Omega 1240i User guide

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Page 1

Hardware Manual

1240i

Programmable Step Motor Driver

motors • drives • controls

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Page 2

T able of Contents

Introduction --------------------------------------------------------------------- 4 Features-------------------------------------------------------------------------- 4 Block Diagram------------------------------------------------------------------- 4 Getting Started ------------------------------------------------------------------ 5

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.

Connecting the Power Supply --------------------------------------------------- 6 Choosing a Power Supply ------------------------------------------------------- 7 Connecting the Motor ----------------------------------------------------------- 8 Connecting to the PC------------------------------------------------------------ 9 Jogging------------------------------------------------------------------------- 10 Limit Switches ----------------------------------------------------------------- 10 Wiring a Mechanical Limit Switch --------------------------------------------- 11 Wiring a Limit Sensor ---------------------------------------------------------- 11 Wiring Inputs------------------------------------------------------------------- 12 Wiring Outputs ----------------------------------------------------------------- 14 Microstepping ------------------------------------------------------------------ 15 Mounting the Drive------------------------------------------------------------- 16 Mounting the Optional MMI --------------------------------------------------- 17 Recommended Motors---------------------------------------------------------- 19 Mechanical Outline------------------------------------------------------------- 20 Technical Specifications -------------------------------------------------------- 21 Mechanical Outline - Optional MMI ------------------------------------------- 22

Features

• Precise pulse width modulation switching amplifiers providing up to 1.2 amps per phase and microstepping to 50,800 steps per revolution.

• Accepts 12 - 42 VDC power supply.

• Powerful, flexible, easy to use indexer.

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

• Microsoft WindowsTM-based software for easy setup and programming

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

• Three outputs for coordinating external equipment.

• External trigger I/O is optically isolated, 5-24V, sinking or sourcing signals.

PC/ MMI port is RS-232.

• 3.0 x 4.0 x 0.65 inch overall dimensions.

• Optional man machine interface (MMI) allows operator to enter distances,

speeds, cycle counts and more.

• CE Compliant

Block Diagram

12 - 42 VDC

INPUT1 INPUT2 INPUT3 INPUT4

CW JOG/IN5

CCW JOG/IN6

CW LIMIT

CCW LIMIT

Optical

Isoation

Optical

Isolation

Internal

Power

Supply

Microstepping

Sequencer

™

Indexer

eeprom

MOSFET

3 State

PWM

Power

Amplifier

motor phase A

motor phase B

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to PC/MMI

RS232

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Optical

Isolation

OUT1 OUT2 OUT3

Page 3

Getting Started

To use your 1240i motor control, you will need the following :

4 a power supply (see page7 for help choosing one). 4 a compatible step motor (see page 19 for recommended motors). 4 a small flat blade screwdriver for tightening the connectors - an Applied Motion

Products screwdriver suitable for this purpose is included with your drive. 4 a personal computer running Windows 3.1, 95, 98 or NT with a 9 pin serial port (486 or better with 8 MB ram recommended)

4 the Si ProgrammerTM software that came with your 1240i 4 the programming cable that came with your 1240i 4 Si ProgrammerTM software manual - on the CD that came with your 1240i

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

All Mating connectors included.

Connecting the Power Supply

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

Power Supply

on the next page.

If your power supply does not have a fuse on the output or some kind of short circuit current limiting feature, you need to put a 1 amp fast acting fuse between the drive and the power supply. Install the fuse on the + power supply lead.

Connect the motor power supply as shown below. Use no smaller than 18 gauge wire. Be careful not to reverse the wires. Reverse connection may destroy your driver, void your warranty and generally wreck your day.

DC Power

Supply

V +

Choosing a

1240i

12 - 42 V

1A fuse

pc/mmi

connector

i/o connector

inputs 1,2,3,4

jog cw jog ccw cw limit

ccw limit out 1,2,3

mounting hole (1 of 4)

power LED

* Always use the blue & white

Applied Motion screwdriver

with these connectors.

Larger screwdrivers may remove

the plastic dimples that prevent

the screws from falling out.

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power/motor

connector

DC power supply

motor

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Page 4

Choosing a Power Supply

Please follow the recommendations below for choosing a power supply:

Voltage

Chopper drives like the 1240i 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

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 28 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.

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 1240i 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 24 volt supply can be expected to draw only half the supply current that it would with a 12 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.

a voltage

Connecting the Motor

Never connect or disconnect the motor to the driver when the power is on. Insulate unused motor leads separately, and then secure. Never connect motor leads to ground or to a power supply.

You must now decide how to connect your motor to the drive.

A+

Red

lead

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

A–

Blue

right.

Yellow

4 Leads

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.

motor

White

B+ B–

Note: NC means not connected to anything.

