parker ZETA6104 Installation Guide

Download

Page 1

ZETA6104 Indexer/Drive

Installation Guide

Rx Tx

COM 1 COM 2 ENCODER LIMITS I/O

GND

6104

Rx+

SHLD

INDEXER DRIVE

Rx-

+5V

Tx+

GND

Tx-

GND

Tx SHLD SHLD GND ZZ+ BB+ AA+ +5V

GND HOM NEG POS

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P V_I/O

PROGRAMMABLE I/O

Compumotor

95-132 VAC95-132 VAC

50/60 Hz

POWER STEP OVER TEMPOVER TEMP MOTOR FAULTMOTOR FAULT

INTERLOCK

CENTER TAP

A A+ AEARTH B+ B-

CENTER TAP

B INTERLOCK

ZETA

MOTOR

AC POWER

Compumotor Division

Compumotor

Parker Hannifin Corporation p/n 88-014782-02B September 1997

Page 2

User Information

! !

WARNING

6000 Series products are used to control electrical and mechanical components of motion control systems. You should test your motion system for safety under all potential conditions. Failure to do so can result in damage to equipment and/or serious injury to personnel.

6000 Series products and the information in this user guide are the proprietary property of Parker Hannifin Corporation or its licensers, and may not be copied, disclosed, or used for any purpose not expressly authorized by the owner thereof.

Since Parker Hannifin constantly strives to improve all of its products, we reserve the right to change this user guide and software and hardware mentioned therein at any time without notice.

In no event will the provider of the equipment be liable for any incidental, consequential, or special damages of any kind or nature whatsoever, including but not limited to lost profits arising from or in any way connected with the use of the equipment or this user guide.

Motion Architect is a registered trademark of Parker Hannifin Corporation. Motion Builder, CompuCAM and DDE6000 are trademarks of Parker Hannifin Corporation. Microsoft and MS-DOS are registered trademarks, and Windows, DDE and NetDDE are trademarks of Microsoft Corporation. Motion Toolbox is a trademark of Snider Consultants, Inc. LabVIEW is a registered trademark of National Instruments Corporation.

Technical Assistance

North America and Asia:

Compumotor Division of Parker Hannifin 5500 Business Park Drive Rohnert Park, CA 94928 Telephone: (800) 358-9070 or (707) 584-7558 Fax: (707) 584-3793 FaxBack: (800) 936-6939 or (707) 586-8586 BBS: (707) 584-4059 e-mail: tech_help@cmotor.com Internet: http://www.compumotor.com

Automation

Contact your local automation technology center (ATC) or distributor, or ...

Europe (non-German speaking):

Parker Digiplan 21 Balena Close Poole, Dorset England BH17 7DX Telephone: +44 (0)1202 69 9000 Fax: +44 (0)1202 69 5750

Germany, Austria, Switzerland:

HAUSER Elektronik GmbH Postfach: 77607-1720 Robert-Bosch-Str. 22 D-77656 Offenburg Telephone: +49 (0)781 509-0 Fax: +49 (0)781 509-176

Product Feedback Welcome

E-mail: 6000user@cmotor.com

Page 3

Change Summary

ZETA6104 Installation Guide

Rev B

September 1997

The following is a summary of the primary technical changes to this document.

This book, p/n 88-014782-02B, supersedes 88-014782-02A and 88-014782-01B.

Revision B Change Wiring diagrams (series/parallel connections) for RSxxx-xxNPS and RSxxx-xxC10 motor

Revision A Changes (from 88-014782-01 B)

Topic Description

New Hardware Revision These are the primary changes resulting from hardware enhancements:

New CE-marked OS Series and RS Series Motors

Miscellaneous Corrections and Clarifications

Continued . . .

options have been corrected Ð see page 9.

¥ New input circuit design for

inputs, you must now connect 5-24VDC (from an on-board

V_I/O terminal on the I/O connector. If V_I/O is connected to +5V, AUX-P can be connected

to a supply of up to +24V; if also be connected to +24V (or to

V_I/O (£1/3 of V_I/O voltage = low, ³2/3 of V_I/O voltage = high).

¥ Jumper JU7 was added to the ZETA6104 PCA. The purpose of JU7 is to select either

4-wire or 2-wire RS-485 communication. The default is 4-wire (JU7 in position 3).

¥ A new chip is used for the programmable output circuit (UDK2559).

This manual has been updated with data to support the new CE-marked OS Series and RS Series motors that may be ordered with your ZETA6104 system.

Corrections:

¥ Operating temperature range is 32-113°F (0-45°C);

previously documented as 32-122°F (0-50°C).

¥ The ZETA6104 does ¥ The Static Torque specs for the ZETA motors were incorrect. The DMTSTT (static torque)

command setting for the ZETA57-83 motor should be DMTSTT2 (not DMTSTT1).

¥ The parallel motor wiring diagrams (see back cover and page 9) were in error and have

now been corrected. ¥ The encoder test procedure on page 21 was corrected. ¥ The motor inductance requirements for non-Compumotor motors (see page 43) is:

recommended range = 5.0 to 50.0 mH; minimum = 0.5 mH; maximum = 80.0 mH.

Clarifications:

¥ All inputs and outputs are optically isolated from the internal microprocessor (not from the

other inputs and outputs). ¥ The programmable outputs (including

5-24VDC. ¥ You must select

power the

+5V terminal and to an external supply will damage the ZETA6104.

¥ If you are using an RS-232 connection between the host computer and the master

ZETA6104 connected to multiple ZETA6104s in an RS-485 multi-drop, make sure the

master ZETA6104 has these settings executed in the order given (you should place these

settings in your power-up STARTP program):

PORT1 (select RS-232 port, COM1, for configuration) ECHO3 (echo to both COM ports) PORT2 (select RS-485 port, COM2, for configuration) ECHO2 (echo to the other COM port, COM1)

either the on-board +5V terminal or an external 5-24VDC power supply to

AUX-P, IN-P or OUT-P pull-up resistors. Connecting AUX-P, IN-P or OUT-P to the

P-CUT, HOM, NEG, POS, TRG-A and TRG-B. To power these

or external source) to the new

V_I/O is connected to an external +24V supply, AUX-P must

GND). Switching levels depend on the power applied to

not support RS-422 communication as noted in the previous rev.

OUT-A) will sink up to 300mA, or source up to 5mA at

Page 4

LVD and EMC Installation Guidelines

The ZETA6104 is in compliance with the Low Voltage Directive (72/23/EEC) and the CE Marking Directive (93/68/EEC) of the European Community.

When installed according to the procedures in the main body of this installation guide, the ZETA6104 may not necessarily comply with the Low Voltage Directive (LVD). To install the ZETA6104 so that it is LVD compliant, refer to supplemental installation instructions provided in Appendix C. If you do not follow these instructions, the protection of the ZETA6104 may be impaired.

The ZETA6104 is sold as a complex component to professional assemblers. As a component, it is not required to be compliant with Electromagnetic Compatibility Directive 89/336/EEC. However, Appendix D provides guidelines on how to install the ZETA6104 in a manner most likely to minimize the ZETA6104Õs emissions and to maximize the ZETA6104Õs immunity to externally generated electromagnetic interference.

Page 5

ABOUT THIS GUIDE

Chapter 1. Installation

What You Should Have (ship kit) ........................................................... 2

Before You Begin ..................................................................................... 2

Recommended Installation Process ............................................. 2

Electrical Noise Guidelines ........................................................... 2

General Specifications ............................................................................ 3

Pre-installation Adjustments................................................................... 4

DIP Switch Settings Ð Motor Current, Address, Autobaud .......... 4

Changing the COM 2 Connector from RS-232 to RS-485 .......... 5

Mounting the ZETA6104.......................................................................... 6

Electrical Connections ............................................................................ 7

Grounding System.......................................................................... 7

Pulse Cut-Off (P-CUT) Ñ Emergency Stop Switch ................... 7

Serial Communication ................................................................... 8

Motor (ZETA and OS/RS motors only) ........................................ 9

End-of-Travel and Home Limit Inputs......................................... 11

Encoder ......................................................................................... 12

Trigger Inputs................................................................................ 13

General-Purpose Programmable Inputs & Outputs ................... 14

RP240 Remote Operator Panel................................................... 18

Input Power ................................................................................... 18

Lengthening I/O Cables ................................................................ 19

Testing the Installation........................................................................... 20

Matching the Motor to the ZETA6104 (OPTIONAL) ........................... 22

Mounting & Coupling the Motor ............................................................ 24

Mounting the Motor....................................................................... 24

Coupling the Motor ....................................................................... 25

Optimizing System Performance (OPTIONAL) ................................. 26

Configuring Active Damping........................................................ 26

Configuring Electronic Viscosity (EV) ........................................ 29

Record Your SystemÕs Configuration .................................................. 30

Recommended Set-up Program Elements ................................ 30

WhatÕs Next? ......................................................................................... 32

Program Your Motion Control Functions.................................... 32

Chapter 2. Troubleshooting

Troubleshooting Basics......................................................................... 34

Reducing Electrical Noise ........................................................... 34

Diagnostic LEDs........................................................................... 34

Test Options.................................................................................. 34

Technical Support......................................................................... 34

Common Problems & Solutions........................................................... 35

Troubleshooting Serial Communication Problems............................. 36

Product Return Procedure .................................................................... 37

Appendix A (Resonance, Ringing & Damping) .......................... 39

Appendix B (Using Non-Compumotor Motors) ......................... 43

Appendix C (LVD Installation Instructions) ................................. 47

Appendix D (EMC Installation Guidelines) ................................. 49

Index.................................................................................................. 53

Purpose of This Guide

This document is designed to help you install and troubleshoot your ZETA6104 hardware system. Programming related issues are covered in the 6000 Series ProgrammerÕs Guide and the 6000 Series Software Reference.

The ZETA6104 product is often referred to the as the Ò6104Ó because it is part of the 6000 family of products. The ZETA6104Õs software and the 6000 Series software documentation (i.e., the Software Reference and the ProgrammerÕs Guide) refer to this product as the Ò6104.Ó

What You Should Know

To install and troubleshoot the ZETA6104, you should have a fundamental understanding of:

¥ Electronics concepts, such as voltage, current, switches. ¥ Mechanical motion control concepts, such as inertia, torque, velocity, distance, force. ¥ Serial communication and terminal emulator experience: RS-232C and/or RS-485

Related Publications

¥ 6000 Series Software Reference, Parker Hannifin Corporation, Compumotor Division;

¥ 6000 Series ProgrammerÕs Guide, Parker Hannifin Corporation, Compumotor Division;

¥ Current Parker Compumotor Motion Control Catalog ¥ Schram, Peter (editor). The National Electric Code Handbook (Third Edition). Quincy,

ÒZETA6104Ó Synonymous with Ò6104Ó

part number 88-012966-01

part number 88-014540-01

MA: National Fire Protection Association

Online Manuals

This manual (in Acrobat PDF format) is available from our web site: http://www.compumotor.com

Page 6

LVD Installation Guidelines

The ZETA6104 is in compliance with the Low Voltage Directive (72/23/EEC) and the CE Marking Directive (93/68/EEC) of the European Community.

ii z ZETA6104 Installation Guide

Page 7

CHAPTER ONE

Installation

IN THIS CHAPTER

¥ Product ship kit list ¥ Things to consider before you install the ZETA6104 ¥ General specifications table ¥ Optional pre-installation alterations

- DIP switch settings Ð motor current, device address, autobaud feature

- Changing the COM 2 port from RS-232C to RS-485 ¥ Mounting the ZETA6104 ¥ Connecting all electrical components (includes specifications) ¥ Testing the installation ¥ Matching the motor to the ZETA6104 ¥ Motor mounting and coupling guidelines ¥ Using the damping features to optimize performance ¥ Preparing for what to do next

To install the ZETA6104 so that it is LVD compliant, refer to the supplemental instructions in Appendix C. Appendix D provides guidelines on how to install the ZETA6104 in

a manner most likely to minimize the ZETA6104Õs emissions and to maximize the ZETA6104Õs immunity to externally generated electromagnetic interference.

Page 8

What You Should Have (ship kit)

Part Name Part Number

ZETA6104 standard product (with ship kit).............. ZETA6104

Ship kit:

120VAC power cord.......................................... 44-014768-01

Motor connector ................................................ 43-008755-01

(ZETA series motors are factory wired with a motor connector)

Wire jumpers: Qty. 3....................................... 44-015142-01

Quick-reference magnet

(see side of ZETA6104 chassis) .................................. 87-014873-01

This user guide

(ZETA6104 Installation Guide)......................... 88-014782-02

6000 Series Software Reference ..................... 88-012966-01

6000 Series ProgrammerÕs Guide................... 88-014540-01

Motion Architect disks: Disk 1 ...................... 95-013070-01

If an item is missing, call the factory (see phone numbers on inside front cover).

Qty. 1....................................... 44-015741-01

Disk 2 ...................... 95-013070-02

Driver & Samples... 95-016324-01

MOTORS: These are the motors that can be ordered with the ZETA6104.

ZETA Motors: *

ZETA57-51 .............. Size 23 single-stack (57-51) motor

ZETA57-83 .............. Size 23 double-stack (57-83) motor

ZETA57-102 ............ Size 23 triple-stack (57-102) motor

ZETA83-62 .............. Size 34 single-stack (83-62) motor

ZETA83-93 .............. Size 34 double-stack (83-93) motor

ZETA83-135 ............ Size 34 triple-stack (83-135) motor

* If you ordered a ZETA6104 and a ZETA motor as a ÒsystemÓ, the

product part number reflects the motor size (e.g., ZETA6104-57-83).

OS Motors (CE Marked):

OS2HB-xxx-xx........ Size 23 half-stack (57-40) motor, 170VDC winding

OS21B-xxx-xx......... Size 23 single-stack (57-51) motor, 170VDC winding

OS21B-xxx-xx......... Size 23 double-stack (57-83) motor, 170VDC winding

RS Motors (CE Marked):

RS31B-xxx-xx......... Size 34 single-stack (83-62) motor, 170VDC winding

RS32B-xxx-xx......... Size 34 double-stack (83-93) motor, 170VDC winding

RS33B-xxx-xx......... Size 34 triple-stack (83-135) motor, 170VDC winding

Before You Begin

WARNINGS

The ZETA6104 is used to control your systemÕs electrical and mechanical components. Therefore, you should test your system for safety under all potential conditions. Failure to do so can result in damage to equipment and/or serious injury to personnel.

Always remove power to the ZETA6104 before:

¥ Connecting any electrical device (e.g., motor, encoder, inputs, outputs, etc.) ¥ Adjusting the DIP switches, jumpers, or other internal components

Recommended Installation Process

This chapter is

organized

sequentially to best

approximate a typical

installation process.

1. Review the general specifications

2. Perform configuration/adjustments (if necessary)

3. Mount the ZETA6104

4. Connect all electrical system components

5. Test the installation

6. Match the motor to the ZETA6104 Ñ optional

7. Mount the motor and couple the load

8. Optimize performance (using the ZETA6104Õs damping features) Ñ optional

9. Record the system configuration (record on the information label and/or in a set-up program)

10. Program your motion control functions. Programming instructions are provided in the 6000 Series ProgrammerÕs Guide and the 6000 Series Software Reference. We recommend using the programming tools provided in Motion Architect for Windows (found in your ship kit). You can also benefit from an optional iconic programming interface called Motion Builder (sold separately).

Electrical Noise Guidelines

¥ Do not route high-voltage wires and low-level signals in the same conduit. ¥ Ensure that all components are properly grounded. ¥ Ensure that all wiring is properly shielded. ¥ Noise suppression guidelines for I/O cables are provided on page 19. ¥ Appendix D (page 49) provides guidelines on how to install the ZETA6104 in a manner

most likely to minimize the ZETA6104Õs emissions and to maximize the ZETA6104Õs immunity to externally generated electromagnetic interference.

2 z ZETA6104 Installation Guide

Page 9

General Specifications

Parameter Specification

Power

AC input .................................................................... 95-132VAC, 50/60Hz, single-phase

Status LEDs/fault detection...................................... Refer to Diagnostic LEDs on page 34

Environmental

Operating Temperature .......................................... 32 to 113°F (0 to 45°C) Ñ over-temperature shutdown fault at 131°F (55°C)

Storage Temperature............................................... -22 to 185°F (-30 to 85°C)

Humidity ................................................................... 0 to 95% non-condensing

Performance

Position Range & Stepping Accuracy ..................... Position range: ±2,147,483,648 steps; Stepping accuracy: ±0 steps from preset total

Velocity Range, Accuracy, & Repeatability............ Range: 1-2,000,000 steps/sec; Accuracy: ±0.02% of maximum rate;

Acceleration Range.................................................. 1-24,999,975 steps/sec

Motion Algorithm Update Rate................................ 2 ms

Serial Communication RS-485 requires internal jumper and DIP switch configuration (see page 5).

Connection Options.................................................. RS-232C, 3-wire; RS-485 (default is 4-wire; for 2-wire move JU7 to position 1);

Maximum units in daisy-chain or multi-drop......... 99 (use DIP switch or ADDR command to set individual addresses for each unit)

Communication Parameters................................... 9600 baud (range is 19200-1200Ñsee AutoBaud, page 4), 8 data bits, 1 stop bit, no parity;

Inputs All inputs are optically isolated from the microprocessor (not from the other inputs).

HOM, POS, NEG, TRG-A, TRG-B, P-CUT .................. Powered by voltage applied to V_I/O terminal (switching levels: £1/3 of V_I/O voltage = low,

Encoder..................................................................... Differential comparator accepts two-phase quadrature incremental encoders with differential

16 General-Purpose Programmable ..................... HCMOS compatible* with internal 6.8 KW pull-ups to IN-P terminalÑconnect IN-P to power

Outputs All outputs are optically isolated from the microprocessor (not from the other outputs).

9 Programmable (includes OUT-A)......................... Open collector output with 4.7 KW pull-ups. Can be pulled up by connecting OUT-P to power

+5V Output................................................................ Internally supplied +5VDC. +5V terminals are available on the COM2, ENCODER and I/O

* HCMOS-compatible switching voltage levels: Low £ 1.00V, High ³ 3.25V.

TTL-compatible switching voltage levels: Low £ 0.4V, High ³ 2.4V.

(refer to page 18 for peak power requirements, based on the motor you are using)

Repeatability: ±0.02% of set rate

Change internal jumpers JU1-JU6 to position 1 to select RS-485 communication

RS-232: Full duplex; RS-485: Half duplex (change jumper JU6 to position 1)

³2/3 of V_I/O voltage = high). V_I/O can handle 5-24V with max. current of 100mA. Internal

6.8 KW pull-ups to AUX-P terminalÑconnect AUX-P to power source (+5V terminal or an external 5-24V supply) to source current or connect AUX-P to GND to sink current; AUX-P can handle 0-24V with max. current of 50mA. Voltage range for these inputs is 0-24V.

(recommended) or single-ended outputs. Maximum voltage = 5VDC. Switching levels (TTL-compatible): Low £ 0.4V, High ³ 2.4V. Maximum frequency = 1.6 MHz. Minimum time between transitions = 625 ns.

source (+5V pin #49 or an external 5-24V supply) to source current or connect IN-P to GND to sink current; IN-P can handle 0-24V with max. current of 100 mA. Voltage range = 0-24V.

source (+5V terminal or an external 5-24V supply); OUT-P can handle 0-24V with max. current of 50mA. Outputs will sink up to 300mA or source up to 5mA at 5-24VDC. 8 general-purpose outputs on the Programmable I/O connector, OUT-A on the I/O connector.

connectors. Load limit (total load for all I/O connections) is 0.5A.

Motor Specifications

Static Torque oz-in

Rotor Inertia oz-in

Bearings

Thrust load lb

Radial load lb

End play (Reversing load in

equal to 1 lb) (mm)

Radial play in

(Per 0.5 lb load) (mm)

Weight lb

(Motor+Cable+Connector) (kg)

Certifications UL Rec.

