Intelligent Motion Systems INT-481 Quick Reference

intelligent motion systems, inc.

Excellence in Motion

TM

QUICK REFERENCE

370 N. MAIN ST., PO BOX 457, MARLBOROUGH, CT 06447

PH: [phone], FAX: [phone]

Internet: www.imshome.com, E-Mail: [e-mail]

TM

INT-481

INTERFACE BOARD FOR THE IM481H DRIVER

INT-481 Quick Reference Guide

The primary function of this Quick Reference Guide is to aquaint
the user with the specifications, basic wiring and configuration of
the INT-481 Interface Board for the IM481H Driver. More
information is available on both products in the full IM481H
product manual saved in Acrobat PDF format on the IMS Product
CD, shipped with the product. It also may be downloaded from
the IMS web site at http://www.imshome.com.

Notes And Warnings

Please observe the following when handling, connecting and using
your INT-481 Interface Board. Failure to observe these points may
result in damage to the Interface Board or the IM481H Driver. All
warranty and disclaimer information is located in the full product
manual on the CD and should be referenced for more information.

For More Information:

See the complete IM481H Product Manual

on the IMS Product CD or at www.imshome.com

Electrical Specifications*

MIN TYP MA X UNIT

Opto Supply

Isolated Inputs .......................................... +5 ........................ +40 ........ V

Input Forward Current

Isolated Inputs ............................................5 ............................1 5 ....... mA

Opto Input Forward Voltage

Isolated Inputs .......................................................... 1. 5 ...... 1. 7......... V

Reverse Breakdown Voltage

Isolated Inputs ............................................5 ............................................... V

Signal Output Current

Full Step, Fault ............................................................................20 ....... m A

Drain Source Voltage

Full Step, Fault ..........................................................................1 00 ........ V

Drain Source Resistance

Full Step, Fault, IDS= 25mA) ..........................6 .5 ..........................Ω

* All test data was taken at 25°C and +V = 45 VDC.

INT-481 P1 Connector Pin Assignment

Output Current Adjust/Current Reduction*

The INT-481 utilizes the IM481H’s internal current source to
adjust the Output Current of the IM481H. To calculate both the
Run Current and the Reduced Current** (hold) refer to the
IM481H instruction manual. The figure below shows the resistor
connections for both run and hold currents.

* When connecting both the current reference and current reduction resistors,

connections should be made as short as possible to minimize the noise coupled
into the driver.

** WARNING! DO NOT install the Current Reduction resistor when the JP2 jumper is

in the “ENON” position. See JP2 under “Isolated Inputs”.

Pin 7

+5VDC Optocoupler Supply

Step Clock Pin 9

CW/CCW Direction Pin 8

Enable/Disable Pin 5

Reset Pin 6

OPTO/+5V

+5V

JP1

GRN

RED
LED1

FAULT

POW

ER

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

1

3

JP2

ENOFF/ENON

1

3

JP1

OPTO/+5V

1
2
3
4

SW1

MS0
MS1
MS2
MS3

21

1

ØB

ØB

ØA

ØA

ENA

RST

+5V

OS

DIR

STP

CLK

FLT

FUL

STP

+V

GND

CUR

ADJ

CUR

RED

1

3

JP2

ENOFF/ENON

1

3

JP1

OPTO/+5V

Isolated Inputs

JP1: If the shunt is placed on the “OPTO” side of the jumper the
power for the Opto Isolators must be provided by the user at Pin
7 on the P1 connector. If the shunt is placed on the “+5V” side of
the jumper then the Opto Isolators will be powered by the
on-board supply and electrical isolation between the inputs and
the drive power will be eliminated.

JP2: If the shunt is placed on the “ENON” side of the jumper then
the drive outputs will be automatically disabled approximately 0.5
seconds after the last step clock input.

NOTE: In this mode the current reduction resister MUST NOT be
used or it will cause erratic operation of the driver. If the shunt is
placed on the “ENOFF” side of the jumper then a current reduc­tion resister can be used to set the level of current in the motor
after the last step clock input.

