Voltage between TX and COM should be -8.0 to -12.0 VDC. Voltage between RX and COM should be 0 to -0.5 VDC. Consult factory if measured voltages are outside these ranges.

5. For RS-232C only: If any cable is more than 50 ft. long, you should use a line driver, optical coupler, or shield. Shields must be connected to earth ground at one end only.

6. Reminder for PDA Users: Prog rams such as Palm’s Hotsync Manager take over a comm. port. Be sure to close/exit these types of programs if you are using serial communication with your Impulse.

7. Important Application Note Regarding PC Com Port: PC FIFO (First In First Out) Buffers should be used and adjusted t o the highe st settings f or fastest pe rformance. This applies to bot h Receive and Transmit Buffers.

• In your Windows operating system, go to Start > Settings > Control Panel > System >

Device Manager > Ports (Com 1, Com 2) > Port Settings > Advanced > Buffer.

3-6

• Select Use FIFO Buffers, and ensure both Buffers (Receive and Transmit) are adjusted to

the High setting for best performance.

C. Connecting an IDC Keypad

Two versions of IDC keypads can be used with the Impulse drive. The FP100 works only with the Impulse, while the FP220 can be used with the Impulse as well as IDC’s Smart Drives (see keypad-specific information below).

Chapter 3 - Connecting and Installing Your Impulse

COM PORT

The COM PORT on the front panel of the Impulse is used for connecting either version of keypad.

Power is applied to either version of keypad when power is connected to the Impulse.

Using a Keypad with Impulse RS232C

FP100 Keypad

Connect the FP100 Keypad to the Impulse with the cable supplied with the keypad.

FP220 Keypad (Version 3.0 or higher)

Only FP220 Keypad ver sions 3.0 an d higher will wo rk with the Impulse drive.

T o use an FP220 keypad with your Impulse, y ou mu st set DIP-switch #3 to the ON position and switch #s 1, 2, and 4 to OF F.

The FP220 uses the same keypad cable as the FP100.

I/O

Keypad with Impulse RS232C

Keypad

Using a Keypad with Impulse RS485

Impulse RS485 requires either the FP100-RS485 or FP220-RS485 keypad.

On the FP220-RS485 keypad only, set DIP switches as described above. Both FP100-RS485 and FP220RS485 keypad are connected as follows:

1. Connect the keypad cable to the keypad and to the Impulse.

2. Connect the keypad power supply cable to the keypad as shown in the illustration.

3. Plug in the AC adapter.

Keypad with Impulse RS485

Keypad

3-7

Chapter 3 - Connecting and Installing Your Impulse

D. Connecting AC Power

There is no ON/OFF switch on the Impulse. AC power is applied by plugging the *power cord (included) into the connector on top of the Impulse.

Input voltage must be in the range of 120 VAC ± 10%, single phase, 50/60 Hz, 500 VA max @ 4 Amps. Operation outside these specifications will result in reduced performance, drive faults, and may damage the drive.

When power is applied, the LED on front of the drive should briefly turn red, then steady green. If a red light is present, see Section E of this chapter for more information on fault detection codes.

*Note: If the AC power cord requires replacement, the replacement must be rated for Hard Usage or Extra Hard Usage.

To AC Power Supply

E. LED Diagnostic Indications

The Impulse drive detects and resolves fault conditions (see table below). Faults are signaled by either a steady red or a flashing red LED on the front panel. A solid green LED indicates normal operation. A slowly flashing green LED indicates a shutdown (disabled), while a rapidly flashing green LED signals a regen dump. Faults are cleared by either 1) cycling power, 2) sending a RESET command via the serial port or configurable logic input, or 3) probing the motor if the LED is steady red.

For more detailed explanation of faults refer to Chapter 7, Troubleshooting the Impulse.

Diagnostic LED Indications

LED Signal Indication

Green (steady) Normal Operation

Slow Flashing Green Shutdown

Quick Flashing Green Regen Dump

Red (steady) Motor Not Probed

1 Flash Red Stalled 2 Flashes Red Undervoltage Fault 3 Flashes Red Overvoltage Fault 4 Flashes Red Overcurrent Fault 5 Flashes Red Interlock Fault 6 Flashes Red Overtemperature Fault 7 Flashes Red EEPROM Checksum Fault

LED

3-8

F. Connecting Inputs and Outputs

Connect your inputs and outputs to IDC’s 961/962 Indexer according to the information below. Schematics for Impulse I/O circuits can be found in Chapter 6, Hardware Reference

Application Notes

1. On 961/2, ensure that Step/D irection and Dif ferential Jumpers are installed (see 961/2 manu al).

2. If using IDC P/N SS-I/O or SS-I/O-6 cable, cut one end of the cable if necessary (see table below for SS-I/O cable color-code). If making your own cable, or using a non-IDC indexer, refer to the Impulse I/O Schematics (Chap. 6) and the 25-pin Connector drawing below.