(N-m)

(kg-m2 x 10Ð6)

(kg)

CE (LVD) CE (LVD & EMC)

Size 23 ZETA Motors Size 34 ZETA Motors Size 23 OS Motors Size 34 RS Motors

ZETA 57-51

65 (0.46)

0.546 (9.998)

25 (11.3)

15 (6.8)

0.005 (0.13)

0.0008 (0.02)

1.6 (0.7)

No No No

ZETA 57-83

125 (0.88)

1.1 (20.1 )

25 (11.3)

15 (6.8)

0.005 (0.13)

0.0008 (0.02)

2.4 (1.1)

No No No

ZETA 57-102

148 (1.05)

1.69 (30.9)

25 (11.3)

15 (6.8)

0.005 (0.13)

0.0008 (0.02)

3.2 (1.5)

No No No

ZETA 83-62

141 (1.00)

3.47 (63.4)

50 (22.6)

25 (11.3)

0.005 (0.13)

0.0008 (0.02)

3.8 (1.7)

No No No

ZETA 83-93

292 (2.11)

6.76 (124)

50 (22.6)

25 (11.3)

0.005 (0.13)

0.0008 (0.02)

5.1 (2.3)

No No No

ZETA 83-135 OS2HB OS21B OS22B RS31B RS32B RS33B

382 (2.70)43(0.30)82(0.58)

10.47 (191)

50 (22.6)

25 (11.3)

0.005 (0.13)

0.0008 (0.02)

8.3 (3.8)

No No No

0.386 (0.070)

13 (5.9)

20 (9.1)

0.001 (0.025)

0.0008 (0.02)

1.0 (0.45)

No Yes No

0.656 (0.119)

13 (5.9)

20 (9.1)

0.001 (0.025)

0.0008 (0.02)

1.5 (0.68)

No Yes No

155

1.09)

1.390 (0.253)

13 (5.9)

20 (9.1)

0.001 (0.025)

0.0008 (0.02)

2.5 (1.14)

No Yes No

141 (1.00)

3.204 (0.583)

180 (81.6)

35 (15.9)

0.001 (0.025)

0.0008 (0.02)

3.2 (1.45)

Yes Yes

w/C10 & EMC kit

292 (2.06)

6.563 (1.195)

180 (81.6)

35 (15.9)

0.001 (0.025)

0.0008 (0.02)

5.3 (2.41)

Yes Yes

w/C10 & EMC kit

382

2.70)

9.652 (1.757)

180 (81.6)

35 (15.9)

0.001 (0.025)

0.0008 (0.02)

7.6 (3.45)

Yes Yes

w/C10 & EMC kit

Speed/Torque Curves ------ Refer to page 10 ------ ------ Refer to page 10 ------ ------ Refer to page 10 ------ ------ Refer to page 10 ------ Dimensions ------ Refer to page 24 ------ ------ Refer to page 24 ------ ------ Refer to page 24 ------ ------ Refer to page 24 ------

Chapter 1. Installation 3

Page 10

Pre-installation Adjustments

Factory Settings May Be Sufficient (if so, skip this section):

¥ Device address is set to zero (if daisy-chaining you can automatically establish with the ADDR command). ¥ Serial communication method is RS-232C.

DIP Switch Settings Ð Motor Current, Address, Autobaud

Move the Cover

CAUTION

Do not set switches 6-11 to ON at the same time. This invokes a factory test mode in which the ZETA6104 executes a motion sequence upon power up.

Top View of ZETA6104

off

12345 12

6 7 8 9 10 11

off

Motor Current

Zeta57-51 Series

Zeta57-83 Series OS2HB Series

Zeta57-102 Series OS21B Series

OS22B Series Zeta83-62 Series RS31B Series Zeta57-51 Parallel

Zeta83-93 Series RS32B Series OS2HB Parallel Zeta57-83 Parallel Zeta57-102 Parallel Zeta83-135 Series RS33B Series OS21B Parallel Zeta83-xxx Parallel OS22B Parallel RS3xB Parallel

Factory Settings: If you ordered a ZETA Series motor as part of your ZETA6104 ÒsystemÓ (e.g., ZETA6104-83-62), then the DIP switches will be factory-configured to operate your specific motor in a series wiring configuration.

If you ordered the ZETA6104 without a motor, or with an OS or RS Series motor, or if you ordered the ZETA Series motor separately (not as a ÒsystemÓ), all DIP switches are factory-set to the OFF position.

(Amps)

0.14 off off off off off

0.26 off off off off on

0.39 off off off on off

0.51 off off off on on

0.64 off off on off off

0.76 off off on off on

0.89 off off on on off

1.01 off off on on on

1.14 off on off off off

1.26 off on off off on

1.38 off on off on off

1.51 off on off on on

1.63 off on on off off

1.76 off on on off on

1.88 off on on on off

2.01 off on on on on

2.14 on off off off off

2.26 on off off off on

2.38 on off off on off

2.51 on off off on on

2.63 on off on off off

2.76 on off on off on

2.88 on off on on off

3.01 on off on on on

3.13 on on off off off

3.26 on on off off on

3.38 on on off on off

3.50 on on off on on

3.63 on on on off off

3.75 on on on off on

3.88 on on on on off

4.00 on on on on on

off off off off off 0 (default) off off off off on 1 off off off on off 2 off off off on on 3 off off on off off 4 off off on off on 5 off off on on off 6 off off on on on 7 off on off off off 8 off on off off on 9 off on off on off 10 off on off on on 11 off on on off off 12 off on on off on 13 off on on on off 14 off on on on on 15 on off off off off 16 on off off off on 17 on off off on off 18 on off off on on 19 on off on off off 20 on off on off on 21 on off on on off 22 on off on on on 23 on on off off off 24 on on off off on 25 on on off on off 26 on on off on on 27 on on on off off 28 on on on off on 29 on on on on off 30 on on on on on 31

on off

The default baud rate is 9600. As an alternative, you can use this procedure to automatically match your terminal's speed of 1200, 2400, 4800, 9600, or 19200 baud.

1. Set switch 6 to on and switch 7 to off.

2. Connect the ZETA6104 to the terminal.

3. Power up the terminal.

4. Cycle power to the ZETA6104 and immediately press the space bar several times.

5. The ZETA6104 should send a message with the baud rate on the first line of the response. If no baud rate message is displayed, verify steps 1-3 and repeat step 4.

6. Change switches 6 & 7 to off.

7. Cycle power to the ZETA6104. This stores the baud rate in non-volatile memor

NOTE: Autobaud works only on the ZETA6104Õs COM 1 serial port.

Automatic Addressing: If you are connecting multiple units (see page 8), you can use the ADDR command to establish a unique address for each unit. The ADDR command overrides the DIP switch setting. For details, refer to the 6000 Series

Software Reference or the 6000 Series Programmer's Guide.

Address

AutoBaud

4 z ZETA6104 Installation Guide

Page 11

Changing the COM 2 Connector from RS-232 to RS-485

)

RS-232C Users

+5V

COM 2

Remove the two retainer screws.

(one on the top of the chassis, one on the bottom of the chassis)

Slide the chassis forward, then away from the heat sink.

(follow the dashed arrow)

GND Rx Tx SHLD

Chassis

Rx+ RxÐ Tx+

TxÐ

GND

RS-485 (optional)

RS-232 (factory default

The ZETA6104Õs COM 2 port is factory configured for RS-232C communication (use the left-hand pin descriptions). If you

need to use RS-485 communication, you may ignore this section and proceed to the Mounting instructions.

do not

Heatsink

Be careful not to catch the 50-pin header clips on the chassis.

Set the jumpers.

RS-232: Leave JU6 set to position 3 (factory default).

RS-485: Set jumper JU6 to position 1 (disables power-up messages, error messages, & echo).

COM 2 port for RS-232, set JU1-JU5 to position 3 (factory default).

COM 2 port for RS-485, set JU1-JU5 to position 1 (as illustrated).

4-wire RS-485, set JU7 to position 3 (factory default).

2-wire RS-485, set JU7 to position 1.

Set the DIP switches.

DIP switch #4: Rx Termination Resistor...........120 W

DIP switch #3: Tx+ Bias Resistor.....................681 W

DIP switch #2: Tx Termination Resistor...........120 W

DIP switch #1: TxÐ Bias Resistor.....................681 W

NOTE: Set the switches to ON (as illustrated) to use the internal resistors. Do this for a single unit or for the last unit in a multi-drop only. If these resistor values are not appropriate for your application, set the switches to OFF and connect your own external resistors. See page 8 for resistor calculations and wiring instructions.

(4-wire is full duplex: transmit and receive at the same time)

(2-wire is half duplex: transmit or

receive at any time)

1234

Reattach the chassis and replace the two retainer screws.

Chapter 1. Installation 5

Page 12

Mounting the ZETA6104

)

Before you mount the ZETA6104

Check the list below to make sure you have performed all the necessary configuration tasks that require accessing internal components (DIP switches, potentiometers, and jumpers). You may, however, be able to adjust DIP switches and pots after mounting, if you allow access to the top of the ZETA6104 chassis.

¥ Select motor current (DIP switches). If you ordered a ZETA motor with your system (e.g., ZETA6104-57-83) and you

intend to use series motor winding, use the factory setting. If you need to change this setting, refer to page 4 for instructions.

¥ Select device address (DIP switches). If you are not connecting multiple ZETA6104 units in an RS-232C daisy chain or an

RS-485 multi-drop, use the factory setting. If you need to change this setting, refer to page 4 for instructions.

¥ Select serial communication method (jumpers & DIP switches). If you are using RS-232C to communicate with the

ZETA6104, use the factory settings. If you need to change these settings (i.e., for RS-485), refer to page 5 for instructions.

¥ Be aware that if you exercise the motor matching procedures on page 22, you will need to access the potentiometers at the top

of the ZETA6104 chassis. (The motor matching procedures are placed after the Electrical Connections section of this manual because the process requires that you first understand how to connect the motor, serial communication, and AC power.)

6.813 (173.1)

5.970 (151.6)

Dimensions in inches (millimeters).

1.465 (37.2)

0.965 (24.5)

4.000

(101.6)

1.000 (25.4)

0.133 (3.4)

8.000

(203.2)

8.600

(218.4)

8.850

(224.8)

3x ¯0.156 (3.9) (clearance for #6 (M3.5) mounting screw

Environmental Considerations

Temperature. Operate the ZETA6104 in ambient temperatures between 32°F (0°C) and 113°F (45°C). Provide a

minimum of 1 inch (25.4 mm) of unrestricted air-flow space around the ZETA6104 chassis (see illustration). The ZETA6104 will shut itself down if its internal sensor reaches 131°F (55°C).

Humidity. Keep below 95%, non-condensing.

Airborne Contaminants, Liquids. Particulate

contaminants, especially electrically conductive material, such as metal shavings and grinding dust, can damage the ZETA6104 and the Zeta motor. Do not allow liquids or fluids to come in contact with the ZETA6104 or its cables.

6 z ZETA6104 Installation Guide

Minimum Airflow Space = 1 inch

1.0 (25.4)

1.0

(25.4)

1.0 (25.4

Page 13

Electrical Connections

To install the ZETA6104 so that it is LVD compliant, refer also to the supplemental instructions in Appendix C. Appendix D provides guidelines on how to install the ZETA6104 in a

manner most likely to minimize the ZETA6104Õs emissions and to maximize the ZETA6104Õs immunity to externally generated electromagnetic interference.

Grounding System

* The function of COM2Õs terminals depends

on whether it is configured for RS-232 (the factory default configuration) or for RS-485 (see page 5 for configuration).

GND

GND (if COM2 is RS-232) *

GND (if COM2 is RS-485) *

GND

COM 1 COM 2

ENCODER

GND SHLD

GND

SHLD

SHLD GND

SHLD

GND

SHLD (if COM2 is RS-232) *

SHLD

NOTE: The inputs and outputs are isolated

from the internal microprocessor, but are not isolated from the other inputs and outputs.

GND

GND (even number pins)

LIMITS

GND

I/O

PROGRAMMABLE I/O

Isolated Ground

Pulse Cut-Off (P-CUT) Ñ Emergency Stop Switch

P-CUT connected to GND (normally-closed switch).

If this connection is opened, motion is killed and the program in progress is terminated.

If the P-CUT input is not grounded when motion is commanded, motion will not occur and the error message ÒWARNING: PULSE CUTOFF ACTIVEÓ will be displayed in the terminal emulator.

+5V connected to AUX-P and V_I/O (sourcing current).

Provides +5V power to the P-CUT pull-up resistor. As an alternative, you can connect AUX-P to an external supply of up to +24V (but do not use both the on-board +5V terminal and an external 5-24V supply). If V_I/O is connected to a +5V supply (on-board or external), AUX-P can be connected to a supply of up to +24V. If V_I/O is connected to an external +24V supply, AUX-P must also be connected to +24V (or to GND).

Switching levels depend on the voltage applied to V_I/O: LOW £ 1/3 of V_I/O voltage; HIGH ³ 2/3 of V_I/O voltage

NOTE: AUX-P and V_I/O are also used by the HOM, NEG, POS & TRG inputs.

SINKING CURRENT: To make P-CUT (as well as HOM, NEG, POS & TRG) sink current,

connect AUX-P to GND.

I/O Connector

Compumotor

95-132 VAC

50/60 Hz

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P V_I/O

INTERLOCK

CENTER TAP

A+

A-

EARTH

B+

B-

CENTER TAP

INTERLOCK

MOTOR

AC POWER

ISO GND

+5VDC

6.8 KW

EARTH

Ground Pin

20.0 KW 18.2 KW

12.1 KW

EARTH

Internal Schematic

LM 339

10.0 KW

30.1 KW

CAUTION: You must select either the on-board +5V terminal or an external power supply to power the

AUX-P pull-up resistor (for the P-CUT, HOM, NEG, POS, TRG-A, and TRG-B inputs).

Connecting AUX-P to the +5V terminal and an external supply will damage the ZETA6104. (The same rule applies to the IN-P and OUT-P terminals, see page 14.)

Chapter 1. Installation 7

Page 14

Serial Communication

RS-232C Connections

Tx Rx GND

COM 1 COM 2

Serial Port Connection

25-Pin COM Port:9-Pin COM Port:

Pin 2 (Rx) Pin 3 (Tx) Pin 5 (GND)

NOTE: Maximum RS-232C cable length is 50 feet (15.25 meters)

Rx Tx GND

Pin 2 (Tx) Pin 3 (Rx) Pin 7 (GND)

Rx Tx GND

Rx Tx GND SHLD

+5V GND Rx Tx SHLD

Rx+ RxÐ

Tx+ TxÐ

GND

RS-485 Connections (4-wire interface, plus ground)

Unit #1

Rx+

COM 2

RS-485 Configuration

Before you can use RS-485 communication, you must reconfigure the COM 2 port by setting internal jumpers JU1-JU6

Unit #2

COM 2

to position 1. 4-wire is default (to use 2-wire, set JU7 to position 1).

Refer to page 5 for instructions.

Unit #3

COM 2

681W

120 W

Unit #31

COM 2

5VDC

DIP switch selects internal resistor values (ON selects the resistor).

Use these resistors only for the last unit (or for a single unit).

If your application requires terminating resistors other than 120W, and/or bias resistors other than 681W, then make sure the internal DIP switches are set to OFF and connect your own external resistors. To calculate resistor values:

NOTE: Maximum RS-485 cable length is 4000 feet (1220 meters)

+5V GND Rx Tx SHLD

RxÐ Tx+

TxÐ

GND

Rx+ RxÐ Tx+

TxÐ

GND

Rx+ RxÐ Tx+

TxÐ

GND

Rx+ RxÐ Tx+

TxÐ

GND

RS-232C Daisy-Chain Connections*

Unit 0

Tx Rx GND

Daisy Chain to a Computer or Terminal

Unit 0

Stand-Alone Daisy Chain

Be sure to set unique devices addresses for each unit.

To set the address, use the DIP switch (see page 4), or use the ADDR command (see 6000 Series ProgrammerÕs Guide).

Ground

TxÐ

Rx+

RxÐ

Shield

+5VDC

120 W

Calculating Resistor Values

Vcc

Balanced Cable.

Vb Rb

Example

Step 1 Calculate the equivalent resistance (Req)* of Rc / / Rb:

Step 2 Calculate the pull-up and pull-down resistor values knowing that

Assumptions: The cable's characteristic impedance (Zo) = 120W.

Rc / / Rb = 120W / / 120W = 60W

the FAILSAFE bias is 200mV and Vcc = 5V: Vb = Vcc (Req / (Ra + Req + Rd)) solving for R' (defined as Ra + Rd) R' = ((Req) Vcc / Vb) - Req R' = ((60W) 5V / 0.2V) - 60W = 1440W

Since Ra and Rd are equal, Ra = Rd = 1440W / 2 = 720W

Step 3 Recalculate the equivalent resistance of RC / / (Ra + Rd):

Rc / / (Ra + Rd) = 120W / / (720W + 720W) = 110.77W

Since the equivalent resistance is close (within 10%) to the characteristic impedance of the cable (Zo), no further adjustment of resistor values is required.

* Actual calculation

for equivalent resistance (e.g., R1 / / R2):

Rc and Rb are equal and are selected to match Zo (Rc = Rb = Zo = 120W).

R1R

(R1 + R2)

Unit 1

Rx Tx GND SHLD

Unit 1

Rx Tx GND SHLD

Master

UnitTx+

For further information, consult a communications interface reference.

Unit 2

Rx Tx GND SHLD

8 z ZETA6104 Installation Guide

Page 15

Motor (ZETA and OS/RS motors only)

Motor Connector

Specifications Ð see page 3.

ZETA, OS and RS Motors

Speed/Torque curves Ð see page 10. Considerations for series & parallel wiring Ð see page 10.

INTERLOCK A

CENTERTAP

A+ AÐ EARTH B+ BÐ

CENTERTAP

B INTERLOCK

MOTOR

WARNING:

Remove AC power before connecting or disconnecting the motor. Lethal voltages are present on the screw terminals

Current settings Ð see page 4. Dimensions Ð see page 24. Cable extension Ð see table below. ZETA & RSxxx-xxC10 motors include a rubber boot for safety.

Non-Compumotor Motors

If you intend to use a non-Compumotor motor, refer to Appendix B for connection instructions and current selection.

ZETA, OS and RS Motor Connections RSxxx-xxNPS and RSxxx-xxC10 Motor Connections

Series Connection

INTERLOCK

ACENTERTAP

A+

AÐ

EARTH

B+

BÐ

CENTERTAP

INTERLOCK

Do not lengthen or remove this jumper.

NOTE: ZETA motors are shipped from the factory wired to the connector in series.

Yellow Blue Red Black

Shield

White Green Orange

Brown

Shield is connected to the motor case and is internally connected to the ground pin on the ZETA6104Õs AC power connector.

Parallel Connection

INTERLOCK

ACENTERTAP

EARTH

CENTERTAP

INTERLOCK

A+

AÐ

B+

BÐ

Red Blue Yellow Black Shield

White Brown Orange Green

See page 10 for guidelines about using a motor in parallel.

Motor

Phase A Windings

Motor

Phase A Windings

Phase B Windings

Series Connection

INTERLOCK

ACENTERTAP

A+

AÐ

EARTH

B+

BÐ

CENTERTAP

INTERLOCK

The green/yellow (Gnd) wire is for safety purposes. The shield connection to the motor case is for EMI purposes (the C10 cable kit provides hardware for the shield connection). C10 cable assembly instructions are provided in the C10 cable kit.

Wire #1 Wire #3 Gnd (Grn/Ylw) Wire #2 Wire #4

Parallel Connection

INTERLOCK

ACENTERTAP

A+

AÐ

EARTH

B+

BÐ

CENTERTAP

INTERLOCK

Wire #1 Wire #3 Gnd (Grn/Ylw) Wire #2 Wire #4

Phase A Windings

Motor Terminal Number/Wire Number:

ZETA6104 Motor Connector Terminal:

Motor Terminal Number/Wire Number:

ZETA6104 Motor Connector Terminal:

Phase B Windings

28 74

Phase A Windings

Phase B Windings

End Cover RemovedSchematic View

Gnd1324

EARTH A+ A- B+ B-

Gnd1324

EARTH A+ A- B+ B-

Auto Current Standy Mode: Reduces motor current by 50% when step pulses from the ZETA6104 have stopped for one second

(CAUTION: torque is also reduced). Full current is restored upon the first step pulse. Enable with the DAUTOS1 command; disable with the DAUTOS¯ command (default is disabled). For more information, refer to the DAUTOS command in the 6000 Series Software Reference.

Extending ZETA Motor Cables

Standard length is 10 ft (3 m); maximum extended length is 200 ft (61 m).

CAUTION: Cables longer than 50 feet (15 m) may degrade performance.

Motor Type (amps) AWG mm

Max. Current < 100 ft (30 m) 100-200 ft (30-60 m)

ZETA57-51(S) 1.26 22 0.34 20 0.50 ZETA57-51(P) 2.38 22 0.34 20 0.50 ZETA57-83(S) 1.51 22 0.34 20 0.50 ZETA57-83(P) 3.13 22 0.34 20 0.50 ZETA57-102(S) 1.76 22 0.34 20 0.50 ZETA57-102(P) 3.50 20 0.50 18 0.75 ZETA83-62(S) 2.26 22 0.34 20 0.50 ZETA83-62(P) 4.00 20 0.50 18 0.75 ZETA83-93(S) 2.88 22 0.34 20 0.50 ZETA83-93(P) 4.00 20 0.50 18 0.75 ZETA83-135(S) 3.50 20 0.50 18 0.75 ZETA83-135(P) 4.00 20 0.50 18 0.75

(S) = Series Configuration (P) = Parallel Configuration

NOTE: Rated current in wire sizes shown may result in a maximum temperature rise of 18°F (10°C) above ambient.