Grn/Wht

A–

White

Green

A+

Red

B–

6 Leads Series Connected 6 Leads Center Tap Connected

lead

motor

Black

Red/

Wht

B+

A–

A+

Grn/Wht

White

Green

Red

lead

motor

Black

Red/

Wht

B+B–

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-8-

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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

Blk/Wht

lead

Blk/Wht

A–

Black

Red

8 Leads Series Connected 8 Leads Parallel Connected

motor

Red/

Wht

B+ B–

Yel/ Wht

A–

Yellow

A+

Org/

Wht

Orange

Black

Red

B+

Yel/ Wht

lead

motor

Red/Wht

Yel low

B–

Connecting to the PC

•Locate your computer within 6 feet of the 1240i.

•Your 1240i 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 1240i. 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 may have to purchase a 25 to 9 pin serial adapter at your local computer store.

•Your 1240i 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 PC/MMI jack on your 1240i.

Jogging

Two of the 1240i input terminals are provided for jogging the motor. The inputs are labeled “JOG CW” and “JOG CCW”. Activating one of the inputs 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. 5-24 volt circuitry can 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 the power supply negative (-) terminal. Then connect the COM input to the power supply positive (+) terminal.

inside 1240i

2200

+ 5-24 VDC

SUPPLY

COM

JOG CW

JOG CCW

Limit Switches

The 1240i 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 1240i 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. This also allows you to have long wires on limit sensors that may be far from the 1240i with less risk of intoducing noise to the 1240i. The schematic diagram of the limit switch input circuit is shown below.

inside 1240i

+5V +5V

10K

Never connect the 1240i 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 the 1240i after the SiTM Programmer software is running on your PC.

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CW LIMIT+

CW LIMIT– CCW LIMIT+ CCW LIMIT–

2200

3 4 1 2

1240i

Controller

Chip

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Page 6

Wiring a Mechanical Limit Switch

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

CW LIMIT+

5-24

VDC

SUPPLY

CCW LIMIT+

1240i

CW LIMIT-

CCW LIMIT-

Wiring a Limit Sensor

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:

Wiring Inputs

The 1240i input circuits can be used with sourcing or sinking signals, 5 to 24 volts. This allows connection to TTL circuits, PLCs, relays and mechanical switches. Because the input circuits are isolated, they require a source of power. If you are connecting to a TTL circuit or to a PLC, you should be able to get power from the PLC or TTL power supply. If you are using relays or mechanical switches, you will need a 5-24 V power supply. This also applies if you are connecting the 1240i inputs to another Si product from Applied Motion, like the Si-1 and Si-100 indexers or the 3540i, Si3540, Si5580, 7080i and Si4500 indexer-drives.

COM COM

IN1

IN2

IN3

IN4

JOG CW

JOG CCW

inside 1240i

2200

CW LIMIT+

DC Power Supply

–

Limit

Sensor

–

output

CW LIMIT-

1240i

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:

Power

Supply

–

Proximity

Sensor

–

output

LIMIT+

1240i

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”.

Note: If current is flowing into or out of an 1240i input, the logic state of that input is low. If no current is flowing, or the input is not connected, the logic state is high.

The diagrams on the following pages show how to connect 1240i inputs to various devices.

The maximum voltage that can be applied to an input terminal is 24 volts DC. Never apply AC voltage to an input terminal.

COM

5-24

VDC

Power

Supply

Use normally open momentary switch to trigger 1240i using Wait Input instruction.

Use single throw switch for parameter selection using If Input instruction.

Use normally open momentary switch for jogging.

switch or relay

(closed=logic low)

Connecting an Input to a Switch or RelayConnecting an Input to a Switch or Relay

Connecting an Input to a Switch or Relay

Connecting an Input to a Switch or RelayConnecting an Input to a Switch or Relay

1240i

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Page 7

IN/JOG COM

1240i

5-24 VDC

MOTION+ MOTION–

SI-1 indexer

Connecting an Input to the Si-1 Motion Output

(Set Si-1 motion signal to “in position”. Si-1 will trigger 1240i at end of each move).

OUT+

or Si-100

Si5580, Si4500

OUT–

3540i, Si3540, 7080i,

Connecting a 3540i, Si3540, Si5580, 7080i or Si4500

(When output closes, 1240i input goes low).

COM

1240i

Power

Supply

5-24

VDC

Power

Supply

Wiring Outputs

Before we discuss the output conditions, we need to talk about the circuitry. All three 1240i 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.

Note: At power-up, the 1240i 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

1240i output terminals. Maximum current is 100 mA per output.

+5V

330

OUT1+ OUT1–

inside 1240i

1240i

Controller Chip

5-24

VDC

Power

Supply

Connecting an NPN Type Proximity Sensor to a 1240i input

(When prox sensor activates, 1240i input goes low).