3. Use a shielded cable, and connect the shield only at the Impulse. Connect shield to pin 9.

4. IDC offers a 25-pin screw-terminal breakout board (shown below) to add convenience and flexibility to your application. Terminals on the breakout board match the pins of the 25-pin connector on the Impulse.

5. When wiring TTL signals to other manufacturer’s indexers, the Step TTL command signals from the controller should be wired to Step +, the Direction signal to Dir + , and the Shut down signal to SD + (Step -, Dir -, and SD - should not be connected). Remember, th e drive common must be connected to the controller common.

Chapter 3 - Connecting and Installing Your Impulse

6. Activating the Shutdown input disables the drive amplifier and de-energizes the motor. Wh en this input is OFF the drive is enabled and the motor is energized. The polarity of this input is configurable.

7. The open-collector Fault Output turns ON (Active High) when any one of the LED- indicated conditions occur (see Section E, LED Diagnostic Indicators). The output stays ON while the LED flashes.

IDC Indexer

(962 Dual-Axis Shown)

Breakout

Board

P/N DB25BO

IDC Cable P/N: SS-IO/SS-IO-6

Pin Impulse Signal Wire Color Pin Impulse Signal Wire C ol o r Pin Impulse Signal Wire Color

1 STEP + Brown 10 COM Gray 19 COM Black/White 2 STEP - Red 11 COM White 20 Reserved Red/Black 3 DIR + Orange 12 Reserved Black 21 Reserved Orange/Black 4 DIR - Pink 13 Reserved Brown/White 22 COM Yellow/Black 5 SD + Yellow 14 INPUT 1 Red/White 23 Output 1 Green/Black 6 SD - Green 15 INPUT 2 Orange/White 24 Reserved Gray/Black 7 FAULT + Light Green 16 INPUT 3 Green/White 25 Reserved Pink/Black 8 FAULT - Blue 17 INPUT 4 Blue/White

S T U P T U

COM COM

S T U P N

2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

Note: Cable SHIELD is internally connected to the

DB25 metal housing.9 Drain Violet 18 COM Violet/White

SHLD FLT-

FLT+

E V

SD-

I R

SD+

DIR-

DIR+

STEPSTEP+ SHLD COM +5 ZZ+ BB+ AA+

3-9

Chapter 3 - Connecting and Installing Your Impulse

G. Mounting the Impulse Drive

This section includes installation requirements, Impulse dimensions, installing and removing mounting brackets, and mounting the Impulse on a DIN rail.

Environmental and Installation Requirements

• Operating Ambient Temperature: Max. 50º C (122º F) @ 4 Amps

• Storage Temperature: Max. 65º C (149º F)

• Not intended for use in humidity above 95% (non-condensing), or at altitudes greater than 3,048 meters [10,000 ft.]

• Heat Dissipation @ 4 A (typical): 32 Watts

• Leave 6 inches above and below drives for airflow and wiring.

• Leave 0.1 inch between drives for easier mounting.

• Air supplied to the Impulse must be uncontaminated.

Mounting Arrangements

The illustration on the right shows an example of an acceptable mounting arrangement.

COM PORT

I/O

COM PORT

I/O

COM PORT

I/O

COM PORT

I/O

6.0 in.

COM PORT

I/O

COM PORT

I/O

COM PORT

I/O

COM PORT

I/O

3-10

Impulse Dimensions

Impulse with DIN-rail Mounting Bracket (P/N PCS-5111

Chapter 3 - Connecting and Installing Your Impulse

TS 35 DIN RAIL

5.599

1.779

6.365

Impulse with Screw-type Mounting Bracket (P/N PCS-5110)

1.779

6.365

5.599

10-32 screw with .305'' head ∅

6.000

1.779

3-11

Chapter 3 - Connecting and Installing Your Impulse

Inserting and Removing Mounting Brackets from the Impulse

Both Impulse mounting brackets are interchangeable and each is inserted or removed according to the following procedures. No tools are required to insert a bracket, however a flat-bladed screwdriver is required for removal. If additional brackets are required, see Chapter 2, Shipping Contents, for part numbers.