AWG mm

-L10, -R10 & -C10 motors are shipped with 10 ft (3 m) cables;

-FLY motor is shipped with 1 ft (0.3 m) flying leads.

-NPS motor does not include cable/leads; 10-foot: use 18 AWG (0.75 mm2) wire. LVD COMPLIANCE: Maximum DC resistance between the ZETA6104Õs

ÒEARTHÓ terminal (Òprotective conductor terminalÓ) and motor body must not exceed 0.1ÊW. (This criteria must be taken into consideration when sizing cross-section (gage) for extended cable lengths.)

NON-LVD: Maximum extended length is 200 ft (61 m), but cables longer than 50

feet (15 m) may degrade performance. See table below for guidelines:

Motor Type (amps) AWG mm

OS2HB(S) 1.51 22 0.34 20 0.50 OS2HB(P) 3.01 22 0.34 20 0.50 OS21B(S) 1.88 22 0.34 20 0.50 OS21B(P) 3.75 20 0.50 18 0.75 OS22B(S) 2.14 22 0.34 20 0.50 OS22B(P) 4.00 20 0.50 18 0.75 RS31B(S) 2.26 22 0.34 20 0.50 RS31B(P) 4.00 20 0.50 18 0.75 ZETA83-93(S) 2.88 22 0.34 20 0.50 ZETA83-93(P) 4.00 20 0.50 18 0.75 ZETA83-135(S) 3.50 20 0.50 18 0.75 ZETA83-135(P) 4.00 20 0.50 18 0.75

Extending OS and RS Motor Cables

Max. Current < 100 ft (30 m) 100-200 ft (30-60 m)

AWG mm

Chapter 1. Installation 9

Page 16

Selecting Series or Parallel Motor Wiring

Zeta Motor Curves

oz-in

(N-m) Power

(0.53)

(0.42)

(0.32)

Torque

(0.21)

(0.11)

oz-in

(N-m) Power

125

(0.88)

100

(0.70)

(0.53)

Torque

(0.35)

(0.18)

oz-in

(N-m) Power

150

(1.05)

120

(0.84)

(0.63)

Torque

(0.42)

(0.21)

oz-in

(N-m) Power

200

(1.40)

160

(1.12)

120

(0.84)

Torque

(0.56)

(0.28)

oz-in

(N-m) Power

400

(2.80)

320

(2.24)

240

(1.68)

Torque

160

(1.12)

(0.56)

oz-in

(N-m) Power

500

(3.50)

400

(2.80)

300

(2.10)

Torque

200

(1.40)

100

(0.70)

Parallel

ZETA57Ð51

20 30 40 50

Speed-RPS

ZETA57Ð83

Series

20 30 40 50

Speed-RPS

ZETA57Ð102

Series

20 30 40 50

Speed-RPS

ZETA83Ð62

Series

20 30 40 50

Speed-RPS

ZETA83Ð93

Series

Parallel

20 30 40 50

Speed-RPS

ZETA83Ð135

Series

20 30 40 50

Speed-RPS

Parallel

Series

Parallel

= Torque

= Power

watts (hp)

Parallel 129 (0.18)

Series 60 (0.08)

watts (hp)

Parallel 175 (0.23)

Series 80 (0.11)

watts (hp)

Parallel 186 (0.25)

Series 80 (0.11)

watts (hp)

Parallel 260 (0.35)

Series 120 (0.16)

watts (hp)

Parallel 350 (0.47)

Series 180 (0.24)

watts (hp)

Parallel 355 (0.48)

Series 193 (0.26)

O & R Motor Curves

oz-in

(N-m) Power

100

(0.70)

(0.56)

Parallel (3.01A

(0.43)

Torque

(0.28)

(0.14)

oz-in

(N-m) Power

300

(2.13)

205

(1.42)

200

(1.42)

Torque

150

(1.07)

100 (0.71)

(0.36)

oz-in

(N-m) Power

200

(1.42)

160

(1.14)

120

(0.85)

Torque

(0.56)

(0.28)

oz-in

(N-m) Power

200

(1.40)

160

(1.12)

120

(0.84)

Torque

(0.56)

(0.28)

oz-in

(N-m) Power

400

(2.80)

Series (2.88A

320

(2.24)

240

(1.68)

Torque

160

(1.12)

(0.56)

oz-in

(N-m) Power

500

(3.50)

Series (3.5A

400

(2.80)

300

(2.10)

Torque

Parallel (4A

200

(1.40)

100

(0.70)

OS2HB

pk)

20 30 40 50

Speed-RPS

OS21B

Series (1.88A

20 30 40 50

Speed-RPS

OS22B

20 30 40 50

Speed-RPS

RS31B

Series (2.26A

pk)

20 30 40 50

pk)

20 30 40 50

pk)

20 30 40 50

Series (2.26A

Speed-RPS

RS32B

Speed-RPS

RS33B

Speed-RPS

Series (1.51A

Parallel (3.75A

pk)

Parallel (4A

pk)

Parallel (4.0A

Parallel (4A

= Torque

= Power

watts (hp)

Parallel 91 (0.12)

Series 68 (0.09)

Use series wiring if your application permits.

ZETA motors come from the factory with a permanently attached motor cable wired to the motor connector for series motor current. The O and R Series motors have flying leads or

pk)

pigtails that you must wire to the motor connector yourself. The operating temperature of a motor connected in series will be lower

watts (hp)

Parallel 263 (0.36)

pk)

Series 102 (0.14)

watts (hp)

Parallel 199 (0.27)

pk)

Series 104 (0.14)

than that of a motor connected in parallel. Typically, series connections work well in high torque/low speed applications.

Series motor wiring diagrams are

provided on page 9.

When to use parallel wiring.

At higher speeds, a motor connected in parallel will produce more torque than the same motor connected in series. Use caution, however, because the operating temperature of

watts (hp)

pk)

Parallel 230 (0.31)

the motor in parallel will be much hotter. If you operate your motor in parallel, measure motor temperature under actual operating conditions. If the motor exceeds its maximum case

Series 120 (0.16)

temperature, reduce the duty cycle to limit motor heating. Compumotorsupplied motors have maximum case temperatures of 212°F (100°C).

watts (hp)

Parallel 359 (0.48)

pk)

Series 186 (0.25)

watts (hp)

Parallel 327 (0.44)

Series 246 (0.33)

To wire the motor for parallel

motor current, refer to the wiring

diagrams on page 9.

Non-Compumotor Motors: If you are using a nonCompumotor motor, refer to Appendix B for connection instructions and current-select DIP switch settings.

10 z ZETA6104 Installation Guide

Page 17

End-of-Travel and Home Limit Inputs

¥ CAUTION: Use either the on-board +5V terminal or an external power supply to power

the AUX-P pull-up resistor (using both will damage the ZETA6104).

¥ Motion will not occur until you do one of the following:

- Install end-of-travel (POS & NEG) limit switches.

- Disable the limits with the LH¯ command (recommended only if load is not coupled).

- Change the active level of the limits with the LHLVL command.

¥ Refer to the Basic Operation Setup chapter in the 6000 Series ProgrammerÕs Guide for

in-depth discussions about using end-of-travel limits and homing.

CONNECTIONS & INTERNAL SCHEMATICS

NOTES

ENCODER Connector

SHLD

HOM connected to GND

The home limit input is used during a homing move, which is initiated with the HOM command. After initiating the homing move, the controller waits for the home switch to close, indicating that the load has reached the ÒhomeÓ reference position. The active level (default is active low) can be changed with the HOMLVL command. You can also use an encoderÕs Z channel pulse, in conjunction with the home switch, to determine the home position (this feature is enabled with the HOMZ1 command).

(normally-open switch).

GND ZZ+ BB+ AA+ +5V

LIMITS Connector

GND HOM NEG POS

POS & NEG connected to GND

Mount each switch such that the load forces it to open before it reaches the physical travel limit (leave enough room for the load to stop). When the load opens the switch, the axis stops at the decel value set with the LHAD command. The motor will not be able to move in that same direction until you execute a move in the opposite direction and the limits with the LH¯ command, but this is recommended only if the motor is not coupled to the load). The active level (default is active low) can be changed with the LHLVL command.

+5V connected to AUX-P and V_I/O

Provides +5V power to the POS, NEG, and HOM input pull-up resistors. As an alternative, you can connect AUX-P to an external supply of up to +24V (but do not use both the on-board +5V terminal and an external 5-24V supply). If V_I/O is connected to a +5V supply (on-board or external), AUX-P can be connected to a supply of up to +24V. If V_I/O is connected to an external +24V supply, AUX-P must also be connected to +24V (or to GND).

Switching levels depend on voltage at V_I/O (LOW £ 1/3 of V_I/O volts; HIGH ³ 2/3 of V_I/O volts).

NOTE: AUX-P and V_I/O are also used by the P-CUT & TRG inputs.

SINKING CURRENT: To make the limit inputs (as well as P-CUT & TRG) sink current, connect AUX-P to GND.

clear the limit by closing the switch (or you can disable

(normally-closed switches).

(sourcing current).

I/O Connector

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P V_I/O

Chassis Ground

Iso Ground

Iso

Ground

+5VDC

6.8 KW

Internal Schematic

Similar circuits for NEG and POS inputs.

20.0 KW 18.2 KW

LM 339

12.1 KW

10.0 KW

30.1 KW

PIN OUTS & SPECIFICATIONS (4-pin LIMITS Connector)

Name In/Out Description Specification for all limit inputs

GND

HOM

NEG

POS

Isolated ground.

Home limit input.

Negative-direction endof-travel limit input.

Positive-direction endof-travel limit input.

¥ Powered by voltage applied to V_I/O terminal (switching levels: Low £1/3 of V_I/O voltage,

High ³2/3 of V_I/O voltage). V_I/O can handle 5-24V with max. current of 100mA. Internal 6.8 KW pull-ups to AUX-P terminalÑconnect AUX-P to power source (+5V terminal or an external 5-24V supply) to source current, or connect AUX-P to GND to sink current; AUX-P can handle 0-24V with

max. current of 50mA. Voltage range for these inputs is 0-24V. ¥ Active level for HOM is set with HOMLVL (default is active low, requires n.o. switch). ¥ Active level for POS & NEG is set with LHLVL (default is active low, requires n.c. switch).

Chapter 1. Installation 11

Page 18

Encoder

CONNECTIONS & INTERNAL SCHEMATICS

Shield Shield Shield

Max. Cable Length is 100 feet. Use 22 AWG wire.

Incremental

Encoder

Colors for Compumotor-supplied Encoders:

-E Series encoders

-RE encoder on OS motor (OSxxx-xxx-RE)

-RC encoder on OS motor (OSxxx-xxx-RC)

-EC encoder on RS motor (RSxxx-xxx-EC)

Colors for -HJ encoder on OS motor (OSxxx-xxx-HJ).

Ground Black Black

Z Channel Ð Orange/White (n/a)

Z Channel + Orange Blue

B Channel Ð Green/White (n/a)

B Channel + Green Brown

A Channel Ð Brown/White (n/a)

A Channel + Brown White

+5VDC Red Red

ENCODER Connector

SHLD GND ZZ+ BB+ AA+ +5V

Internal Schematic

Isolated Ground

Same Circuit as A Channel

+5VDC

Chassis Ground

+1.8VDC

22 KW

+5VDC

NOTE

If you are using a single-ended encoder, leave the A-, B-, and Z- terminals on the ZETA6104 unconnected.

PIN OUTS & SPECIFICATIONS (9-pin ENCODER Connector)

Pin Name In/Out Description

SHLD

GND

ZÐ

Z+

BÐ

B+

AÐ

A+

+5V

-----

OUT

ShieldÑInternally connected to chassis ground (earth).

Isolated logic ground.

ZÐ Channel signal input.

Z+ Channel signal input.

BÐ Channel quadrature signal input.

B+ Channel quadrature signal input.

AÐ Channel quadrature signal input.

A+ Channel quadrature signal input.

+5VDC output to power the encoder.

Differential comparator accepts two-phase quadrature incremental encoders with differential (recommended) or single-ended outputs. Max. frequency is 1.6 MHz. Minimum time between transitions is 625 ns. TTL-compatible voltage levels: Low £ 0.4V, High ³ 2.4V. Maximum input voltage is 5VDC.

Requirements for Non-Compumotor Encoders

¥ Use incremental encoders with two-phase quadrature output. An index or Z channel

output is optional. Differential outputs are recommended.

¥ It must be a 5V (< 200mA) encoder to use the ZETA6104Õs +5V output. Otherwise, it must

be separately powered with TTL-compatible (low £ 0.4V, high ³ 2.4V) or open-collector outputs.

¥ The decoded quadrature resolution should be less than the motor resolution by a factor of

four to take advantage of the ZETA6104Õs position maintenance capability.

Specification for all encoder inputs

12 z ZETA6104 Installation Guide

Page 19

Trigger Inputs

ENCODER Connector

TRG-A/B connected to GND

The active level (default is active low) can be changed with the INLVL command.

These inputs are like the general-purpose inputs on the 50-pin header. The differences are (1) the triggers are pulled up via the AUX-P pull-up terminal and powered by the voltage applied to the V_I/O terminal; and (2) the triggers can be programmed with the INFNCi-H command to function as position capture inputs and registration inputs.

(normally-open switches).

I/O Connector

+5V connected to AUX-P and V_I/O

Provides +5V power to the TRG-A & TRG-B input pull-up resistors. As an alternative, you can connect AUX-P to an external supply of up to +24V (but do not use both the on-board +5V terminal and an external 5-24V supply). If V_I/O is connected to a +5V supply (on-board or external), AUX-P can be connected to a supply of up to +24V. If V_I/O is connected to an external +24V supply, AUX-P must also be connected to +24V (or to GND).

Switching levels depend on voltage at V_I/O (LOW £ 1/3 of V_I/O volts; HIGH ³ 2/3 of V_I/O volts).

NOTE: AUX-P and V_I/O are also used by the HOM, NEG, POS & P-CUT inputs.

SINKING CURRENT: To make the trigger inputs (as well as HOM, NEG, POS & P-CUT) sink

current, connect AUX-P to GND.

(sourcing current).

SHLD GND ZZ+ BB+ AA+ +5V

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P V_I/O

Iso

Ground

+5VDC

6.8 KW

Chassis Ground

20.0 KW 18.2 KW

12.1 KW

Internal Schematic

Similar circuit for TRG-A.

LM 339

10.0 KW

30.1 KW

Connection to a Sinking Output Device Connection to a Sourcing Output Device

Electronic Device

The output should be able to sink at least 1mA of current.

Out 5-24 Volts

Output

Ground

Pulled up

to +5V

(sourcing)

ZETA6104

I/O Connector

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P V_I/O

(see schematic drawing above)

Electronic Device ZETA6104

Out 5-24 Volts

Output

Ground

Pulled

down to

ground

(sinking)

I/O Connector

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P V_I/O

(see schematic drawing above)

Connection to a Combination of Sinking & Sourcing Outputs

Electronic Device ZETA6104

Output

Out 5-24 Volts

Ground

Typical value for R = 450W (assuming R1 = 0) Note: The value of R may vary depending on the value of R1 and V1.

Pulled up

to +5V

(sourcing)

I/O Connector

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P V_I/O

(see schematic drawing above)

If you will be connecting to a combination of sourcing and sinking outputs, connect AUX-P to +5-24V to accommodate sinking output devices. Then for each individual input connected to a sourcing output, wire an external resistor between the ZETA6104Õs trigger input terminal and ground (see illustration). The resistor provides a path for current to flow from the device when the output is active.

PROGRAMMING TIP

Connecting to a sinking output? Set the trigger inputÕs active level to low

with the INLVL command (¯ = active low, default setting). Connecting to a sourcing output? Set the trigger inputÕs active level to

high with the INLVL command (1 = active high). Thus, when the output is active, the TIN status command will report a Ò1Ó

(indicates that the input is active), regardless of the type of output that is connected.

For details on setting the active level and checking the input status refer to the INLVL and TIN command descriptions in the 6000 Series Software Reference.

Chapter 1. Installation 13

Page 20

General-Purpose Programmable Inputs & Outputs

VM50 ADAPTOR Ñ for screw-terminal connections

Color stripe

PROGRAMMABLE I/O

2-Foot Cable

(provided with VM50)

Color stripe

(pin #1)

Pin outs on the VM50 are identical to the pin outs for the 50-pin connectors (only if the cable is connected as illustrated).

The VM50 snaps

on to any standard

DIN rail.

PIN OUTS & SPECIFICATIONS

Pin Function Internal Schematics Specifications

1 Input #16 (MSB of inputs)

PROGRAMMABLE I/O

50-pin plug is compatible with OPTO-22ª signal conditioning equipment.

3 Input #15

5 Input #14 7 Input #13

9 Input #12 11 Input #11 13 Input #10 15 Input #9 17 Output #8 (MSB of outputs) 19 Output #7 21 Output #6 23 Output #5 25 Input #8 27 Input #7 29 Input #6 31 Input #5 33 Output #4

35 Output #3 37 Output #2 39 Output #1 (LSB of outputs) 41 Input #4 43 Input #3 45 Input #2 47 Input #1 (LSB of inputs) 49 +5VDC

NOTE: All even-numbered pins are connected to a common logic ground (DC ground) Ñ see drawing on page 7.

LSB = least significant bit; MSB = most significant bit

2 4 6 8 10 12 14 16 18 20

1 3 5 7 9 11 13 15 17 19

22 24 26232825302732293431363338354037423944414643484550

VM50 Adaptor Board

Inputs

External 5-24VDC Supply

(an alternative to using the

on-board +5V terminal)

When connecting to a sinking output device, connect IN-P to the +5V terminal OR to a user-supplied external supply of up to 24VDC (but not to both).

Connection

Ground

Connection

ZETA6104

GND

+5V

IN-P

Input

Outputs (including OUT-A)

External 5-24VDC Supply

(an alternative to using the

on-board +5V terminal)

Pull-up: Connect OUT-P to the +5V terminal OR to a user-supplied external supply of up to 24VDC (but not to both).

Output

Connection

Ground

Connection

ZETA6104

GND

+5V

OUT-P

UDK2559

+5VDC

6.8 KW

47 KW

+5VDC

4.7 KW

ISO GND

74HCxx

ISO GND

47 4921

Inputs

HCMOS-compatible voltage levels (low £ 1.00V, high ³ 3.25V).

Voltage range = 0-24V.

Sourcing Current: On the I/O connector, connect IN-P to +5V or connect IN-P to an

external 5-24VDC power supply (but not to both).

Sinking Current: On the I/O connector, connect IN-P to GND.

STATUS: Check with TIN or INFNC.

Active level: Default is active low, but can be changed to active high with the INLVL command.

Outputs (including OUT-A)

Open collector output.

Pull-up connection on I/O connector: Connect OUT-P to +5V, or to an external

5-24VDC power supply (but not to both).

Outputs will sink up to 300mA or source up to 5mA at 5-24VDC.

STATUS: Check with TOUT or OUTFNC.

Active level: Default is active low, but can

Open

Collector

be changed to active high with the OUTLVL command.

ISO GND

CAUTION: You must select either the on-board +5V terminal or an external power supply to power the

IN-P and OUT-P pull-up resistors. Connecting IN-P or OUT-P to the +5V terminal and an

external supply will damage the ZETA6104. (The same rule applies to the AUX-P terminal.)

14 z ZETA6104 Installation Guide

Page 21

INPUT CONNECTIONS Ñ Connecting to electronic devices such as PLCs

Connection to a Sinking Output Device

Connection to a Sourcing Output Device

Connection to a Combination of Sinking & Sourcing Outputs

Electronic

Device

The output should be able to sink at least 1mA of current.

Out 5-24 Volts

Output

Ground

Electronic

Device

Output

Out 5-24 Volts

Ground

Electronic

Device

Output

Out 5-24 Volts

Ground

Pulled up

to +5V

(sourcing)

Connection

Pulled

down to

ground

(sinking)

Connection

Pulled up

to +5V

(sourcing)

Connection

GND

+5V

IN-P

Input

Ground

GND

+5V

IN-P

Input

Ground

GND

+5V

IN-P

Input

Ground

ZETA6104

+5VDC

6.8 KW

47 KW

ISO GND

ZETA6104

+5VDC

6.8 KW

47 KW

ISO GND

ZETA6104

+5VDC

6.8 KW

47 KW

ISO GND

74HCxx

ISO GND

74HCxx

ISO GND

74HCxx

PROGRAMMING TIP

Connecting to a sinking output? Set the

inputÕs active level to low with the INLVL command (¯ = active low).

Connecting to a sourcing output? Set

the inputÕs active level to high with the INLVL command (1 = active high).

Thus, when the output is active, the TIN status command will report a Ò1Ó (indicates that the input is active), regardless of the type of output that is connected.