5-24

5-24 VDC

VDC

Power

Supply

Connecting a PNP Type Proximity Sensor to a 1240i input

(When prox sensor activates, 1240i input goes low).

output

NPN

Proximity

Sensor

–

output

PNP

Proximity

Sensor

–

COM

1240i

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Schematic Diagram of 1240i Output Circuit

Since there is no electrical connection to the 1240i, 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 1240i output to an optically isolated PLC input.

5-24 VDC

Power Supply

+–

OUTPUT+

COMMON

PLC

1240i

OUTPUT-

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INPUT

Page 8

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 1240i precisely control the amount of current in each phase at each step position as a means of electronically subdividing the steps even further. The 1240i 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 0.2 pitch lead screw, you get 0.0001 inches/step.

Mounting the Drive.

The 1240i has four 0.156 inch diameter holes in the circuit board for mounting. Always use standoffs or spacers to support the 1240i: a 1240i with power connected will be damaged if you set it on a conductive surface without supports. The standoffs or spacers can be up to 0.25 inch in outer diameter. You can use #4 or #6 screws to fasten the 1240i.

0.156 inch Diameter mounting holes

The microstep resolution of the 1240i is set by the Si ProgrammerTM software.

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0.156 inch Diameter

mounting holes

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Page 9

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 1240i with the programming cable. You will not, however, need the adapter plug. The MMI has the same telephone style connector as the 1240i.

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 1240i, 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.

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 keypad assembly.

When you flush mount the MMI in a panel, only the thin section will stick out from your panel - the large portion mounts

MMI (rear section)

MMI (front section and gasket)

behind your panel. You’ll need to cut a precise section from your panel. There is a cardboard template in the MMI’s shipping box for this purpose.

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

123 456 789

SPACE BKSP ENTER

➝

YES NO

➝

panel

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

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 1240i. The hole must be at least 5/8” in diameter

gasket (included)

sealant (not included)

panel

for the connector to fit thorugh. You will also need two holes that line up with the big mounting holes in the MMI. The mechanical outline on page 22 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. Silicone or

123 456 789

SPACE BKSP ENTER

➝

YES NO

➝

MMI

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

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Page 10

Recommended Motors

Mechanical Outline

Motor

Number

HT11-012 1.0 HT11-013 1.0

5014-842 1.0 HT17-068 HT17-072 HT17-076

HT23-393 1.2 HT23-396 1.2

HT23-399

Winding

Connection

series series series

parallel parallel

parallel parallel parallel

1.2

parallel

Max T orque

oz-in

7 10 19

1.2

1.1

115 170

Current Setting

Amps/phase

4.00 IN.

3.85 IN.

0.15 IN.

2.85 IN.

3.00 IN.

4 HOLES, 0.156 DIA.

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0.65 IN.

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Page 11

T echnical Specifications

Mechanical Outline - Optional MMI

Amplifiers

Power Supply

Inputs

Outputs

Microstepping

Motion Update

Physical

Dual H-bridge, 3 state, pulse width modulated (PWM) switching at 25 kHz. 0.2 - 1.2 amps/phase output current, software selectable. 48 watts maximum output power. Automatic idle current reduction (software programmable) reduces current to motor when idle. Minimum motor inductance is 0.8 mH.

Accepts 12 - 42 VDC power supply. 1.2 amps typical max. load.

5 - 24 VDC, optically isolated. 2200 ohms internal resistance. Can be configured for sinking (NPN) or sourcing (PNP) signals.

Optically isolated. 5-24 VDC, 100 mA max.

13 software selectable resolutions. Steps per revolution with 1.8° motor: 2000, 5000, 10000, 12800, 18000, 20000, 21600, 25000, 25400, 25600, 36000, 50000, 50800. Waveform: pure sine.

12800 Hz.

Constructed on 0.063 inch thick printed circuit board. Four mounting holes, 0.156 inch diameter. Overall size : 3.00 x 4.00 x 0.65 inches.

0.15 lb. 0 to 50°C ambient operating temperature. See page 20 for detailed drawing.

1.38

0.13

2.988

0.960

0.963

1.975

➝

➝ ➝

➝

123

YES NO

789

456

0.425

SPACE BKSP ENTER

Connectors

Agency Approvals

European style screw terminal blocks. Power Supply and Motor: 6 position. Wire size: AWG 16 - 28. Signal input/output: 19 position. Wire size: AWG 16 - 28.

CE compliant to EN55011A, EN50082-1(1997)

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4.90

3.875 CENTERED

4.90

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Page 12

Notes

a.r. 1240iweb.p65 4/24/2000

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Applied Motion Products, Inc.

404 Westridge Drive Watsonville, CA 95076

T el (831) 761-6555 (800) 525-1609 Fax (831)-761-6544

http://www.applied-motion.com