Installation of Bracket

1. Insert the bracket into the bracket housing from the top side of the Impulse as show n in the drawing on the right.

2. Slide bracket downward until a single click is felt (detent position). The bracket will be seated in the position shown at righ t. Note: If you push the bracket beyond the detent position (second click), it will be necessary to push the bracket back to the detent position.

Do not attempt to remove the bracket by pulling it from the bottom of the bracket housing. Both brack et and bracket housing coul d be per manent ly damaged.

(DIN Rail Bracket Shown)

Installation

Slide Bracket into Position as Shown Here

Insert

Bracket

Removal of Bracket

(DIN Rail Bracket Shown)

1. Insert the tip of a flat-bladed screwdriver between the bracket-release arms as shown in the drawing at right.

2. Gently twist the tip of the screwdriver until the arms are spread apart enough to clear the detent mechanism on the housing. Maintain this position.

3. While holding the arms apart with the screwdriver, push the bracket toward the top of the bracket housing as shown in the drawing.

Do not attempt to remove the bracket by pulling it from the bottom of the bracket housing. Both brack et and bracket housing coul d be per manent ly damaged.

Removal

Insert screwdriver blade perpendicular to bracket (profile of blade shown in spread position)

Twist until arms are spread apart - hold in position

Push bracket free of

arms and out the bracket housing

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Impulse DIN-Rail Mounting

The DIN-rail mounting system is a combination of 1) a removable mounting bracket, which locks the drive onto the DIN-rai l (ins tallation on pr evious p age), plus 2) the DIN-r ail hang er on t he upper rear part of the housing that suspends the weight of the drive on the rail.

Chapter 3 - Connecting and Installing Your Impulse

Mounting the Impulse on the DIN-Rail

1. Hook the top of the DIN-rail hanger over the top of the DIN-rail.

2. Rotate the Impulse drive downward until it locks into place on the rail.

3. Pull back slightly on the drive to ensure it is securely fastened to the rail.

Removal of Impulse from the DIN-Rail

Mounting

Impulse Securely Mounted on DIN-Rail

1. Ensure power to the drive is OFF.

2. Remove the motor connector.

3. Insert tip of flat-bladed screwdriver into slot provided on the bottom of the mounting bracket (see drawings on the right).

4. Gently pry down ward unti l the brack et disconnects from the rail. Note: The bracket will fall approximately 1 inch, but will still be retained by the Impulse housing. Do not attempt to remove the bracket by pulling it from the housing.

5. The bracket can be reset to the detent position by pushing upward until a click is felt (see “Installation of Bracket” on the previous page).

Removal

Insert screwdriver blade and pull downward

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Chapter 3 - Connecting and Installing Your Impulse

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Chapter 4 - Configuring Impulse with Applic ation Developer

Chapter 4 - Configuring Impulse with Application Developer™

This chapter covers the installation and use of IDC’s Application Developer software to configure your Impulse drive.

Installing Application Developer on Windows 95/98/2000/ME/NT

1. Place the IDC CD in your CD-ROM drive and click on the Start button.

2. Click on Run.

3. Type the following in the Command Line box that appears (replace “x” with your CD drive letter if different): x:\App_Dev\Setupex.exe

4. Click OK and follow the onscreen instructions.

5. Restart Windows (recommended).

There are no known installation problems with Application Developer, but please call the IDC Applications Department at (800) 747-0064 or (707) 789-1000 (from outside U.S.) if you need assistance installing this software.

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Chapter 4 - Configuring Impulse with Application Developer

Using Application Developer

Application Developer’s graphic user interface allows you to configure and program your Impulse using an appropriately equipped computer. Upon starting Application Developer you will be given four options for beginning the configuration of your application (see window below).

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page 4-5

Select from one of the following options to begin configuring your Impulse:

1. Upload Project. If your drive has already been configured, this option allows you to upload a project file from the drive for editing (modification), troubleshooting, etc. See Upload Project on the next page for more information on using this option. The Project Wizard is the best method for initial drive configuration and building a new project file.