Typical Opto Isolated Inputs

JP1 And JP2 Jumpers

Revision 061605

GRN

RED
LED1

FAULT

POWER

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

1

3

JP2

ENOFF/ENON

1

3

JP1

OPTO/+5V

1
2
3
4

SW1

MS0
MS1
MS2
MS3

21

1

Pin 13

Pin 14

Pin 15

Current Adjust Resistor

1/8 W 1% W

Reduction Adjust Resistor

1/8 W 1% W

WARNING! The INT-481 Interface Board and IM481H Driver
components are sensitive to Electrostatic Discharge (ESD). All
handling should be done at an ESD protected workstation.

WARNING! Hazardous Voltage Levels may be present if you are
using an open frame power supply to power the INT-481 Interface
Board and IM481H Driver.

WARNING! Ensure that the Power Supply output voltage does not
exceed the maximum input voltage of the IM481H Driver.

WARNING! Do not operate the IM481H Driver without a
Current Adjustment Resistor! If you are installing the INT-481

Interface Board the resistors may be added to it.
A resistor MUST be placed between the Current Adjust Input (Pin

14) and ground (Pin 13) to keep the IM481H Driver, the INT-481
Interface Board and/or motor in a safe operating range.

WARNING! Do not connect or disconnect the motor leads or the
AC power supply with power applied.

Please see the motor and driver documentation for other warnings
and notes.

Pin #

Pin Name

Description

1

Phase B

—

—

Phase B Output

2

Phase B

Phase B Output

3

Phase A—Phase A Output

—

4

Phase A Phase A Output

5

Enable When this input is HIGH, motor phases are energized.
6 Reset When LOW, this input will Reset the Driver.
7 Opto Supply +5 to +24 VDC external Optocoupler power supply.

8

Direction

This input changes the direction of the motor. The physical
direction depends on the connection of the motor windings.

9

Step Clock

A positive going edge on this input advances the motor one
increment. The size of the increment is dependent on the
Microstep Select Inputs.

10

Fault

This Output indicates a short circuit has occurred or a low
was detected on the Fault Input. This Output is active HIGH.

11

Full Step

This Output indicates when the driver positions the motor
one Full Step. This output can be used to count the number
of Full Steps the motor has moved regardless of the
number of Microsteps. This output is active HIGH.

12

+V +12 to +48 VDC Motor Power Supply.

13

Ground Power Supply Ground.

14

Current
Adjust

Phase Current Adjustment Input. A voltage applied to this
Input sets the peak Phase Current of the motor.

15

Current
Reduction

Phase Current Reduction Input. A resistor connected
between this pin and Pin 14 (if used to set motor current)
will proportionately reduce the current in both windings
approximately 0.5 seconds after the last positive edge of
the Step Clock Input.

© Intelligent Motion Systems, Inc.

LED Indicators

The green LED is controlled by the on-board +5VDC power supply.
The red LED is controlled by the Fault Output of the IM481H. If the

red LED is illuminated turn off power and check for a system fault.
A fault may be caused by a short or incorrect wiring of the motor

or power supply. A fault condition can only be reset by cycling
power or toggling of the Reset Input on P1 Pin 6. In the case of
an over temperature fault allow the drive to cool before re­applying power.

Fault Protection

The INT-481 adds phase to ground fault protection to the
IM481H. If a phase to ground fault is detected the IM481H will
latch the signal, set the Fault Output and illuminate the red Fault
LED. To clear the fault condition, the IM481H will have to be
Reset or power will need to be cycled.

The INT-481 buffers the IM481H Fault Output signal through an
open drain N-channel FET. The signal at the terminal strip is
inverted and is active LOW.

In the case of an over temperature fault, neither the red LED or
the Fault Output become activated. The IM481H’s motor outputs
will disable. They will not re-enable until the drive cools to a safe
operating level.

Full Step Output

The INT-481 buffers the IM481H Full Step Output through an
open drain N-channel FET. The signal available at the terminal
strip is inverted and is active low. Reset or Power Up = Full Step.

Recommended Wiring

Logic level cables must not run parallel to power cables. Power
cables will introduce noise into the logic level cables and make
your system unreliable.

Logic level cables must be shielded to reduce the chance of EMI
induced noise. The shield needs to be grounded at the signal
source to AC ground. The other end of the shield must not be
tied to anything, but allowed to float. This allows the shield to act
as a drain.