Details on setting the active level and checking the input status are provided in the 6000 Series ProgrammerÕs Guide. Refer also to the INLVL and TIN command descriptions in the 6000 Series Software Reference.

Typical value for R = 450W (assuming R1 = 0) Note: The value of R may vary depending on the value of R1 and V1.

NOTE: If you will be connecting to a combination of sourcing and sinking outputs, connect IN-P to +5V (or to an

external 5-24VDC supply) to accommodate sinking output devices. Then for each individual input connected to a sourcing output, wire an external resistor between the ZETA6104Õs programmable input terminal and ground (see ÒRÓ in above drawing). The resistor provides a path for current to flow from the device when the output is active.

Chapter 1. Installation 15

Page 22

OUTPUT CONNECTIONS (includes OUT-A) Ñ for electronic devices such as PLCs

Connection to a Sinking Input (active high) Connection to a Sourcing Input (active low)

External Supply

Electronic

Device

Input

Ground

(up to 24VDC)

GND

+5V

OUT-P

Output

Connection

Ground

Connection

ZETA6104

ISO GND

+5VDC

4.7 KW

UDK2559

(open collector)

ISO GND

Connection to a Combination of Sinking & Sourcing Inputs

External Supply

Electronic

Devices

Sourcing Input

Sinking Input

V+

Input

Ground

Input

Ground

(up to 24VDC)

GND

OUT-P

Output 1

Output 2

Ground

Connection

+5V

ZETA6104

ISO GND

+5VDC

4.7 KW

UDK2559

(open collector)

4.7 KW

UDK2559

(open collector)

ISO GND

Combinations of sourcing and sinking inputs can be accommodated at the same voltage level. Be aware of the input impedance of the sourcing input module, and make sure that there is enough current flowing through the input module while in parallel with the OUT-P pull-up resistor.

Connection to an Inductive Load (active low)

External Supply

(up to 24VDC)

GND

OUT-P

Output

Connection

+5V

ZETA6104

ISO GND

+5VDC

4.7 KW

UDK2559

(open collector)

Use an external diode when driving inductive loads. Connect the diode in parallel to the inductive load, attaching the anode to the ZETA6104 output and the cathode to the supply voltage of the inductive load.

Electronic

Device

V+

Input

Ground

External Supply

(up to 24VDC)

GND

OUT-P

Output

Connection

Ground

Connection

+5V

ZETA6104

ISO GND

+5VDC

4.7 KW

UDK2559

(open collector)

ISO GND

PROGRAMMING TIP

Connecting to an activehigh sinking input? Set

the outputÕs active level to high with the OUTLVL command (1 = active high).

Connecting to an activelow sourcing input? Set

the outputÕs active level to low with the OUTLVL command (¯ = active low).

Thus, when the ZETA6104Õs output is activated, current will flow through the attached input and the TOUT status command will report a Ò1Ó (indicates that the output is active), regardless of the type of input that is connected.

Details on setting the active level and checking the output status are provided in the 6000 Series ProgrammerÕs Guide. Refer also to the OUTLVL and TOUT command descriptions in the 6000 Series Software Reference.

16 z ZETA6104 Installation Guide

Page 23

THUMBWHEEL CONNECTIONS Ñ for entering BCD data

Connection to the Compumotor TM8 Module

TM8 Thumbwheel Module

+ 1 2 3 4 5 6 7 8

+5 GND I5 I4 I3 I2 I1 O5 O4 O3 O2 O1

ZETA6104

Programmable Input #1 Programmable Input #2 Programmable Input #3 Programmable Input #4 Programmable Input #5

Pin #49 (+5VDC)

Pin #48 (GND) Programmable Output #1 Programmable Output #2 Programmable Output #3

Optional Sign Bit

Connection to your own Thumbwheel Module

Thumbwheel#1Thumbwheel#2Thumbwheel#3Thumbwheel#4Thumbwheel#5Thumbwheel#6Thumbwheel#7Thumbwheel

Sign Bit

Input #9 (sign) Input #8 MSB Input #7 Input #6 Input #5 LSB Input #4 MSB Input #3 Input #2 Input #1 LSB

most

significant

digit

least

significant

digit

ZETA6104

Output #4 Output #3 Output #2 Output #1 I/O GND

Chapter 1. Installation 17

Page 24

RP240 Remote Operator Panel

RP240 Back Plane

GND Rx Tx +5V

Input Power

COM 1 COM 2

Rx Tx GND SHLD

+5V GND Rx Tx SHLD

Rx+ RxÐ Tx+

TxÐ

GND

RP240 Connections when using RS-485

GND Rx Tx +5V

If you will use RS-485 serial communication, you must connect the RP240 to the connector (and connect the RP240's +5V lead to the

+5V terminal on the I/O connector).

In addition, you will have to issue these commands to configure the ZETA6104 to communicate successfully with the RP240 connected to connected to

PORT1........Select COM 1 as the affected port.

DRPCHK1.... On powerup, check for RP240 on COM 1.

PORT2........Select COM 2 as the affected port.

DRPCHK¯.... On powerup, do not check for RP240

..................on COM 2.

COM 1 and with RS-485 COM 2.

COM 1

COM 1 COM 2

Rx Tx GND SHLD +5V GND Rx Tx SHLD

SHLD GND

ENCODER

ZÐ Z+ BÐ B+ AÐ A+ +5V

LIMITS

GND HOM NEG POS

TRG-A TRG-B OUT-A GND

I/O

P-CUT +5V OUT-P IN-P AUX-P V_I/O

PROG

Rx+ RxÐ Tx+ TxÐ

GND

SHLD

6104

SHLD

INDEXER DRIVE

POWER

STEP

OVER TEMP

MOTOR FAULT

EARTH

Compumotor

95-132 VAC

50/60 Hz

ZETA

AC POWER

Power Cable

Provided in ship kit (p/n 44-014768-01) Length: 6.6 ft (2.0 m)

WARNING: The motor case (via the EARTH terminal) and the ZETA6104Õs SHLD

terminals are grounded through the AC power connector ground pin. You must provide a proper AC power ground for safety purposes.

Power Input Specification

95-132VAC, 50/60Hz, single-phase Peak Power requirements depend on the motor you use:

Motor Current Cabinet Peak Motor Peak Shaft Peak Total Volt-Amp Type (Amps) Loss (W) Loss (W) Power (W) Power (W) Rating (VA)

ZETA57-51(S) 1.26 11.9 25 60 97 145 ZETA57-51(P) 2.38 16.1 50 129 195 293

ZETA57-83(S) 1.51 12.7 27 80 120 180 ZETA57-83P 3.13 19.6 54 175 249 373

ZETA57-102(S) 1.76 13.6 30 80 124 185 ZETA57-102P 3.50 21.7 60 186 268 402

ZETA83-62(S) 2.26 15.5 50 120 186 278 ZETA83-62P 4.00 24.8 88 260 373 560

ZETA83-93(S) 2.88 18.4 52 180 250 376 ZETA83-93P 4.00 24.8 72 350 447 671

ZETA83-135(S) 3.50 21.7 57 193 272 408 ZETA83-135P 4.00 24.8 65 355 445 667

OS2HB(S) 1.51 21.1 67 34 122 199 OS2HB(P) 3.01 39.1 187 79 305 466

OS21B(S) 1.88 22.6 61 67 150 240 OS21B(P) 3.75 48.8 180 114 343 509

OS22B(S) 2.14 20.4 55 89 165 262 OS22B(P) 4.00 44.5 147 165 357 542

RS31B(S) 2.26 20.0 50 120 200 300 RS31B(P) 4.00 40.0 110 240 400 600

RS32B(S) 2.88 30.4 61 149 241 372 RS32B(P) 4.00 48.8 170 226 445 668

RS33B(S) 3.50 33.3 73 210 316 493 RS33B(P) 4.00 56.6 164 299 519 769

(S): Series Configuration (P): Parallel Configuration

LEDs (after power is applied):

POWER .................. On (green).

STEP ....................... Off. Or green if motion is commanded.

OVER TEMP ........... Off. Or red if the internal sensor reaches 131°F (55°C).

MOTOR FAULT ...... Off. Or red if there is a short in the motor windings or motor cable,

or if the INTERLOCK jumper on the motor connector is removed or extended.

18 z ZETA6104 Installation Guide

Page 25

Lengthening I/O Cables

Bear in mind that lengthening cables increases noise sensitivity. (The maximum length of cables is ultimately determined by the environment in which the equipment will be used.) If you lengthen the cables, follow the precautions below to minimize noise problems.

¥ Use a minimum wire size of 22 AWG.

¥ Use twisted pair shielded cables and connect the shield to a SHLD terminal on the

ZETA6104. Leave the other end of the shield disconnected.

¥ Do not route I/O signals in the same conduit or wiring trays as high-voltage AC wiring

or motor cables.

Reducing noise on limit, trigger, and P-CUT inputs. If you are experiencing noise problems, try adding resistors to reduce noise sensitivity (see illustration below).

You must use either the on-board +5V terminal or an external power supply to power the AUX-P pull-up resistor (for the P-CUT, HOM, NEG, POS, TRG-A, and TRG-B inputs). Connecting AUX-P to the +5V terminal and an external supply will

damage the ZETA6104.

ZETA6104

Terminal could be: P-CUT, HOM, NEG, POS, TRG-A, or TRG-B

Input Terminal

Isolated Ground

Earth

V_I/O

AUX-P

GND

Shield

Power Supply Options

OPTIONAL

External Power Supply

(5-24VDC)

Add a resistor between the input and the power supply (this will lower the input impedance and reduce noise sensitivity). Use a value between 330W and 2.2KW, depending on noise suppression required.

Output Device,

Switch, etc.

Long Shielded Cable

Chapter 1. Installation 19

Page 26

Testing the Installation

This test procedure allows you to control I/O and produce motion. Make sure that exercising the I/O will not damage equipment or injure personnel. We recommend that you leave the motor uncoupled from the load, but if you have coupled the load to the motor, make sure that you can move the load without damaging equipment or injuring personnel.

Test Setup

Computer

Terminal

Terminal Emulation for IBM/Compatibles

To communicate with the ZETA6104, you will need a terminal emulation program. We recommend you use Motion Architect, a Windowsbased program that is provided in your ship kit. Motion Architect provides terminal emulation and program editor features as part of its ensemble of programming tools.

Using Motion Architect:

1. To install, insert Disk 1 into your disk drive and run the Setup program (setup.exe).

2. After the Setup program is finished click on ÒRun Motion ArchitectÓ.

3. From the Product/Selection dialog box, select ÒZETA6104Ó and click OK.

4. Click on ÒTerminalÓ from the main menu to run the terminal emulator.

WARNING

COM 1 COM 2

Serial Connection:

RS-232C

RS-485

(see page 8)

I/O Connections

(see pages 7-19)

ENCODER

LIMITS

I/O PROGRAMMABLE I/O

Rx Tx GND SHLD +5V GND Rx Tx SHLD

SHLD GND ZÐ Z+ BÐ B+ AÐ A+ +5V

GND HOM NEG POS

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P V_I/O

Rx+ RxÐ Tx+ TxÐ

GND

POWER

STEP

OVER TEMP

MOTOR FAULT

Compumotor

95-132 VAC

50/60 Hz

6104

INDEXER DRIVE

INTERLOCK

CENTER TAP

A+

A-

EARTH

B+

B-

CENTER TAP

INTERLOCK

ZETA

MOTOR

AC POWER

If you use a different terminal emulation software package, make sure to configure it as follows:

9600 Baud 8 Data Bits No Parity 1 Stop Bit Full Duplex Enable XON/XOFF

Having serial communication problems?

Refer to page 35 and 36 for help.

The test procedures below are based on the factory-default active levels for the ZETA6104Õs inputs and outputs. Verify these settings with the following status commands:

Command Entered Response Should Be

INLVL *INLVL¯¯¯¯_¯¯¯¯_¯¯¯¯_¯¯¯¯_¯¯ HOMLVL *HOMLVL¯ LHLVL *LHLVL¯¯ OUTLVL *OUTLVL¯¯¯¯_¯¯¯¯_¯

20 z ZETA6104 Installation Guide

Connect to

grounded

120VAC

(see page 18)

The installation test will cause motion. Make sure the motor is secured in place. If you have coupled the load to the motor, make sure that the load can move without causing injury to equipment or personnel.

NOTE

Motor

Page 27

Connections Test Procedure Response Format (left to right)

End-of-travel and Home Limits

NOTE: If you are not using end-of-travel limits, issue the Disable Limits (LH¯) command

and ignore the first two bits in each response field.

1. Enable the hardware end-of-travel limits with the LH3 command.

2. Close the end-of-travel switches and open the home switch.

TLIM response:

bit 1= POS (positive travel) limit bit 2= NEG (negative travel) limit bit 3 = HOM (home) limit

3. Enter the TLIM command. The response should be *TLIM11¯.

4. Open the end-of-travel switches and close the home switch.

5. Enter the TLIM command. The response should be *TLIM¯¯1.

6. Close the end-of-travel switches and open the home switch (return to original config.).

7. Enter the TLIM command. The response should be *TLIM11¯.

Motor and Encoder (motion)

1. Enter the ENC¯ command to enable the motor step mode.

Enter the PSET¯ command to set the motor position to zero. Enter the TPM command to determine the motor position. The response should be

TPM response = motor counts

TPE response = encoder counts

*TPM+¯ (motor is at position zero).

Enter the D25¯¯¯ command, followed by the GO command. The motor will move one revolution (25000 steps) in the clockwise direction (viewed from the flange end).

Enter the TPM command to determine the motor position. The response should be *TPM+25¯¯¯ (motor is at position 25000).

2. NOTE: Ignore this step if you are not using encoder feedback. This test assumes you are

Direction of rotation:

using a 1000-line encoder yielding a 4000 count/rev resolution.

Enter the ENC1 command to enable the encoder step mode.

Enter the PSET¯ command to set the encoder position to zero.

Enter the TPE command to determine the encoder position. The response should be *TPE+¯ (encoder is at position zero).

Clockwise

(positive counts)

Counter-clockwise

(negative counts)

If the encoder is coupled to the motor shaft: Enter the D4¯¯¯ command, followed by the GO command. The encoder (and motor) will move one revolution (4000 counts) in the clockwise direction (viewed from the flange end).

If the encoder is not coupled to the motor shaft: Manually rotate the encoder shaft one revolution in the clockwise direction (viewed from the flange end).

Enter the TPE command to determine the encoder position. The response should be *TPE+4¯¯¯ (encoder is at position 4000).

Enter the ENC¯ command to return the ZETA6104 to the default motor step mode.

Programmable Inputs (incl. triggers)

1. Open the input switches or turn off the device driving the inputs.

2. Enter the TIN command. The response should be *TIN¯¯¯¯_¯¯¯¯_¯¯¯¯_¯¯¯¯_¯¯.

TIN response:

bits 1-16 = prog. inputs 1-16 bits 17 & 18 = TRG-A & TRG-B

3. Close the input switches or turn on the device driving the inputs.

4. Enter the TIN command. The response should be *TIN1111_1111_1111_1111_11.

Programmable Outputs

1. Enter the OUTALL1,9,1 command to turn on (sink current on) all programmable

outputs. Verify that the device(s) connected to the outputs activated properly.

2. Enter the TOUT command. The response should be *TOUT1111_1111_1.

TOUT response:

bits 1-8 = prog. outputs 1-8 bit 9 = OUT-A

3. Enter the OUTALL1,9,¯ command to turn off all programmable outputs. Verify that the

device(s) connected to the outputs de-activated properly.

4. Enter the TOUT command. The response should be *TOUT¯¯¯¯_¯¯¯¯_¯.

RP240

Pulse Cut

1. Cycle power to the ZETA6104.

2. If the RP240 is connected properly, the RP240Õs status LED should be green and one of the

lines on the computer or terminal display should read *RP24¯ CONNECTED.

If the RP240Õs status LED is off, check to make sure the +5V connection is secure.

If the RP240Õs status LED is green, but the message on the terminal reads *NO REMOTE PANEL, the RP240 Rx and Tx lines are probably switched. Remove power and correct.

3. Assuming you have not written a program to manipulate the RP240 display, the RP240

screen should display the following:

COMPUMOTOR 6104 INDEXER/DRIVE RUN JOG STATUS DRIVE DISPLAY ETC

1. Open the P-CUT switch or turn off the device driving the P-CUT input.

2. Enter the TINO command (note the condition of the 6th bit from the left). The response should be *TINO¯¯¯¯_¯¯¯¯.

ASSUMPTIONS

¥ RP240 connected to COM 2

¥ COM 2 (PORT2) configured

for RP240. To verify, type these commands:

PORT2 <cr> DRPCHK<cr>

The system response should report Ò*DRPCHK3Ó.

TINO response:

bit 6 = pulse cut input bits 1-5, 7 & 8 are not used

3. Close the P-CUT switch or turn on the device driving the P-CUT input.

4. Enter the TINO command. The response should be *TINO¯¯¯¯_¯1¯¯.

Chapter 1. Installation 21

Page 28

Matching the Motor to the ZETA6104 (OPTIONAL)

Due to slight manufacturing variations, each motor has its own particular characteristics. In the procedure below, you will adjust three potentiometers (pots), to match your ZETA6104 to your specific motor. You will also select the best current waveform to use with your motor.

If you purchased a ZETA6104 and ZETA motor system (not applicable to OS and RS motors), the ZETA6104 and the ZETA motor were matched to each other at the factory. However, you may still want to perform the matching procedure below, because your operating conditions may not be the same as factory conditions.

The ZETA6104Õs pots are located behind the removable metal cover on top of the chassis.

Phase Balance (Magnitude of Phase B with respect to Phase A) Phase A Offset (DC Offset of Phase A motor current) Phase B Offset (DC Offset of Phase B motor current)

123456789101112

Before You Start

¥ Note that if you replace the ZETA6104 unit or the motor, you will have to redo this procedure. ¥ Set up a serial communication link and terminal emulator (see installation test on page 20). ¥ Connect the motor to the ZETA6104. ¥ Secure the motor in a location such that you can turn the pots and feel or hear the motor at the

same time. (You should perform this procedure with the motor not coupled to the load, because the characteristics you are matching are those only of the drive/motor combination.)

¥ Apply AC power when necessary to perform the steps below.

Step 1

Apply power to the ZETA6104, and allow it to reach a stable operating temperature. This may take up to 30 minutes. For optimum results, perform the matching procedure at the same ambient temperature at which your application will operate.

Step 2

For the adjustments that follow, consult the table below to find the speed at which to run the motor. These are speeds that cause resonance in the unloaded motor. When the motor is running at a resonant speed, you will notice increased noise and vibration. To make resonance the most noticeable, you may need to vary the speed around the value given below for your motor. You can find the resonant speed by touching the motor lightly with your fingertips as you vary the speed. When you feel the strongest vibrations, the motor is running at resonant speed.

Motor Offset Adjust (rps) Balance Adjust (rps) Waveform Adjust (rps)

ZETA57-51 .......... 4.72 ................ 2.36 ................. 1.18

ZETA57-83 .......... 4.66 ................ 2.33 ................. 1.17

ZETA57-102.......... 4.12 ................ 2.06 ................. 1.03

ZETA83-62 .......... 2.96 ................ 1.48 ................. 0.74

ZETA83-93 .......... 2.96 ................ 1.48 ................. 0.74

ZETA83-135.......... 2.89 ................ 1.45 ................. 0.73

OS2HB ............. 4.52 ................ 2.26 ................. 1.13

OS21B ............. 4.49 ................ 2.24 ................. 1.12

OS22B ............. 4.51 ................ 2.26 ................. 1.13

RS31B ............. 2.79 ................ 1.40 ................. 0.70

RS32B ............. 2.72 ................ 1.36 ................. 0.68

RS33B ............. 2.65 ................ 1.32 ................. 0.66

22 z ZETA6104 Installation Guide

Page 29

Step 3

Run your motor at the resonant speed listed in the Offset Adjust column. Vary the speed slightly until you find the resonance point.

To initiate motion, type these commands (followed by a carriage return) to the ZETA6104 from the terminal emulator:

MC1 (This command makes the motion run continuously until you issue a !S command.) Vn (This command sets the velocity to n . For example, V4.66 sets the velocity to 4.66 rps.) GO (This command initiate motion.)

To vary the speed while the motor is moving, type these immediate commands:

!Vn (This command selects the new velocity of n.) !GO (This command changes the motorÕs velocity to the new velocity value of n.)

NOTE: To stop the motor during this procedure, issue the !S command.

Re-issue the GO command to resume motion.

Step 4

Step 5

Step 6

Step 7

Step 8

Step 9

Adjust the Phase A Offset and Phase B Offset pots for minimum motor vibration and smoothest operation. Alternate between Phase A and PhaseÊB to find the minimum vibration point.