2. Launch Now - Allows you to go directly to the main menu or tool bar buttons to quickly configure or change project parameters. See Launch Now on page 4-4 for more information.

3. Project Wizard - Clickin g on the Project Wizard button will take you through the quickest, most accurate method of configuring the initial setup parameters for your project file (see page 4-5 for details).

4. Open an Existing Project. To bypass the Project W izard and select a stored file from the Open File window, click on the Open an Existing Project button (see page 4-4).

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Upload Project

1. Begin by clicking the Upload Project button on the Application Developer Startup window. Yo u will see the Control Type Selection menu (shown right).

2. Configuration begins by selecting your Impulse from the list of Steppers. Click OK.

3. Select the Port you will use to connect the Impulse.

Chapter 4 - Configuring Impulse with Applic ation Developer

Comm Port Settings

(for reference only)

RS-232C/RS-485

Baud Rate 19200 (fixed) Stop Bits 1 Data Bits 8 Parity None XON/XOFF Yes

4. Select the Unit Number (from 1 - 99) of the Impulse being configured.

5. To test communication u sing the current setup, click on Test Connection. Click OK.

6. Skip the section on Using the Project Wizard and go to Fine Tuning Your Application.

Note: Echo and Mode are not available; they have no effect on the Impulse drive.

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Chapter 4 - Configuring Impulse with Application Developer

Launch Now

This method of begi nning Application Develo per is typically used by more experienced users o f IDC products. Select your Impu l se vers ion and press OK. You can now go directly to the Main Menu or tool bar buttons to configure the Impulse (see Fine-Tuning Your Application).

Open an Existing Project

If you want to open a project file which has been st ored on disk (not in the Impu lse), select Open an Existing Project. Select the desired file and click on the Open button. After opening an existing

project file, it is still possible to use the Project W izard at any time by simply clicking on the W izard toolbar button. See Fine-Tuning Your Application if you do not wish to use the Project Wizard.

4-4

Using the Project Wizard

1. Click the Project Wizard button on the Application Developer Startup window.

• Select the product you are configuring, Impulse in this case, and click on Next.

• The Wizard Navigator (left side of window) allows you to quickly locate your current posi-

tion in the setup process. The column of boxes represents the parameter being configured. A box’s color r epresents its configuration status, i.e. gray indicates a parameter not yet configured, yellow indicates the parameter currently being configured, and black indicates completed configuration of the parameter.

Wizard Navigator

Chapter 4 - Configuring Impulse with Applic ation Developer

2. Click on the Next button and the Motor setup window will appear . The configuration pro cedure in Motor Setup differs slightly depending upon whether you are using IDC or Custom (userdefined) motor (see A ppendix C t o configur e a custom mo tor). IDC -supplied motors hav e been precisely characterized in motor files which reside in an Application Developer directory . These files cannot be altered or deleted. User-defined (custom) motor files must be created by the user.

If you want to change the operational characteristics of an IDC m otor, you can do so b y selecting an IDC motor from the scrollable list and saving it under a new file name in the Motor Editor (the original motor file remains unchanged under its original file name).

• From the pull down menu, s elect the IDC mot or you will be us ing, or click on Add Custom

Motor and see Appendix C for information on configuring a custom motor file.

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Chapter 4 - Configuring Impulse with Application Developer

3. Click Next and the first of three possible Mechanics setup windows will appear. The Mechanics window that appears depends on the selection made in the Select an IDC

Mechanical System list.

Mechanics window A (shown below) appears when a Motor Only is being configured. This

window shows the IDC motor or user-defined file name in the Part # text input box, and the Motor Rotor Inertia (in kg-cm

• Select Motor Only.

• Load Inertia - Enter Load Inertia in the text input box.

• Move Unit - Choose your move unit from the pulldown menu.

) of the motor being configured.

Mechanics window B (below) will appear if an IDC Mechanical System (other than Motor Only) is selected. This window allows you to select an IDC Mechanical System, the Part # of the system, and the Stroke Length, Travel, Gear Ratio, or Table Diameter of the system.

• Select the category of IDC Mechanical System you are using.

• Select the Part # of the system.

• Select the Stroke Length (cylinders), Travel (tables), Gear Ratio (gearmotors), or Table

Diameter (rotary tables).

• Enter the Load Ma ss (cylinders and ta bles), o r Load Inertia (gearmo tors and rotary tables).

• Select the Move Unit for the system.

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