Motor cabling in excess of 1 foot requires twisted pair shielded
cable to reduce the transmission of EMI. The shield must be
connected to AC ground at the driver. The other end of the shield
must not be tied to anything, but allowed to float. This allows the
shield to act as a drain.

Power supply leads to the driver need to be twisted. If more than
one driver is to be connected to the same power supply, run
separate power and ground leads from the supply to each driver.

Refer to the IM481H operating instructions for recommended
motor and power supply cables.

Mechanical Specifications

Dimensions in Inches (mm)

Resolution Microstep Select DIP Switch Settings

Microstep/Step

Steps/Rev

SW 1:1

(MSEL0)

SW 1:2

(MSEL1)

SW 1:3

(MSEL2)

SW 1:4

(MSEL3)

Binary Microstep Resolution Settings (1.8˚ Motor)

2
4

8
16
32
64

128
256

400
800

1,600

3.200

6,400
12,800
25,600
51,200

ON ON ON ON
OFF

ON ON ON

ON

OFF ON ON

OFF

OFF ON ON

ON

ON OFF ON

OFF

ON OFF ON

ON

OFF OFF ON

OFF

OFF

OFF ON

Decimal Microstep Resolution Settings (1.8˚ Motor)

5
10
25
50

125
250

1,000
2,000

5,000
10,000
25,000
50,000

ON ON ON

OFF

OFF

ON ON OFF

ON

OFF ON OFF

OFF

OFF ON OFF

ON

ON OFF OFF

OFF

ON OFF OFF

Invalid Resolution Settings: May Cause Erratic Operation

ON OFF OFF OFF
OFF

OFF OFF OFF

GRN

RED
LED1

FAULT

POW

ER

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

1

3

JP2

ENOFF/ENON

1

3

JP1

OPTO/+5V

1
2
3
4

SW1

MS0
MS1
MS2
MS3

21

1

ØB

ØB

ØA

ØA

ENA

RST

+5V

OS

DIR

STP

CLK

FLT

FUL

STP

+V

GND

CUR

ADJ

CUR

RED

1
2

3

4

SW1

MS0
MS1
MS2
MS3

ON

Microstep Resolution Selection

The number of microsteps per step is selected by the dip switch
(SW1). The following table shows the standard resolution values
along with the associated switch settings.

MSEL Switch Shows 50 Microsteps/Step Selected

In the above table ON is ground and OFF is floating.

*

Mounting Information

INT-481 Interface Board with IM481H Driver and H-481 Heat Sink

INT-481 Interface Board and IM481H Driver

Panel Mounted without H-481 Heat Sink

* The Isolating Thermal Pad (TI-481) item #4 is supplied with the Interface Board.

Mounting Parts List**

Item # Description Qty.

1 IM481H Microstepping Driver ....................................... 1

2 INT-481 Inteface Board ........................................................1

3 H-481 Heat Sink .........................................................................1

4 TI-481 Isolating Thermal Pad .......................................... 1

A #6-32 x 0.625” Pan Head Screw............................... 2

B #6 Split Lock Washer ............................................................ 2

C #6 Flat Washer, 0.250” OD,

0.145” ID, 0.030” Thick ............................................. 2

E #8-32 x 2” Pan Head Screw ............................................2

F #8 Split Lock Washer ............................................................ 2

H Spacer, 0.312” OD, 0.171” ID, 0.500” L........... 2

GRN

RED
LED1

FAULT

POWER

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

1

3

JP2

ENOFF/ENON

1

3

JP1

OPTO/+5V

1
2
3
4

SW1

MS0
MS1
MS2
MS3

21

1

3.000
(76.2)

0.275
(6.99)

2.450

(62.23)

1.550

(39.37)

0.575
(14.6)

2 XØ 0.143

(3.6) Thru.

0.620

(15.75)

0.920

(23.37)

Heat Sink
This Side

21 Pin Right Angle

Connector

HY481-CN021

*

** The hardware items A, B, C, E, F, H, are supplied with the H-481 Heat Sink Kit

but not with the INT-481 Interface Board.

NOTE: The torque specification for the #6-32 INT-481 and IM481H mounting screws

is 5.0 - 7.0 lbs-in.

WARNING! The Heat Sink mounting surface must be a
smooth, flat surface with no burrs, protrusions, cuttings
or other foreign objects!