Run your motor at the resonant speed listed in the Balance Adjust column. Vary the speed slightly until you find the resonance point.

Adjust the balance pot until you find the setting that provides minimum motor vibration and smoothest operation.

Repeat steps 3Ð6.

Run the motor at the resonant speed listed in the Waveform Adjust column. Vary the speed slightly until you find the resonance point.

Choose the current waveform that provides minimum motor vibrations and smoothest operation at the speed you selected in step 8. To find the best waveform, compare motor performance as you select different waveforms using the !DWAVEF command.

Waveform DWAVEF Setting

-4% 3rd harmonic !DWAVEF1 ¬ Factory default

-10% 3rd harmonic !DWAVEF2

-6% 3rd harmonic !DWAVEF3

Pure sine !DWAVEF4 ¬ Do not use if drive resolution (DRES) is set to 200 steps/rev

NOTE: The DWAVEF command setting is NOT automatically saved in non-volatile memory; therefore, if

DWAVEF1 in not adequate, you have to place an alternative DWAVEF setting in a set-up (STARTP) program. Refer to page 31 for an example.

Step 10

Step 11

Disconnect AC power to turn off the ZETA6104. Replace the cover over the pots. This completes the matching procedure.

Proceed to the next section to mount and couple the motor.

Chapter 1. Installation 23

Page 30

Mounting & Coupling the Motor

WARNINGS

¥ Improper motor mounting and coupling can jeopardize personal safety, and compromise system performance. ¥ Never disassemble the motor; doing so will cause contamination, significant reduction in magnetization, and loss of torque. ¥ Improper shaft machining will destroy the motorÕs bearings, and void the warranty. Consult a factory Applications Engineer

(see phone number on inside of front cover) before you machine the motor shaft.

Mounting the Motor

Use flange bolts to mount rotary step motors. The pilot, or centering flange on the motorÕs front face, can help you position the motor.

Do not use a foot-mount or cradle configuration, because the motorÕs torque is not evenly distributed around the motor case. When a foot mount is used, for example, any radial load on the motor shaft is multiplied by a much longer lever arm.

The motors can produce very high torque and acceleration. If the mounting is inadequate, this combination of high torque/high acceleration can shear shafts and mounting hardware. Because of shock and vibration that high accelerations can produce, you may need heavier hardware than for static loads of the same magnitude.

Under certain move profiles, the motor can produce low-frequency vibrations in the mounting structure that can cause fatigue in structural members. A mechanical engineer should check the machine design to ensure that the mounting structure is adequate.

Motor Dimensions (xxxx) denotes millimeters

ZETA Series, 23 Frame

Model A

ZETA57-51 2.00 (1150.23) ZETA57-83 3.10 (1175.23) ZETA57-102 4.10 (101.60)

0.215

(5.461)

2.27

max

(4.953)

dia (4)

1.856

(47.14)

0.195

on 2.625 (66.67) BC

(57.66)

1.502

1.498

120

(305) 8 wire shielded

(38.15) (38.05)

0.82

(20.83)

0.72

(18.29)

0.2500

(6.35)

0.2495

(6.34)

Shaft Dia (2)

0.063(1.60)

0.19 (4.83)

0.83

(21.08)

0.73

(18.54)

#6-32 UNC-2B Thd

x 0.25 DP

(6.50)

(3) Equally Spaced on 1.865 BC

(47.37)

1.118

(28.40) dia

ZETA Series, 34 Frame

Model A

ZETA83-62 2.50 (1162.00) ZETA83-93 3.70 (1193.98) ZETA83-135 4.10 (129.00)

O Series, 23 Frame

Model Lmax

OS2HB 1.60 (40.70) OS21B 2.06 (52.40) OS22B 3.10 (78.80)

3.25

(82.55)

max

0.2500

(6.35

-A-

0.0000

0.0005

0.000)

0.127)

0.002 (0.05

3.40

(86.36)

Max Casting Size

2.877

(73.07)

2.873

(72.97)

)

0.81

(20.57)

120 (305)

8 wire shielded

2.730

(69.34)

2.750

(69.85)

0.228

dia

0.218 on 3.875 (98.42) BC

0.25

(6.35)

13.5

(342.9)

0.20

(5.08)

0.055

(1.40)

max.

(5.79) (5.54)

(31.24) (29.21)

dia (4)

0.003 (0.076)-B-0.003 (0.076)-A-

1.23

1.15

(18.29)

(19.05)

Encoder (optional)

0.2500

(6.35

0.72

max.

0.75

0.063

(1.60)

0.19

(4.83)

0.002 (0.05

-B-

0.0000

0.0005

0.000)

0.127)

)

1.21

1.17

(30.70) (29.72)

0.3750

(9.52)

0.3745

(9.51)

Shaft Dia (2)

Flexible rubber boot may be bent as shown. Nominal height 1.0 (25.4)

Motor painted black

18.0

(457.2)

min.

1.06

(26.92)

#6-32 UNC-2B Thd x 0.25 DP

(6.50)

(4) Equally Spaced

on 2.952 BC

0.750

(19.05) dia

x 0.050 Deep

(1.27)

Bore Min

10¡

2.44

(61.98)

(74.98)

24 z ZETA6104 Installation Guide

Page 31

R Series, 23 Frame End Bell Construction (NPS)

Model Lmax L2

RS31B- NPS 3.62 (nn91.95) 2.87 (nn72.90) RS32B- NPS 4.77 (121.16) 4.02 (102.11) RS32B- NPS 6.05 (153.67) 5.30 (134.62)

(85.85)

2 x 45¡

¯2.875 0.002

(73.025 0.051)

0.003 (0.077)-A-

3.38

4 x ¯0.218 (5.46) thru equally spaced on a

¯3.875 (98.43) B.C.

0.0000

¯0.3750

0.0005

0.000)

(9.53

0.013)

)

0.002 (0.051

-A-

1.25

(31.75)

0.003 (0.077)-A-

max.

0.06 (1.52)

0.18 (4.57)

R 1.72

(43.69)

2.02

(51.31)

max.

Removable insulating bushing Construction = conduit. Connection (1/2 NPS TAP) with 0.56 (14.22) I.D. removable insulating bushing

R Series, 34 Frame Regular Construction (R10)

Model Lmax

RS31B- R10 2.58 (nn65.54) RS32B- R10 3.76 (nn95.51) RS32B- R10 5.06 (128.53)

0.75 (19.05)

full depth

0.344 (8.738)

1.25 (31.75)

Flat Configuration = F Rear Shaft Configuration = D

0.75 (19.05)

full depth

0.344

(8.738)

1.25 (31.75)

Flat Configuration = F

3.38

(85.85)

2 x 45¡

Standard Front Shaft Configurations Double Shaft Configuration

0.374

0.50 0.02

(12.7 0.051)

0.0469 0.0050

(1.191 0.128)

(9.50

1.25 (31.75)

#303 Woodruff Key Configuration = W

4 x ¯0.218 (5.46) thru equally spaced on a

¯3.875 (98.43) B.C.

¯2.875 0.002

(73.025 0.051)

0.003 (0.077)-A-

¯.3750

(9.53

0.002 (0.051

-A-

0.0000

0.0005

0.000)

0.013)

1.25 (31.75)

)

0.000

0.010

0.00)

0.26)

1.43 0.04

(36.32 1.02)

Indicated dimension

applies from end of extension to face of rear end bell (cover and gasket removed)

L max.

0.06 (1.52)

0.18 (4.57)

0.003 (0.077)-A-

Motor leads (fly) or with 10 ft cable (R10)

Standard Front Shaft Configurations Standard Double Shaft Configuration

0.50 0.02

(12.7 0.051)

0.0469 0.0050

(1.191 0.128)

0.374

(9.50

1.25 (31.75)

0.000

0.010

0.00)

0.26)

¯0.3750

(9.53

1.12 0.04

(28.45 1.02)

0.0000

0.0005

0.000)

0.013)

0.002 (0.051

#303 Woodruff Key Configuration = W

¯0.3750

(9.53

0.002 (0.051

)

0.0000

0.0005

0.000)

0.013)

)

Motor Temperature & Cooling

The motorÕs face flange is used not only for mounting; it is also a heatsink. Mount the face flange to a large thermal mass, such as a thick steel plate. This is the best way to cool the motor. Heat will be conducted from inside the motor, through the face flange, and dissipated in the thermal mass. You can also use a fan to blow air across the motor for increased cooling, if you do not get enough cooling by conduction through the face flange.

In addition, the ZETA6104 has an automatic standby current feature that reduces motor current by 50% if no step pulses have been commanded for a period of 1 second or more. (WARNING:Êtorque is also reduced.) Full current is restored upon the first step pulse. To enable this feature use, the DAUTOS1 command (default is disabled, DAUTOS¯). The DAUTOS command setting is NOT automatically saved in non-volatile memory; therefore, if you intend to use this mode on power up, you have to place the DAUTOS1 command in a set-up (STARTP) programÑsee example on page 31.

Coupling the Motor

To ensure maximum performance, align the motor shaft and load as accurately as possible (although some misalignment may be unavoidable. The type of misalignment will affect your choice of coupler.

Single-Flex Coupling: Use for angular misalignment only. One (only) one of the shafts must be free to move in the radial direction without constraint.

Do not use a single-flex coupling with parallel

misalignmentÑthis will bend the shafts, causing excessive bearing loads and premature failure.

Double-Flex Coupling: Use whenever two shafts are joined with parallel misalignment, or a combination of angular and parallel misalignment. Single-flex and double-flex couplings may or may not accept end play, depending on their design.

Rigid Coupling: Not recommended, because they cannot compensate for any misalignment. Use only if the motor or load is on some form of floating mounts that allow for alignment compensation. Rigid couplings can also be used when the load is supported entirely by the motorÕs bearings. A small mirror connected to a motor shaft is an example of such an application.

Coupling Manufacturers: HUCO, 70 Mitchell Blvd, Suite 201, San Rafael, CA 94903, (415) 492-0278

ROCOM CORP., 5957 Engineer Drive, Huntington Beach, CA 92649, (714) 891-9922

Aligned

End Float

Angular Misalignment

Parallel Misalignment

Combined Parallel & Angular Misalignment

Chapter 1. Installation 25

Page 32

Optimizing System Performance (OPTIONAL)

The ZETA6104 is equipped with three damping circuits that minimize resonance and ringing, and thus enhance stepper performance:

¥ Anti-Resonance Ð General-purpose damping circuit. The ZETA6104 ships from the

factory with anti-resonance enabled (see DAREN command). No configuration is necessary.

The ZETA6104 automatically switches between the damping circuits, based upon the motorÕs speed.

Anti-resonance provides aggressive and effective damping at speeds greater than 3 revolutions per second (rps). If you are using a high-inductance motor (not applicable to ZETA, OS or RS motors), you should disable anti-resonance with the DAREN¯ command.

¥ Active Damping Ð Extremely powerful damping circuit at speeds greater than 3 rps.

The ZETA6104 ships from the factory with active damping disabled. To enable active damping and optimize it for a specific motor size and load, refer to the Configuring Active Damping procedure below.

¥ Electronic Viscosity Ð Provides passive damping at lower speeds (from rest to 3 rps).

The ZETA6104 ships with electronic viscosity disabled. To enable electronic viscosity and optimize it for a specific application, refer to the Configuring Electronic Viscosity procedure below.

For a theoretical discussion about these three circuits and how they minimize resonance and ringing, refer to Appendix A.

NOTE: You need to "match the motor to the ZETA6104Ó before you can configure active damping or electronic viscosity. Refer to the matching procedure on page 22.

Configuring Active Damping

¥ Couple the motor to the load (see pages 24-25 for details). Active damping must be

configured under the normal mechanical operating conditions for your application.

¥ Record the setup command settings. The procedure below helps you identify the

appropriate set-up commands (DMTIND, DMTSTT, and DACTDP) that will prepare your system for optimized performance. These commands are saved in non-volatile memory. However, you may still want to record these values so you can later place them in a set-up program (a set-up program executes user-specified commands that establish power-up operational defaults for your application). Page 31 shows an example of how to place these commands in a set-up (STARTP) program.

Step 1

Verify correct motor-to-ZETA6104 matching. See Matching the Motor to the ZETA6104 on page 22. To be fully effective, the active damping circuit requires proper

matching. If you are replacing a component (new ZETA6104 or motor in an existing application), you must rematch your system.

Before You Start

26 z ZETA6104 Installation Guide

Page 33

Step 2

Establish appropriate inductance and static torque settings. If you ordered a ZETA6104 and a ZETA motor together as a ÒsystemÓ, these settings were made at the factory

(OS and RS motors may not be ordered as a ÒsystemÓ). Use the DMTIND command to set the inductance, and use the DMTSTT command to set the static torque (see table below). The DMTIND and DMTSTT values are automatically saved in battery-backed RAM.

Motor --- INDUCTANCE ---

Range DMTIND MH Setting

ZETA57-51(S) 20.08 & greater DMTIND1 * 0.26 Ð 0.72 36 Ð 100 DMTSTT1 * ZETA57-51(P) 5.03 Ð 10.30 DMTIND3 0.26 Ð 0.72 36 Ð 100 DMTSTT1 *

ZETA57-83(S) 20.08 & greater DMTIND1 * 0.26 Ð 0.72 36 Ð 100 DMTSTT1 * ZETA57-83(P) 5.03 Ð 10.30 DMTIND3 0.26 Ð 0.72 36 Ð 100 DMTSTT1 *

ZETA57-102(S) 20.08 & greater DMTIND1 * 0.73 Ð 1.41 101 Ð 200 DMTSTT2 ZETA57-102(P) 5.03 Ð 10.30 DMTIND3 0.73 Ð 1.41 101 Ð 200 DMTSTT2

ZETA83-62(S) 10.31 Ð 20.07 DMTIND2 0.73 Ð 1.41 101 Ð 200 DMTSTT2 ZETA83-62(P) less than 5.02 DMTIND4 0.73 Ð 1.41 101 Ð 200 DMTSTT2

ZETA83-93(S) 10.31 Ð 20.07 DMTIND2 1.42 Ð 2.33 201 Ð 330 DMTSTT3 ZETA83-93(P) less than 5.02 DMTIND4 1.42 Ð 2.33 201 Ð 330 DMTSTT3

ZETA83-135(S) 10.31 Ð 20.07 DMTIND2 2.34 Ð 3.48 331 Ð 492 DMTSTT4 ZETA83-135(P) less than 5.02 DMTIND4 1.42 Ð 2.33 201 Ð 330 DMTSTT2

OS2HB(S) 5.03 Ð 10.30 DMTIND3 0.26 Ð 0.72 36 Ð 100 DMTSTT1 * OS2HB(P) less than 5.02 DMTIND4 0.26 Ð 0.72 36 Ð 100 DMTSTT1 *

OS21B(S) 10.31 Ð 20.07 DMTIND2 0.26 Ð 0.72 36 Ð 100 DMTSTT1 * OS21B(P) less than 5.02 DMTIND4 0.26 Ð 0.72 36 Ð 100 DMTSTT1 *

OS22B(S) 10.31 Ð 20.07 DMTIND2 0.73 Ð 1.41 101 Ð 200 DMTSTT2 OS22B(P) less than 5.02 DMTIND4 0.73 Ð 1.41 101 Ð 200 DMTSTT2

RS31B(S) 10.31 Ð 20.07 DMTIND2 0.73 Ð 1.41 101 Ð 200 DMTSTT2 RS31B(P) less than 5.02 DMTIND4 0.73 Ð 1.41 101 Ð 200 DMTSTT2

RS32B(S) 10.31 Ð 20.07 DMTIND2 1.42 Ð 2.33 201 Ð 330 DMTSTT3 RS32B(P) less than 5.02 DMTIND4 1.42 Ð 2.33 201 Ð 330 DMTSTT3

RS33B(S) 5.03 Ð 10.30 DMTIND3 2.34 Ð 3.48 331 Ð 492 DMTSTT4 RS33B(P) less than 5.02 DMTIND4 2.34 Ð 3.48 331 Ð 492 DMTSTT4

(S) = Series Connection; (P) = Parallel Connection * = Factory default setting (unless you ordered the ZETA6104 with a ZETA motor as a ÒsystemÓ).

Range DMTSTT N-m Oz-in Setting

--- STATIC TORQUE ---

Step 3

Calculate only the maximum Active Damping (DACTDP) setting.

CAUTION

The purpose of this step is to identify the maximum DACTDP value for your system Ð DO NOT enter the DACTDP command now. In steps 5-7 of this procedure, never set the DACTDP value

higher than this maximum setting.

To calculate the maximum DACTDP value, first calculate your systemÕs total inertia (include the motorÕs rotor inertiaÑsee table on page 3). Then consult the table of inertia ranges below to find the DACTDP setting that corresponds to your systemÕs total inertia. If you are on the

boundary between two settings, pick the lower of the two numbers.

DACTDP Setting Total Inertia kg-cm

DACTDP15 0.088 to 0.205 8.8 to 20.5 0.481 to 1.121 DACTDP14 0.205 to 0.572 20.5 to 57.2 1.121 to 3.144 DACTDP13 0.572 to 1.069 57.2 to 106.9 3.127 to 5.845 DACTDP12 1.069 to 1.754 106.9 to 175.4 5.845 to 9.590 DACTDP11 1.754 to 2.727 175.4 to 272.7 9.590 to 14.910

DACTDP1¯ 2.727 to 3.715 272.7 to 371.5 14.910 to 20.312 DACTDP9 3.715 to 5.020 371.5 to 502.0 20.312 to 27.447 DACTDP8 5.020 to 6.275 502.0 to 627.5 27.447 to 34.308 DACTDP7 6.275 to 8.045 627.5 to 804.5 34.308 to 43.986 DACTDP6 8.045 to 9.595 804.5 to 959.5 43.986 to 52.460

DACTDP5 9.595 to 11.760 959.5 to 1176.0 52.460 to 64.297 DACTDP4 11.760 to 14.250 1176.0 to 1425.0 64.297 to 77.884 DACTDP3 14.250 to 15.900 1425.0 to 1590.0 77.884 to 86.905 DACTDP2 15.900 to 17.770 1590.0 to 1777.0 86.905 to 97.129 DACTDP1 17.770 to 20.570 1777.0 to 2057.0 97.129 to 112.465

DACTDP¯ Active Damping Disabled (factory default)

Total Inertia kg-m2 x 10-6 Total Inertia oz-in

Chapter 1. Installation 27

Page 34

Step 4

Make a baseline move with active damping disabled. This is your baseline move. Notice the sound, amount of motor vibration, etc. This move shows how your system operates with anti-resonance enabled, and active damping disabled. Each time you adjust the DACTDP setting (in steps 5-7), you will compare results against this baseline move.

1. Issue the DACTDP¯ command to disable active damping.

2. Make a move that is representative of your application, with similar velocity and acceleration. The velocity must be greater than 3Êrps, in order for the ZETA6104 to activate anti-resonance or active damping.

WARNING

Make sure that causing motion will not damage equipment or injure personnel.

The following six commands illustrate a simple incremental point-to-point move:

MC0 ; select the preset positioning mode MA0 ; select the incremental preset positioning mode A10 ; set the acceleration to 10 revs/sec/sec V8 ; set the velocity to 8 revs/sec/sec D250000 ; set the distance to 250,000 steps, equal to 10 revs GO ; initiate the move ; ************************************************************** ; * NOTE: To stop a move in progress, issue the !S command. * ; * To repeat the move, issue the GO command. To reverse * ; * direction, issue the D~ command and the GO command. * ; **************************************************************

Step 5

Step 6

Step 7

Make a move with active damping enabled. Compare the sound and vibration to the baseline move.

1. Issue the DACTDP1 command to enable active damping. This enables active damping at its lowest setting, and inhibits anti-resonance.

2. Make a move that is representative of your application. Use the same motion parameters that you set up in step 4. If you have not changed these settings, simply issue the GO command.

Increase the setting. Issue the DACTDP2 command (unless DACTDP1 is your calculated maximumÑsee step 3). Make the move again. Compare the sound and vibration to the levels obtained at DACTDP1.

Find the ideal DACTDP setting. Continue to increase the DACTDP setting by single increments. During a repetitive move, you can change the setting Òon the flyÓ (while the move is in progress) if you precede the DACTDP command with a Ò!Ó (e.g., !DACTDP2). This allows you to immediately compare two different settings.

Increase the setting until you obtain optimum results for your move. This will be the setting that yields the lowest audible noise and smoothest motor operation. Write down this setting so that you can include it in your programming (perhaps in the set-up program).

Never exceed your maximum setting (see step 3). For many applications, you will not need to go as high as the maximum setting. If you do not see perceptible improvement from one switch setting to the next, use the lower switch setting.

Higher switch settings result in higher dynamic motor current during transients, which can cause increased motor heating. Higher current also increases motor torque, resulting in sharper accelerations that can jerk or stress the mechanics in your system. If you test each intermediate DACTDP setting, you can evaluate the effects on your mechanics as you gradually increase damping.

28 z ZETA6104 Installation Guide

Page 35

Configuring Electronic Viscosity (EV)

¥ If you configured active damping (see procedure above), leave the DACTDP setting set at the

value you chose. You do not need to disable active damping while you configure EV.

¥ Couple the motor to the load (see pages 24-25 for details). EV must be configured

under the normal mechanical operating conditions for your application.

¥ Record the DELVIS command setting. The procedure below helps you identify the

appropriate set-up command (DELVIS) that will prepare your system for optimized performance. DELVIS is not saved in non-volatile memory. Therefore, you should write down this command as you qualify it in this procedure, then place it in a program. Page 31 shows an example of how to place DELVIS in a set-up (STARTP) program (a set-up program executes user-specified commands that establish power-up operational defaults for your application).

Before You Start

Step 1

Step 2

Verify correct motor-to-ZETA6104 matching. See Matching the Motor to the ZETA6104 on page 22. To be fully effective, the active damping circuit requires proper

matching. If you are replacing a component (new ZETA6104 or motor) in an existing application, you must rematch your system.

Make a baseline move with EV disabled. This is your baseline move. Notice the sound, amount of motor vibration, perceptible ringing, etc. This move shows how your system operates with EV disabled. Each time you adjust the DELVIS setting (in steps 3 & 4), you will compare results against this baseline move.

1. Issue the DELVIS¯ command to disable active damping.

2. Make a move that is representative of your application, with similar velocity and acceleration. The velocity must 3Êrps or less, in order for the ZETA6104 to activate EV.

WARNING

Make sure that causing motion will not damage equipment or injure personnel.

The following six commands illustrate a simple incremental point-to-point move:

MC0 ; select the preset positioning mode MA0 ; select the incremental preset positioning mode A10 ; set the acceleration to 10 revs/sec/sec V2 ; set the velocity to 2 revs/sec/sec D250000 ; set the distance to 250,000 steps, equal to 10 revs GO ; initiate the move ; ************************************************************** ; * NOTE: To stop a move in progress, issue the !S command. * ; * To repeat the move, issue the GO command. To reverse * ; * direction, issue the D~ command and the GO command. * ; **************************************************************

Step 3

Step 4

Make a move with EV enabled. Compare the results with the baseline move.

1. Issue the DELVIS1 command to enable EV.

2. Make a move that is representative of your application. Use the same motion parameters that you set up in step 1. If you have not changed these settings, simply issue the GO command.

Find the ideal EV setting. Continue to increase the DELVIS setting by single increments (the maximum setting is DELVIS7), and executing a move. Repeat this step until you find the setting that gives the best performance. You can try all seven settings. Incorrect settings will not cause damage.

During a repetitive move, you can change the setting Òon the flyÓ (while the move is in progress) if you precede the DELVIS command with a Ò!Ó (e.g., !DELVIS2). This allows you to immediately compare two different settings.

Chapter 1. Installation 29

Page 36

Record Your SystemÕs Configuration

You may wish to record your configuration information in the chart below.

Axis Name

Motor Inductance Setting (

Motor Static Torque Setting (

Waveform Setting (

Electronic Viscosity Setting (

Active Damping Setting (

Anti-Resonance Enabled? (

Current Standby Enabled? (

COM 1 Serial Port Function COM 2 Serial Port Function

RS-485 Resistor Values

DIP Switch Settings

This chart is repeated, along with other facts, on the magnetic information label located on the side of the ZETA6104 chassis. You can leave the label on the ZETA6104, or you can remove it and place it in a convenient location near the ZETA6104 (e.g., on an equipment cabinet door).

Use a marker or pen to write configuration information in the spaces at the bottom of the label. If you have multiple ZETA6104s, you can remove the labels and stack them on top of each other, with the bottom edge of each visible. This shows information about all axes at a glance.

Motor Size

DMTIND

DMTSTT

DWAVEF

DELVIS

DACTDP

DAREN1

DAUTOS1

OFF

) ) ) ) ) )

Yes

)

Yes

RS-232 RP240

RS-232

Terminate Bias

123456789101112

RP240 RS-485

¬COM port functions set with internal jumpers

and the PORT and DRPCHK commands.

¬ RS-485 resistors are selected with internal DIP

switches, or connected externally.

Recommended Set-up Program Elements

Most of the software configuration commands (see table below) are not saved in non-volatile

NOTE

In most applications, the factory default settings are adequate.

Command Function Factory Default Setting

DACTDP Enable/disable active damping. Active damping is automatically inhibited at or

DAREN Enable/disable anti-resonance. Anti-resonance is automatically inhibited at or

DAUTOS Enable/disable automatic current standby mode in which current to the motor is

DELVIS Enable/disable electronic viscosity. Electronic viscosity is automatically inhibited

DMTIND Match the inductance of your motor (used only for active damping). DMTIND1 (³ 20 MH) *

DMTSTT Match the motorÕs static torque (used only for active damping). DMTSTT1 (0.26-0.72 N-m; 36-100 Oz-in) *

DRPCHK Establish the type of check for an RP240. In general, this command is necessary

DWAVEF Match the motor waveform (required for matching the motor to the ZETA6104). DWAVEF1 (-4% 3rd harmonic)

ECHO Enable/disable echoing of characters. If communicating over RS-232 to the

PORT Identify the COM port to be affected by subsequent serial communication set-up

* These commands are automatically saved in non-volatile memory.

If ordered as a system (with a motor), the ZETA6104 is shipped with the DMTIND and DMTSTT commands set to match the motor.

below 3 rps. If active damping is enabled, anti-resonance is automatically inhibited. (See set-up procedure on page 26.)

below 3 rps, and it is inhibited if active damping is enabled.

reduced to 50% if no pulses are commanded for 1 second. Full current is restored upon the next pulse command.

above 3 rps. (See set-up procedure on page 29.)

only if you are using RS-485, which forces the RP240 to be connected to the COM

connector, instead of being connected to the COM 2 connector.

master ZETA6104 in an RS-485 multi-drop, see setup requirements on page 36.

commands (DRPCHK, E, ECHO, EOT, BOT, EOL, ERROK, ERRBAD, ERRDEF, XONOFF, and ERRLVL).

memory and therefore must be executed every time the ZETA6104 is powered up or reset. Therefore, you may wish to include the software configuration commands in the set-up program.

The set-up program is automatically executed when the ZETA6104 is powered up or reset; in it, you place the configuration commands that establish the operational readiness you require for your particular application. A sample set-up program is provided below. For more detailed information on creating a set-up program, refer to the 6000 Series ProgrammerÕs Guide.

DACTDP¯ (disabled)

DAREN1 (enabled)

DAUTOS¯ (disabled)

DELVIS¯ (disabled)

DRPCHK3 *

ECHO1 (enabled; but if using RS-485,

COMÊ2 is changed to ECHO¯ by default)

PORT1 (COM 1 is affected)

30 z ZETA6104 Installation Guide

Page 37

Set-up Program Example

Assumptions: The ZETA6104 is used with a Zeta83-93 motor wired in series.

RS-232C is connected to the COM 1 serial port. An RP240 is connected to the COM 2 serial port.

DEF SETUP ; Begin definition of the program called setup DWAVEF1 ; Select -4% 3rd harmonic waveform DMTIND2 ; Set motor inductance for ZETA83-93 motor in series DMTSTT3 ; Set motor static torque for ZETA83-93 motor in series DACTDP7 ; Enable active damping for total inertia of 40 oz-in DELVIS2 ; Enable electronic viscosity with value of 2 DAREN1 ; Enable anti-resonance PORT1 ; Subsequent serial communication setup affects COM1 port DRPCHK0 ; COM1 to be used for 6000 language commands PORT2 ; Subsequent serial communication setup affects COM2 port DRPCHK1 ; Check COM2 for RP240 -- If no RP240, use for 6000 commands PORT1 ; Subsequent serial-related commands will affect COM1 port ; ************************************************************************* : * Insert other appropriate commands in the setup program (e.g., custom * ; * power-up message, scaling factors, input function assignments, output * ; * function assignments, etc.). * ; * See Programmer's Guide, chapter 3, for more information. *

; ************************************************************************* END ; End definition of program called setup STARTP SETUP ; Assign the program named setup as the program to be executed

; on power up or reset

Chapter 1. Installation 31

Page 38

WhatÕs Next?

By now, you should have completed the following tasks, as instructed earlier in this chapter:

1. Review the general specifications Ñ see page 3

2. Perform configuration/adjustments, as necessary Ñ see pages 4-5

3. Mount the ZETA6104 Ñ see page 6

4. Connect all electrical system components Ñ see pages 7-19

Supplemental installation instructions for LVD-compliance are provided in Appendix C.

5. Test the installation Ñ see pages 20-21

6. Match the motor to the ZETA6104 (OPTIONAL) Ñ see pages 22-23

7. Mount the motor and couple the load Ñ see pages 24-25

8. Optimize system performance (OPTIONAL) by implementing Active Damping and Electronic Viscosity Ñ see pages 26-29

9. Record your system configuration information Ñ see pages 30-31

Program Your Motion Control Functions

You should now be ready to program your ZETA6104 for your application. Knowing your systemÕs motion control requirements, refer now to the 6000 Series ProgrammerÕs Guide for descriptions of the ZETA6104Õs software features and instructions on how to implement them in your application. Be sure to keep the 6000 Series Software Reference at hand as a reference for the 6000 Series command descriptions.

For assistance with your programming effort, we recommend that you use the programming tools provided in Motion Architect for Windows (found in your ship kit). Additional powerful programming and product interface tools are available (see below).

Motion Architect Motion Architect¨ is a Microsoft¨ Windowsª based 6000 product programming tool

(included in your ship kit). Motion Architect provides these features (refer to the Motion Architect User Guide for detailed information):

¥ System configurator and code generator: Automatically generate controller code

for basic system set-up parameters (I/O definitions, feedback device operations, etc.).

¥ Program editor: Create blocks or lines of 6000 controller code, or copy portions of

code from previous files. You can save program editor files for later use in BASIC, C, etc., or in the terminal emulator or test panel.

¥ Terminal emulator: Communicating directly with the ZETA6104, you can type in

and execute controller code, transfer code files to and from the ZETA6104.

¥ Test panel and program tester: You can create your own test panel to run your

programs and check the activity of I/O, motion, system status, etc. This can be invaluable during start-ups and when fine tuning machine performance.

¥ On-line context-sensitive help and technical references: These on-line

resources provide help information about Motion Architect, as well as access to hypertext versions of the 6000 Series Software Reference and the 6000 Series ProgrammerÕs Guide.

Other Software Tools Available

To Order these software packages, contact your local Automation Technology Center (ATC) or distributor.

Motion Builderª. A Windows-based iconic programming interface that removes the requirement to learn the 6000 programming language.

DDE6000ª. Facilitates data exchange between the ZETA6104 and Windowsª applications that support the dynamic data exchange (DDE) protocol. NetDDEª compatible.

Motion Toolboxª. A library of LabVIEW monitoring the ZETA6104. Available for the Windows environment.

virtual instruments (VIs) for programming and

32 z ZETA6104 Installation Guide

Page 39

CHAPTER TWO

Troubleshooting

IN THIS CHAPTER

¥ Troubleshooting basics:

- Reducing electrical noise

- Diagnostic LEDs

- Test options

- Technical support

¥ Solutions to common problems

¥ Resolving serial communication problems

¥ Product return procedure

Page 40

Troubleshooting Basics

When your system does not function properly (or as you expect it to operate), the first thing that you must do is identify and isolate the problem. When you have accomplished this, you can effectively begin to resolve the problem.

The first step is to isolate each system component and ensure that each component functions properly when it is run independently. You may have to dismantle your system and put it back together piece by piece to detect the problem. If you have additional units available, you may want to exchange them with existing components in your system to help identify the source of the problem.

Determine if the problem is mechanical, electrical, or software-related. Can you repeat or recreate the problem? Random events may appear to be related, but they are not necessarily contributing factors to your problem. You may be experiencing more than one problem. You must isolate and solve one problem at a time.

Log (document) all testing and problem isolation procedures. You may need to review and consult these notes later. This will also prevent you from duplicating your testing efforts.

Once you isolate the problem, refer to the problem solutions contained in this chapter. If the problem persists, contact your local technical support resource (see Technical Support below).

Reducing Electrical Noise

Refer to the guidelines on page 19. General information on reducing electrical noise can be found in the Engineering Reference section of the Parker Compumotor/Digiplan catalog. Appendix D (page 49) provides guidelines on how to install the ZETA6104 in a manner most likely to minimize the ZETA6104Õs emissions and to maximize the ZETA6104Õs immunity to externally generated electromagnetic interference.

Diagnostic LEDs

Test Options

Technical Support

POWER ............. On (green) if 120VAC connected. Off if no power.

STEP................. Flashes on (green) with each pulse sent to the motor. Off if no pulses.

OVER TEMP ........ On (red) if internal sensor reaches 131°F (55°C). Off = O.K.

MOTOR FAULT.... On (red) if there is a short in the motor windings, if the motor cable is

disconnected or shorted, or if the INTERLOCK jumper on the MOTOR connector is removed or extended. Off = O.K.

¥ Test Panel. Motion ArchitectÕs Panel Module allows you to set up displays for testing

system I/O and operating parameters. Refer to the Motion Architect User Guide for details.

¥ Hardware Test Procedure (see pages 20-21).

¥ Motion Test. A test program is available to verify that the ZETA6104 is sending

pulses to the motor and that the motor is functioning properly. The test program can be initiated by issuing the TEST command over the serial interface, or by accessing the RP240 TEST menu (see 6000 Series ProgrammerÕs Guide for RP240 menu structure).

WARNING

The TEST program causes the end-of-travel limits to be ignored. If necessary, disconnect the load to ensure the test moves do not damage your equipment or injure personnel.

If you cannot solve your system problems using this documentation, contact your local Automation Technology Center (ATC) or distributor for assistance. If you need to talk to our in-house application engineers, please contact us at the numbers listed on the inside cover of this manual. (These numbers are also provided when you issue the HELP command.) NOTE: Compumotor maintains a BBS that contains the latest software upgrades and latebreaking product documentation, a FaxBack system, and a tech support email address.

34 z ZETA6104 Installation Guide

Page 41

Common Problems & Solutions

NOTE: Some software-related causes are provided because it is sometimes difficult to identify a problem as either hardware or software related.

Problem Cause Solution

Communication (serial) not operative, or receive garbled characters

Direction is reversed. 1. Phase of step motor reversed (motor

Distance, velocity, and accel are incorrect as programmed.

Encoder counts missing.

Erratic operation. 1. Electrical noise and/or improper

LEDs See Diagnostic LEDs above (page 34) Motion does not occur. 1. Check LEDs.

Motor creeps at slow velocity in encoder mode (ENC1).

Programmable inputs not working.

Programmable outputs not working.

Torque, loss of. 1. Improper wiring.

Trigger, home, end-oftravel, or P-CUT inputs not working.

1. Improper interface connections or communication protocol

2. COM port disabled

3. In daisy chain or multi-drop, the unit may not be set to proper address

does not move in the commanded direction).

2. Phase of encoder reversed (reported TPE direction is reversed).

1. Incorrect resolution setting. 1.a. Set the drive resolution to 25,000 steps/rev (DRES25¯¯¯ command).

1. Improper wiring.

2. Encoder slipping.

3. Encoder too hot.

4. Electrical noise.

5. Encoder frequency too high.

shielding.

2. Improper wiring.

2. End-of-travel limits are active.

3. P-CUT (Pulse cut-off) not grounded.

4. Drive fault detected.

5. Undervoltage (AC supply < 95 VAC)

6. Improper wiring.

7. Load is jammed.

8. No torque from motor.

1. Encoder direction opposite of motor direction.

2. Encoder connected to wrong axis.

1. IN-P (input pull-up) not connected to a power supply.

2. If external power supply is used, the grounds must be connected together.

3. Improper wiring.

1. Output connected such that it must source current (pull to positive voltage).

2. OUT-P not connected to power source.

3. If external power supply is used, the grounds must be connected together.

4. Improper wiring.

2. No power (POWER LED off).

3. Overtemp, low voltage, or motor fault.

4. Drive shutdown.

5. Current standby mode enabled

1. If external power supply is used, the grounds must be connected together.

2. Improper wiring.

1. See Troubleshooting Serial Communication section below.

2.a. Enable serial communication with the E1 command.

2.b. If using RS-485, make sure the internal jumpers are set accordingly (see page 5). Make sure COM 2 port is enabled for sending 6000 language commands (execute the PORT2 and DRPCHK¯ commands).

3. Verify DIP switch settings (see page 4), or proper use of ADDR command.

1. Swap the A+ and AÐ connection at the MOTOR connector.

2. Swap the A+ and AÐ connection at the ENCODER connector. SOFTWARE ALTERNATIVE: If the motor (and the encoder if one is used) is

reversed, you can use the CMDDIR1 command to reverse the polarity of both the commanded direction and the polarity of the encoder feedback counts).

1.b. Set the ERES command setting (default setting is 4,000 counts/rev) to match the post-quadrature resolution of the encoder. Compumotor encoders:

E Series Encoders .................................................... ERES4000

OS motor with -HJ encoder (OSxxx-xxx-HJ) ........ ERES2048

OS motor with -RE encoder (OSxxx-xxx-RE) ....... ERES4000

OS motor with -RC encoder (OSxxx-xxx-RC) ...... ERES4000

RS motor with -EC encoder (RSxxx-xxx-EC) ....... ERES4000

1. Check wiring.

2. Check and tighten encoder coupling.

3. Reduce encoder temperature with heatsink, thermal insulator, etc.

4.a. Shield wiring.

4.b. Use encoder with differential outputs.

5. Peak encoder frequency must be below 1.6MHz post-quadrature. Peak frequency must account for velocity ripple.

1.a. Reduce electrical noise or move ZETA6104 away from noise source.

1.b. Refer to Reducing Electrical Noise on page 34.

2. Check wiring for opens, shorts, & mis-wired connections.

1. See Diagnostic LEDs above.

2.a. Move load off of limits or disable limits with the LH¯ command.

2.b. Set LSPOS to a value greater than LSNEG.

3. Ground the P-CUT connection.

4. Check status with TASXF command (see bit #4).

5. Check status with TASXF command (see bit #2). Check AC supply.

6. Check motor and end-of-travel limit connections.

7. Remove power and clear jam.

8. See problem: Torque, loss of.

1. Switch encoder connections A+ & A- with B+ & B-.

2. Check encoder wiring.

1.a. When inputs will be pulled down to 0V by an external device, connect IN-P to +5V supplied or to an external 5-24V positive supply (but not to both).

1b. When inputs are pulled to 5-24V by an external device, connect IN-P to 0V.

2. Connect external power supply's ground to ZETA6104Õs ground (GND).

3. Check wiring for opens, shorts, and mis-wired connections.

1. Outputs are open-collector and can only sink current -- change wiring.

2. Connect OUT-P to the +5V terminal or to an external supply of up to 24V.

3. Connect the external power supplyÕs ground to the ZETA6104Õs ground (GND).

4. Check wiring for opens, shorts, and mis-wired connections.

1. Check wiring to the motor, as well as other system wiring.

2. Check power connection (POWER LED should be on.

3. Check LED status (see Diagnostic LEDs above).

4. Enable drive with the DRIVE1 command.

5. If more torque is needed at rest, disable standby mode (DAUTOS¯ command)

1. Connect external power supplyÕs ground to ZETA6104Õs ground (GND).

2.a. Check wiring for opens, shorts, and mis-wired connections.

2.b. When inputs are pulled down to 0V by an external device, connect AUX-P to +5V supplied or to an external +5-24V supply (but not to both).

2.c. When inputs are pulled to 5-24V by external device, connect AUX-P to 0V.

2.d. Make sure a 5-24V power source is connected to the V_I/O terminal.

Chapter 2. Troubleshooting 35

Page 42

Troubleshooting Serial Communication Problems

General Notes ¥ Power up your computer or terminal BEFORE you power up the ZETA6104.

¥ Make sure the serial interface is connected as instructed on page 8. Shield the cable to earth

ground at one end only. The maximum RS-232 cable length is 50 feet (15.25 meters).

¥ RS-232: Handshaking must be disabled. Most software packages allow you to do this.

You can also disable handshaking by jumpering some terminals on the computerÕs/ terminalÕs serial port: connect RTS to CTS (usually pins 4 and 5) and connect DSR to DTR (usually pins 6 and 20).

¥ RS-485: Make sure the internal DIP switches and jumpers are configured as instructed on

page 5.

Test the Interface 1. Power up the computer or terminal and launch the terminal emulator.

2. Power up the ZETA6104. A power-up message (similar to the following) should be

displayed, followed by a prompt (>):

*PARKER COMPUMOTOR 6104 Ð SINGLE AXIS INDEXER/DRIVE *RP240 CONNECTED

3. Type ÒTREVÓ and press the ENTER key. (The TREV command reports the software

revision.) The screen should now look as follows (if not, see Problem/Remedy table below).

*PARKER COMPUMOTOR 6104 Ð SINGLE AXIS INDEXER/DRIVE *RP240 CONNECTED

>TREV *TREV92-014630-01-4.7 6104

Problem Remedy (based on the possible causes)

No Response ¥ COM port not enabled for 6000 language communication.

If RS-232 connected to COM 1: issue ÒPORT1Ó and ÒDRPCHK¯Ó commands. If RS-232 connected to COM 2: issue ÒPORT2Ó and ÒDRPCHK¯Ó commands. If RS-485 connected to COM 2: issue ÒPORT2Ó and ÒDRPCHK¯Ó commands.

¥ RS-232: Echo may be disabled; enable with the ECHO1 command.

¥ If you are using an RS-232 connection between the host computer and the master

ZETA6104 connected to multiple ZETA6104s in an RS-485 multi-drop, make sure the master ZETA6104 has these settings executed in the order given (you should place these settings in your power-up STARTP program):

PORT1 (select RS-232 port, COM1, for configuration) ECHO3 (echo to both COM ports) PORT2 (select RS-485 port, COM2, for configuration) ECHO2 (echo to the other COM port, COM1)

¥ Faulty wiring. See instructions on page 8. RS-485: verify internal DIP switch and

jumper settings on page 5. Also check for shorts or opens.

¥ Is the cable or computer/terminal bad? HereÕs a test:

1. Disconnect the serial cable from the ZETA6104 end only.

2. Connect the cableÕs Rx and Tx lines together (this echoes the characters back to the host).

3. Issue the TREV command. If nothing happens, the cable or computer/terminal may be faulty.

¥ The controller may be executing a program. Issue the !K command or the

<ctrl>K command to kill the program.

36 z ZETA6104 Installation Guide

Page 43

Problem/Remedy Table (continued)

Problem Remedy (based on the possible causes)

Garbled Characters ¥ Verify setup: 9600 baud (range is 19200-1200Ñsee AutoBaud, page 4),

Double Characters ¥ Your terminal emulator is set to half-duplex; set it to full-duplex.

Product Return Procedure

8 data bits, 1 stop bit, no parity; RS-232: Full duplex; RS-485: Half duplex (change internal jumper JU6 to position 1).

¥ RS-485: Transmission line not properly terminated. See page 5 for internal DIP

switch and jumper settings. See page 8 for connections and calculating termination resistors (if not using the internal resistors via internal DIP switches).

¥ Faulty wiring. See instructions on page 8. RS-485: verify internal DIP switch and

jumper settings on page 5. Also check for shorts or opens.

Step 1

Step 2

Step 3

Obtain the serial number and the model number of the defective unit, and secure a purchase order number to cover repair costs in the event the unit is determined by the manufacturers to be out of warranty.

Before you return the unit, have someone from your organization with a technical understanding of the ZETA6104 system and its application include answers to the following questions:

¥ What is the extent of the failure/reason for return? ¥ How long did it operate? ¥ Did any other items fail at the same time? ¥ What was happening when the unit failed (e.g., installing the unit, cycling power, starting other

equipment, etc.)? ¥ How was the product configured (in detail)? ¥ Which, if any, cables were modified and how? ¥ With what equipment is the unit interfaced? ¥ What was the application? ¥ What was the system environment (temperature, enclosure, spacing, contaminants, etc.)? ¥ What upgrades, if any, are required (hardware, software, user guide)?

Call for return authorization. Refer to the Technical Assistance phone numbers provided on the inside front cover of this document. The support personnel will also provide shipping guidelines.

Chapter 2. Troubleshooting 37

Page 44

Page 45

Appendix A

Resonance, Ringing & DampingÑ

Discussion & Theory

In this appendix we will discuss resonance and ringing in step motors. This information will help you configure the ZETA6104Õs damping featuresÑantiresonance, active damping, and electronic viscosity.

All step motors have natural resonant frequencies, due to the nature of their mechanical construction. Internally, the rotor acts very similarly to a mass suspended on a springÑit can oscillate about its commanded position. Externally, the machine, mounting structure, and drive electronics can also be resonant, and interact with the motor. During a move, two types of problems can arise from these causes: resonance and ringing transients.

Resonance (Steady State Response)

Resonance is a steady state phenomenonÑit occurs when the motorÕs natural resonant frequencies are excited at particular velocities. It is not caused by transient commands that we give the motor. If you slowly increase your motorÕs speed from zero to 20 rps, for example, you may notice ÒroughÓ spots at certain speeds. The roughness is resonance; it is depicted in the next drawing.

Actual

Velocity

Instead of moving at the commanded velocity, the motor is oscillating between speeds faster and slower than commanded. This causes error in rotor position.

Resonance points can differ in intensity. The drawing shows a typical caseÑas motor speed increases, resonances of varying levels occur. Usually, the motor can accelerate through the resonance point, and run smoothly at a higher speed. However, if the resonance is extreme, the rotor can be so far out of position that it causes the motor to stall.

Resonance is affected by the load. Some loads are resonant, and can make motor resonance worse. Other loads can damp motor resonance. To solve resonance problems, system designers will sometimes attach a

Resonances

Commanded

Time

damping load, such as an inertial damper, to the back of the motor. However, such a load has the unwanted effect of decreasing overall performance, and increasing system cost.

The ZETA6104 has internal electronics that can damp resonance, and increase system performance. No external devices are necessary.

Ringing (Transient Response)

Inside a step motor, the rotor behaves like a mass on a spring, as mentioned above. When commanded to quickly accelerate to a given velocity, the rotor will ÒringÓ about that velocity, oscillating back and forth. As shown in the next drawing, the ringing decaysÑgrows smaller over timeÑand the rotor eventually settles at the commanded velocity.

Ringing Transients

Velocity

CommandedActual

Time

Notice that ringing can be caused both by accelerating or decelerating to a commanded velocity, and decelerating to a stop. In any of these cases, ringing causes error in rotor position.

Ringing is a transient phenomenon (unlike resonance, which occurs during steady state operations). It is a

Page 46

response to a sudden change that we impose on the system, such as ÒAccelerate to VelocityÓ or ÒStop.Ó

Several problems are associated with ringing. It can cause audible noise; the motor must have a margin of extra torque to overcome the ringing; and longer settling times can decrease throughput.

To eliminate these problems, system designers use damping to force the ringing to decay quickly. Inertial dampers have been used as components in passive damping methods. Accelerometers, encoders, and tachometers have been used as components in active damping methods. These devices can have the unwanted effect of limiting performance, adding complexity, and increasing cost.

The ZETA6104 has internal electronics that can damp ringing transients, and cause them to decay quickly. No external devices are necessary.

Electronic Viscosity Ð Provides passive damping at lower speeds. The ZETA6104 ships with electronic viscosity disabled. You must use the DELVIS command to enable electronic viscosity, and optimize it for a specific application (see procedure on page 29).

The first two damping circuitsÑanti-resonance and active dampingÑwork at speeds greater than three revolutions per second (rps). Electronic viscosity works at speeds from rest up to three rps. The ZETA6104 will automatically switch between the damping circuits, based upon the motorÕs speed. The next drawing shows the effective range of each circuit.

Anti-Resonance or

Velocity

3 rps 3 rps

Active Damping (above 3 rps)

Electronic Viscosity (below 3 rps)

Time

Damping in the ZETA6104

The ZETA6104 has three different circuits that can damp resonance and ringing.

Anti-Resonance Ð General-purpose damping circuit. The ZETA6104 ships from the factory with antiresonance enabled. No configuration is necessary. Anti-resonance provides aggressive and effective damping.

Active Damping Ð Extremely powerful damping circuit. The ZETA6104 ships from the factory with active damping disabled. You must use the DACTDP command to enable active damping and optimize it for a specific motor size and load (see procedure on page 26).

ZETA6104 Ð Internal Circuitry

Current Command

Current Command Modulator

Power Amplifier

Above 3Êrps, the ZETA6104 automatically enables either anti-resonance or active dampingÑbut not both at the same time. They are mutually exclusive.

If active damping is set to zero (DACTDP¯), the ZETA6104 enables anti-resonance. If the DACTDP command is set to any setting other than zero, the ZETA6104 enables active damping. This relationship is shown in the next drawingÑnotice in the drawing that anti-resonance can also be disabled with a command (DAREN¯).

Differences between anti-resonance and active damping are described next; refer to the block diagram below.

Motor Terminal Voltages

Motor

Anti-Resonance Enable: DAREN1 Disable: DAREN¯

Dynamic Error Modulates

Current Command

(above 3 rps only)

Drawing shows factory default settings: ¥ Anti-Resonance enabled (DAREN1) ¥ Active Damping disabled (DACTDP¯)

40 z ZETA6104 Installation Guide

Anti-

Resonance

(DACTDP¯)

Active

Damping

(DACTDP1-15)

Scaling for Motor Parameters: ¥ Static Torque (DMTSTT command)

¥ Inductance (DMTIND command)

Scaling for

System Inertia

(DACTDP command)

Page 47

Anti-Resonance (AR)

Anti-resonance monitors the ZETA6104Õs motor terminals, and looks at power exchange between the ZETA6104 and motor. From this, it extracts information about error in rotor position caused by resonance or ringing. It modifies the internal motor current command to correct for the error.

Anti-resonance is a general-purpose circuit. It corrects rotor position error, without knowledge about the systemÑwhether the motor is large or small, or the system inertia is high or low. You cannot modify the circuitÕs gains, or customize it for a particular applicationÑbut, anti-resonance is easy to use. When enabled via the DAREN1 command, it works automatically.

Active Damping (AD)

Active damping monitors the ZETA6104Õs motor terminals and, like anti-resonance, uses the same current command modulator to modify motor current.

Active damping uses a different method to extract information about rotor position error, however. The circuitÕs gains are adjustableÑyou can configure it for your particular system. The DMTIND and DMTSTT commands scale the circuit for motor inductance and static torque, respectively. The DACTDP command scales the circuit for system inertia.

The active damping circuit uses this information for two purposes:

1. It determines error in rotor position very accurately.

2. It adjusts the gains of its feedback loop, based upon how much inertia the system has, and how much torque the motor can produce.

If the rotor rings or vibrates, the active damping circuit will detect the corresponding error in rotor position. It will then modify the motor current command to damp the ringing.

DIP switches on top of the ZETA6104 set the amount of motor current during normal operations; this current is constant. To damp ringing, the active damping circuit can cause the ZETA6104 to produce up to twice as much current as is set by the DIP switches. The extra current is only applied during damping oscillations, and lasts a very brief time.

the bandwidth down to 150ÊHz. With this lower bandwidth, the drive electronics become Òsluggish.Ó Ordinarily, when the rotor oscillates, it generates current in the motorÕs coils; but with EVÕs lower bandwidth, the driveÕs electronics impede the flow of current caused by oscillations.

The effect on the motor is as if there were a viscous drag on the rotor. At the end of a move, oscillations are damped, and the rotor quickly comes to rest. After accelerating or decelerating to velocities below 3 rps, the rotor quickly settles at the commanded velocity. During moves below 3 rps, EV significantly reduces low speed velocity ripple.

EV is a ÒpassiveÓ circuit. It imposes viscosity on the system, but has no feedback loop to monitor the effect of the viscosity. EV keeps the amount of viscosity the same, regardless of the response of the system.

You can adjust the amount of viscosity by using the DELVIS command. This allows you to tailor the circuit for different motor sizes and system inertias, and adapt it to your application.

Recommendations

We recommend that you configure active damping and electronic viscosity. Even if you believe resonance and ringing will not cause problems in your system, you may find that the ZETA6104Õs damping circuits provide increased smoothness, reduced audible noise, and better performance. Refer to the configuration procedures beginning on page 26.

If you choose not to use active damping and electronic viscosity, at least use anti-resonance. The ZETA6104 is shipped from the factory with anti-resonance enabled (DAREN1).

Electronic Viscosity (EV)

The ZETA6104 uses closed-loop current control to develop and maintain precise currents in the motor phases. When EV is off, the current loops have a bandwidth of approximately 1000 Hz. Because this bandwidth is well beyond the knee of step motor speed-torque curves, the current loop dynamics do not limit the response of the motor.

EV monitors motor velocity, and turns on below 3 rps. It ÒdetunesÓ the current loop compensation values and brings

Appendix A Ð Resonance, Ringing & Damping 41

Page 48

Page 49

Appendix B

Using Non-Compumotor Motors

We recommend that you use Compumotor motors with the ZETA6104. If you use a nonCompumotor motor, it must meet the following requirements:

¥ Inductance: 0.5 mH minimum; 5.0 to 50.0 mH recommended range; 80.0 mH maximum.

¥ A minimum of 500VDC high-pot insulation rating from phase-to-phase and phase-to-ground.

¥ The motor must be designed for use with a bipolar drive (no common center tap).

¥ The motor must not have riveted rotors or stators.

¥ Do not use solid rotor motors.

¥ Test all motors carefully. Verify that the motor temperature in your application is within the

system limitations. The motor manufacturerÕs maximum allowable motor case temperature must not be exceeded. You should test the motor over a 2-to-3 hour period. Motors tend to have a long thermal time constant, but can still overheat, which results in motor damage.

CAUTION: Consult your motor vendor to verify that your motor meets the above specifications. If you have questions regarding the use of a non-Compumotor motor with the ZETA6104, consult your local Automation Technology Center (ATC) or distributor, or refer to the numbers listed under Technical Assistance on the inside front cover of this document.

Wiring Configurations

Refer to the manufacturerÕs motor specification document to determine the motorÕs wiring configuration. You can also determine the wiring configuration with an ohmmeter using the procedures below (4-Lead Motor, 6-Lead Motor, 8-Lead Motor). Once you determine the correct motor wiring configuration, use the terminal connection diagram, shown at the end of this section, that applies to your configuration.

4-Lead Motor

1. Label one motor lead A+.

2. Connect one lead of an ohmmeter to the A+ lead and

touch the other lead of the ohmmeter to the three remaining motor leads until you find the lead that creates continuity. Label this lead AÐ.

3. Label the two remaining leads B+ and BÐ. Verify that

there is continuity between the B+ and BÐ leads.

4. Proceed to the Terminal Connections section below.

6-Lead Motor

1. Determine, with an ohmmeter, which three of the six motor leads are common (one phase).

2. Label each one of these three motor leads A.

3. Using the ohmmeter, verify that the remaining three leads are common.

4. Label the remaining three leads B.

5. Set the ohmmeter range to the 100 ohm scale (approximately).

6. Connect the ohmmeterÕs negative lead to one of the motor leads labeled A. Alternately measure the resistance to the two remaining motor leads also labeled A. The resistance measurements will reflect one of the following two scenarios.

Scenario #1 Ñ The resistance measurements to the two remaining motor leads are virtually identical. Label the two remaining motor leads A+ and AÐ. Label the motor lead connected to the negative lead of the ohmmeter AÊCENTER TAP (this is the center tap lead for Phase A of the motor).

Scenario #2 Ñ The resistance measurement to the second of the three motor leads measures 50% of the resistance measurement to the third of the three motor leads. Label the second motor lead AÊCENTER

TAP (this is the center tap lead for Phase A of the

motor). Label the third motor lead AÐ. Label the motor lead connected to the ohmmeter A+.

7. Repeat the procedure as outlined in step 6 for the three leads labeled B (BÊCENTER TAP is the center tap lead for Phase B of the motor).

8. Proceed to the Terminal Connections section below.

Page 50

8-Lead Motor

Because of the complexity involved in phasing an 8-lead motor, you must refer to the manufacturerÕs motor specification document. You can configure the 8-lead motor in parallel or series. Using the manufacturerÕs specifications, label the motor leads as shown in the next drawing.

Phase A Windings

Phase B Windings

21 43

Series Configuration Procedure:

1. Connect A2 & A3 together and relabel this common point AÊCENTER TAP.

2. Connect B2 & B3 together and relabel this common point BÊCENTER TAP.

3. Relabel the A1 lead A+.

4. Relabel the A4 lead A-.

5. Relabel the B1 lead B+.

6. Relabel the B4 lead B-.

7. Proceed to the Terminal Connections section below.

Parallel Configuration Procedure:

1. Connect motor leads A1 & A3 together and relabel this common point A+.

2. Connect motor leads A2 & A4 together and relabel this common point AÐ.

3. Connect motor leads B1 & B3 together and relabel this common point B+.

4. Connect motor leads B2 & B4 together and relabel this common point BÐ.

5. Proceed to the Terminal Connections section below.

Terminal Connections

After you determine the motorÕs wiring configuration, connect the motor leads to the ZETA6104Õs 9-pin MOTOR connector according to the appropriate diagram below.

4-Lead Motor

A+

ZETA6104

INTERLOCK

CENTER TAP

EARTH

CENTER TAP

INTERLOCK

CENTER TAP

EARTH

CENTER TAP

INTERLOCK

CENTER TAP

EARTH

CENTER TAP

INTERLOCK

CENTER TAP

EARTH

CENTER TAP

INTERLOCK

A+ AÐ

B+ BÐ

ZETA6104

A+ AÐ

B+ BÐ

ZETA6104

A+ AÐ

B+ BÐ

ZETA6104

A+ AÐ

B+ BÐ

AÐ

B+

BÐ

6-Lead Motor

A+

A-CT

AÐ

B+

B-CT

BÐ

8-Lead Motor

Series

A2 A3

B2 B3

8-Lead Motor

Parallel

A2 A3

B2 B3

44 z ZETA6104 Installation Guide

Page 51

Direction of Motor Rotation

The procedures above do not determine the direction of motor shaft rotation. To find out which direction the shaft turns, you must power up your system and command motion. If the shaft turns in the opposite direction than you desire, exchange the motor leads connected to A+ and

AÐ to reverse the direction of rotation.

CAUTION

Motor shaft rotation may be opposite than you expect. Do not connect a load to the shaft until you first determine the direction of shaft rotation.

Setting Motor Current

To set motor current for a non-Compumotor motor, refer to the formulas below that correspond to your motor (4lead, 6-lead, 8-lead) and use the current settings shown on page 4 to set the motorÕs current.

WARNING

Do not connect or disconnect the motor with the power on. Doing so will damage the contacts of the motor connector and may cause personal injury.

¥ If you wire the motor in series, use the DIP switch

tableÕs current settings and the converted value to set the motor current.

¥ If you wire the motor in parallel, you must double

the converted value and use the DIP switch tableÕs current settings to set the motor current.

Bipolar Rating: If the manufacturer specifies the motor current as a bipolar series rating:

¥ If you wire the motor in series, use the DIP switch

tableÕs current settings directly.

¥ If you wire the motor in parallel, you must double

the manufacturerÕs rating and then use the DIP switch tableÕs current settings to set the motor current.

If you have any questions about setting motor current, consult your local Automation Technology Center (ATC) or distributor, or refer to the numbers listed under Technical Assistance on the inside front cover of this document.

4-Lead Motors

If you use a 4-lead motor, the manufacturerÕs current specification will translate directly to the values shown for current in the DIP switch table on page 4.

6-Lead Motors

If you use a 6-lead motor, and the manufacturer specifies the motor current as a bipolar rating, you can use the DIP switch tableÕs current settings directly (no conversion) to set motor current.

If the manufacturer specifies the motor current as a unipolar rating, use the following formula to convert the unipolar current rating to the correct bipolar rating:

Unipolar Current * 0.707 = Bipolar Current

After you make the conversion, use the values shown for current in the DIP switch table to set the motor current.

8-Lead Motors

Manufacturers generally use either a unipolar rating or a bipolar rating for motor current in 8-lead motors.

Unipolar Rating: If the manufacturer specifies the motor current as a unipolar rating:

¥ Use the following formula to convert the unipolar

current rating to the correct bipolar rating:

Unipolar Current * 0.707 = Bipolar Current

Appendix B Ð Using Non-Compumotor Motors 45

Page 52

Page 53

Appendix C

LVD Installation Instructions

For more information about the Low Voltage Directive (LVD), see 73/23/EEC and 93/68/EEC, published by the European Economic Community (EEC).

Environmental Conditions

Pollution Degree: The ZETA6104 is designed for pollution degree 2.

Installation Category: The ZETA6104 is designed for installation category II.

Electrical

Connecting & Disconnecting Power Mains

The ZETA6104Õs protective earth connection is provided through its make-first/break-last earth terminal on the power mains connector. You must reliably earth the ZETA6104Õs protective earth connection.

Using an Isolation Transformer

The ZETA6104Õs mains voltage is limited to 120 VAC nominal. If your mains voltage is higher, use an isolation transformer located between the power mains and the ZETA6104. Your isolation transformer should be insulated toÊ~2300V rms.

Do not interrupt the protective earth conductor between the source mains and the isolation transformerÕs secondary. The core of the isolation transformer and the driveÕs protective conductor terminal must both be connected to the mains protective earth conductor.

CAUTION Ñ Do not use an autotransformer.

Adding Line Fuses

Line fuses need to be added to protect the transformer and associated wiring. If the live wire cannot be readily identified, fuse both phase conductors. The value of fuse required is given by: (1.5 x VA)/(supply volts) [amps]

Fuse types should be anti-surge HBC.

WARNING Ñ Safety Ground (Earth Ground)

should never be fused.

Providing a Protective Earth Connection for Motors

You must provide a connection from the motor to a reliable protective earth contact point. This connection provides a protective earth for the motor, and is in addition

to the earth connection provided by the drain wire in the motorÕs power cable. The motorÕs protective earth connection is important for safety reasons, and must not

be omitted.

Make connections according to the diagram and instructions below:

Motor

Safety Earth

Cable

(green/yellow)

1. Use a spade lug in combination with a star washer and mounting bolt to make good contact with the bare metal surface of the motorÕs mounting flange.

2. Use a green and yellow striped wire to make the connection between the motor and earth. Wire gauge must be no thinner than the current carrying wire in the motorÕs power cable.

3. Resistance between the motor and earth must be no greater than 0.1 W. Use thicker gauge wire if the resistance is too high.

Page 54

Mechanical

Installing in an Enclosure: The ZETA6104 must be installed within an enclosure. The enclosureÕs interior must not be accessible to the operator. The enclosure should be opened only by skilled or trained service personnel.

Table of Graphic Symbols & Warnings

The following symbols may appear in this manual, and may be affixed to the products discussed in this manual.

Symbol Description

Earth Terminal

Servicing the ZETA6104

Changing Firmware: Only skilled or trained personnel should change firmware.

Changing Batteries: The ZETA6104 contains a replaceable lithium battery, of type Duracell DL2450, or Sanyo CR2450, or equivalent. Only skilled or trained personnel should change batteries. Dispose of batteries in

accordance with local regulations.

Do Not Replace Fuses: The ZETA6104 has no fuses designed to be replaced by the user. Fuse failure indicates that other components have also failed. Fuses and other components should only be replaced by Compumotor or its designated repair facilities.

Thermal Safety

The Motor May Be HOT: The motor may reach high temperatures during normal operations, and may remain hot after power is removed.

Sonic Pressure

High Sound Level: The sound level from some large frame step motors (NEMA 34, NEMA 42, and larger) may exceed 85 dBA. Actual sound level is application dependent, and varies with motor loads and mounting conditions. Measure the sound level in your application; if it exceeds 85 dBA, install the motor in an enclosure to provide sound baffling, or provide ear protection for personnel.

BATTERY

Protective Conductor Terminal

Frame or ChassisTerminal

Equipotentiality

Caution, Risk of Electric Shock

Caution, Refer to Accompanying Text

Hot Surface

Recycle Battery

48 z ZETA6104 Installation Guide

Page 55

Appendix D

EMC Installation Guidelines

General Product Philosophy

The ZETA6104 was not designed originally for EMC compliance. Therefore, it will require specific measures to be taken during installation. The ultimate responsibility for ensuring that the EMC requirements are met rests with the systems builder.

It is important to remember that for specific installations, the full protection requirements of the EMC Directive 89/336/EEC need to be met before the system is put into service. This must be verified either by inspection or by testing. The following EMC installation instructions are intended to assist in ensuring that the requirements of the EMC directive are met. It may be necessary to take additional measures in certain circumstances and at specific locations.

It should be stressed that although these recommendations are based on expertise acquired during tests carried out on the ZETA6104, it is impossible for Compumotor to guarantee the compliance of any particular installation. This will be strongly influenced by the physical and electrical details of the installation and the performance of other system components. Nevertheless, it is important to follow all the installation instructions if an adequate level of compliance is to be achieved.

Safety Considerations

The ZETA6104 is intended for installation according to the appropriate safety procedures including those laid down by the local supply authority regulations. The recommendations provided are based on the requirements of the Low Voltage Directive and specifically on EN60204. It should be remembered that safety must never be compromised for the purpose of achieving EMC compliance. Therefore in the event of a conflict occurring

Handling & Installing Ferrite Absorbers

Take care when handling the absorbersÑthey can shatter if dropped on a hard surface. For this reason the suggested method of installation is to use a short length of 19mm diameter heat-shrink sleeving (see Figure 1). This gives a degree of physical protection while the cable is being installed. The sleeving should have a shrink ratio of at least 2.5:1. Cable ties may be used as an alternative, however they give no physical protection to the absorber.

between the safety regulations and the following recommendations, the safety regulations always

take precedence.

Ferrite absorber

retained by

Ferrite Absorbers and P-Clips

Figure 1. Ferrite Sleeve Installation

heatshrink sleeving

Ferrite Absorber Specifications

The absorbers described in these installation recommendations are made from a low-grade ferrite material which has high losses at radio frequencies. They therefore act like a high impedance in this waveband.

P-Clip Installation Details

The function of the P-clip is to provide a 360-degree metallic contact and thus a convenient means of ensuring a proper R.F. ground. When dealing with EMI issues, it is important to remember that continuity, a DC connection,

The recommended components are produced by Parker Chomerics (617-935-4850) and are suitable for use with cable having an outside diameter up to 10-13mm. The specification is as follows:

Chomerics part # 83-10-M248-1000 83-10-A637-1000 Outside diameter 17.5mm 28.5mm Inside diameter 10.7mm 13.77mm Length 28.5mm 28.57mm Impedance at 25MHz 80W 135W Impedance at 100MHz 120W 210W Curie temperature 130°C 130°C (the device should not be operated near this temperature)

does not at all speak to the integrity of an AC (highfrequency) connection. High-Frequency bonding typically involves wide, flat cabling to establish a suitable system ground. When applied properly, the P-clip has been shown to give an adequate high-frequency contact.

When installing a P-clip (see Figure 2), install as close to the cable end as possible, provided a suitable ground, backplane, earth stud or bus bar is accessible, (this may mean removing the paint from a cabinet or panel). Remove only the outer (vinyl) jacket of the braided screen

Page 56

cable (this allows the braid to continue to the cable connector), be careful not to damage the braid. Snap the P-clip over the exposed braid, and adjust for a tight fit. Secure the clip to the designated ground with a machine screw and lock washer. The use of brass or other inert conductive metal P-clip is recommended. Cover any exposed bare metal with petroleum jelly to resist corrosion.

A filter must be installed between the incoming AC supply and the input to the drive. The manufacturerÕs part numbers for suitable filters are:

Corcom 10VV1

Corcom World Headquarters Phone: 847-680-7400 Fax: 847-680-8169

Schaffner FN670-10/06

Schaffner EMC Inc. Phone: 201-379-7778 Fax: 201-379-1151

Mount the filter within 2 inches (50mm) of the ZETA6104 as shown in Figure 3 below. Ensure that there is no paint on the mounting panel under the filter mounting lugsÑit is vital that there is good large-area

contact between the filter and the panel.

P-Clip

Figure 2. P-Clip Installation

Remove outer jacket only do not cut braid

Connect the incoming AC supply cable to the push-on terminals on the filter, with the earth lead connected to a local earth stud, bus bar or metal back-plane. Route the supply cable so that it runs close to the walls of the

Installation

External Enclosure

Introduction

The measures described in this section are primarily for the purpose of controlling conducted emissions. To control radiated emissions, all drive and control systems must be installed in a steel equipment cabinet which will give adequate screening against radiated emissions. This external enclosure is also required for safety reasons. There must be no user access while the equipment is operating. This is usually achieved by fitting an isolator switch to the door assembly.

To achieve adequate screening of radiated emissions, all panels of the enclosure must be bonded to a central earth point. The enclosure may also contain other equipment and the EMC requirements of these must be considered during installation. Always ensure that drives and controllers are mounted in such a way that there is adequate ventilation.

enclosure. Connect the earth terminal on the filter case to the earth stud.

Fit a ferrite absorber over the cable before wiring the filter output terminals to the AC input on the drive. Locate the absorber as close as possible to the drive using heat-shrink sleeving (see Figure 1 above). Take the ZETA6104 earth connection from the same stud that retains the filter case earth, as shown in Figure 3 below.

Motor Connections

Compumotor Motors

Parker Compumotor ZETA Series step motor systems ship with motors that do not incorporate the use of a braided screen for the control of conducted emissions. Therefore, when used in installations where the motor cable is not within earthed conduit the entire length of travel, the standard motor cable should not be used.

At the drive end of the motor cable, fit a ferrite absorber

Preparing the ZETA6104: The ZETA6104 must be mounted to a conductive panel. Before mounting the ZETA6104, remove the paint from the rear face of the mounting hole that will be closest to the input filter location as shown in Figure 3 below, and if necessary from the corresponding area on the rear panel of the enclosure. This is to guarantee a good high-frequency connection between the drive case and the cabinet. After mounting the unit use petroleum jelly on the exposed metal to minimize the risk of future corrosion.

over the cable before wiring to the motor connector (it may be necessary to remove the existing connector). Locate the absorber as close as possible to the connector using heat-shrink sleeving.

For motors with exposed cabling (not within earthed conduit), follow the guidelines below:

¥ Removable Cabling: Remove the motor cable from

the standard motor, and replace with a suitable cable described below, see Motor Cables.

¥ Permanent Cabling: Cut off cable in excess of

Filtering the AC Supply

Introduction

These recommendations are based on the use of proprietary screen filter units which are readily available. However, the full EMC test includes a simulated lightning strike which will damage the filter unless adequate surge suppression devices are fitted. These are not normally incorporated into commercial filters since the lightning strike test can be destructive. This test is normally carried out on the overall system and not on individual components; therefore, the surge protection should be provided at the system boundary.

approximately 4 inches (10 cm). Configure the motor for series or parallel operation and attach a suitable braided screen cable to the motor, see Motor Cables below.

Termination of the braid shield at the motor must be made using a 360° bond to the motor body, and this may be achieved by using a suitable clamp. Many stepper motors are designed to accommodate an appropriate terminal gland which can be used for this purpose. If this is not the case, P-clip the braid to the rear end bell of the motor housing, as shown in Figure 4. This will not only provide a good high-frequency bond, but strain relief as well.

50 z ZETA6104 Installation Guide

Page 57

At the drive end, run the motor cable down to the mounting panel, expose a short length of braiding and anchor to the panel with a P-clip. The ZETA Series require a safety earth connection to the motor (see green and yellow striped wire in Figure 4) Ñ take this from the stud or bus bar. Run the safety earth lead alongside the motor lead. Note that the motor cable should be kept away from I/O cables carrying control signals.

Motor Cables

For 10 foot (replacement) cable lengths, use 4-core 1mm

(AWG 18) (SWG 20) braided screen cable for the motor connections on the ZETA6104. At the drive end, fit a ferrite absorber over the cable before wiring to the motor connector. Locate the absorber as close as possible to the connector using heat-shrink sleeving.

All after-market motor connections must be made using a high quality braided-screen cable. Cables using a metallized plastic foil for an earth screen are unsuitable and provide very little screening. Terminating to the screen in a mechanically stable manner is difficult because the screen itself is comparatively fragile Ñ bending it in a tight radius can seriously affect the screening performance.

There must be no break in the 360° coverage that the screen provides around the cable conductors. If a connector must be used it should retain the 360° coverage, possibly by the use of an additional metallic casing where it passes through the bulkhead of the enclosure. The cable screen must not be connected to the cabinet at the point of entry. Its function is to return high-frequency chopping current back to the drive or controller. This may require mounting the connector on a sub-panel insulated from the main cabinet, or using a connector having an internal screen which is insulated from the connector housing.

Within the cabinet itself, all the motor cables should lie in the same trunking as far as possible. They must be kept separate from any low-level control signal cables. This applies particularly where the control cables are unscreened and run close to the drive or other sources of electrical noise.

Motor Feedback Cables

Feedback devices such as encoders, tachometers and Hall effect sensors also require the use of high-quality braided screen cable. If it is necessary to replace the standard feedback cable, select a braided screen cable that matches the gage of the devices original cable and attach as close to the transducer as possible. Avoid complex and bulky connections that can cause degradation in feedback signal quality. If possible, use in-line cable splicing techniques, and cover the splice point with heat-shrink tubing. Remove a section of the braided shield cableÕs insulation to expose the braid, and tie the braid to earth using the same P-clip 360° bond as shown in Figure 2. Differential signals should use twisted pair cable to minimize magnetic coupling. At the receiving end, fit a ferrite absorber over the feedback cable before wiring the connector, then P-clip the braid to a suitable ground (metal back-plane of drive mounting panel, or earth point of device that receives the feedback)Ñ see Figure 3.

Step Motors

It is preferable to use motors with screw terminations whenever possible. If flying-lead motors are used, it is important that the unscreened leads are converted into a braided-screen cable within 4 inches (10cm) of the motor body. A separate terminal box may be used for this purpose but the braided cable screen must be properly strapped to the motor body, as shown in Figure 4. Motors fitted with terminal boxes also allow local selection of series or parallel connection, reducing the cost of the cable running back to the drive.

Control Signal Connections

High-quality braided screen cable should be used for control connections. In the case of the ZETA6104, which has differential step-direction inputs, it is preferable to use a cable with twisted pairs to minimize magnetic coupling. No connection is made to the cable screen at the drive itself. Fit a ferrite absorber close to the I/O connector and run the cable down to the mounting panel as shown in Figure 3. Expose a short length of the braided screen and anchor to the panel with a P-clip.

The level at which the I/O operates means that the signals are unlikely to meet EMC immunity requirements if taken outside the enclosure without proper screening.

50-Pin Ribbon Cable: It is recommended when using the 50-Pin Ribbon Cable I/O found on the ZETA6104 that a

terminal break out box such as the VM50 be used (see Figure 3). Mount the VM50 close to the ZETA6104, keeping the ribbon cable as short as possible. Bundle any excess ribbon cable and secure close to a panel wall. Individual I/O points will require the use of individually shielded cable runs, with braids bonded to the panel (close to VM50) with a P-clip.

Communications: In applications that require serial communications with the ZETA6104, take special care to

assure proper wiring practices are utilized. Good quality braided screen cable should be used for the communication cabling. In the specific case of differential mode (RS-485) protocol, twisted pair cable shall be used. No connection is made to the cable screen at the drive itself. Fit a ferrite absorber close to the communications connector and run the cable down to the mounting panel as shown in Figure 3. Expose a short length of the braided screen and anchor to the panel with a P-clip. Avoid routing communication cables near high power lines, and sources of high energy impulses.

Remember to route control signal connections well away (at least 8 inches) from relays and contactors. Control wiring should not be laid parallel to power or motor cables and should only cross the path of these cables at right angles. Bear in mind that control cables connected to other equipment within the enclosure may interfere with the controller, particularly if they have come from outside the cabinet. Take particular care when connecting external equipment with the cabinet door open, for instance a computer or terminal; static discharge may cause damage to unprotected inputs.

Appendix D Ð EMC Installation Guidelines 51

Page 58

Braided-screen

Cables

Comm-

Encoder

Limits Cable

I/O Cable

Motor Cable (braided-screen)

Rx Tx GND SHLD +5V GND Rx Tx SHLD

SHLD GND Z- Z+ B- B+ A- A+ +5V

GND HOM NEG POS

TRG-A TRG-B OUT-A GND P-CUT +5V OUT-P IN-P AUX-P

Rx+ RxTx+ TxGND

6104

INDEXER DRIVE

POWER

STEP

OVER TEMP

MOTOR FAULT

INTERLOCK

CENTER TAP

A+

A-

EARTH

B+

B-

CENTER TAP

INTERLOCK

COM 1 COM 2 ENCODER LIMITS I/O

Motor Safety Earth (grn/yel)

ZETA

MOTOR

Ferrite absorber

Programmable

I/O Cable

VM50

Figure 3. EMC Connections for ZETA6104

Motor/Encoder

Cable

Ribbon Cable

AC Input Filter

Remove paint behind this area

Step Motor

Compumotor

95-132 VAC

50/60 Hz

AC POWER

PROGRAMMABLE I/O

Braided-screen

AC Input

Cable

LVD/EMC Compliance for RS Motors

CompumotorÕs RS Series motors may be ordered with the C10 cable kit for LVD/EMC compliance (part number is RSxxx-xxC10). The C10 cable kit may also be ordered separately (part number is C10). Instructions for assembling the cable are provided in the C10 cable kit.

Exposed Braid

Outter Jacket

Inner Jacket

Safety Earth

Cable

(green/yellow)

Figure 4. EMC Connections for Step Motor Ñ P-Clip, Safety Earth

52 z ZETA6104 Installation Guide

Drive End Motor End

Rubber Moisture Seal

Top Half of Casting

EMI Shield

Motor Cable

(10-foot)

Gland

Brass Contact Sleeve

Base Half of Casting

Thread Converter

Page 59

INDEX

3rd harmonic 23 4-lead motor ( 6-lead motor ( 5V power supply

connections

item, like P-CUT, Encoder, etc.)

load limit 3 8-lead motor ( 6000user@cmotor.com (

non-Compumotor) wiring 43 non-Compumotor) wiring 43

(see page for connection

non-Compumotor) wiring 44

e-mail address) i

AC input power connections & specs

18 acceleration range 3 accuracy

stepping 3

velocity 3 active damping

configuration procedure 26

definition 41 active levels (see polarity) ADDR (auto addressing) command 4 address

auto-address multiple units 4

DIP switch selection 4 air-flow space, minimum 6 airborne contaminants 6 anti-resonance

configuring 26

definition 41 assumptions (skills & knowledge

required for installation) i auto addressing multiple units 4 auto baud procedure 4 auto current standby 9, 25

balance 22 battery, changing 48 baud rate 3

automatic selection 4 BBS (bulletin board service) 34 BCD input via thumbwheels 17 bearings, zeta & OS/RS motors 3 bias resistors

calculating 8

DIP switch selection 5 bipolar current 45

cables

I/O, extending 19 motor 9 serial communication (max. length)

calculating bias & termination resistors

8 change summary i circuit drawings (see back cover of

manual, and Òschematics, internalÓ)

COM 2 port function 5 common problems & solutions 35 communication

Motion Architect 32

serial (see serial communication)

terminal emulation 20

troubleshooting 36 conduit 2, 19 configuration

active damping 26

address 4

anti-resonance 26

autobaud 4

bias resistor selection 5

COM 2 port function 5

electronic viscosity 29

inductance 27

matching the ZETA6104 to the

motor 22 motor current 4 recording 30 RS-485 setup 5 serial communication on COM 2 5 static torque 27 termination resistor selection 5

connections

computer 8, 20 daisy-chain 8 EMC-compliance guidelines 49 encoder 12 end-of-travel limit inputs 11 grounding 7 home limit inputs 11 lengthening cables 19 LVD-compliant installation 47 motor 9

non-Compumotor 44, 45

wiring options 9, 10 multi-drop 8

PLC inputs 16 PLC outputs 15 power (VAC) input 18 programmable inputs 15 programmable outputs 16 pulse cut-off input (P-CUT) 7 RP240 18 RS-232C 8 RS-485 8 terminal 8, 20 testing 20, 21 thumbwheels 17 trigger inputs 13

VM50 screw terminal adaptor 14 contaminants 6 cooling the motor 25 coupling the motor to the load 25 current, motor

automatic reduction (DAUTOS) 9,

25 bipolar rating 45 selecting 4

non-Compumotor motors 45 unipolar rating 45 waveform 23

DACTDP (active damping) command 27

part of set-up program 30

daisy-chain connections 8 damping

configuration

active damping 26

anti-resonance 26

electronic viscosity 29 defined 40

DAREN (anti-resonance) command 40

part of set-up program 30

DAUTOS command 9, 25

part of set-up program 30

DDE6000ª 32 DELVIS (electronic viscosity)

command 29 part of set-up program 30

device address (see address) diagnostic LEDs 34 dimensions

motor 24 ZETA6104 6

Page 60

DIP switch settings

address 4 autobaud feature 4 bias & termination resistors 5

motor current 4 disassembling the ZETA6104 5 DMTIND (inductance) command 27

part of setup program 30 DMTSTT (static torque) command 27

part of set-up program 30 drive resolution 35 drive/motor matching 22 DRPCHK command 18

part of set-up program 30 DWAVEF (waveform) command 23

part of set-up program 30

e-mail address for feedback i ECHO 30 electrical noise 2, 34

EMC installation guidelines 49

suppressing 19 electronic viscosity

configuration procedure 29

definition 41 EMC installation guidelines 49 emergency stop ( encoder

connections 12

testing 21 resolution 35 specifications 12

end-of-travel limits

connections 11 testing 21

environmental specifications 3, 6 extending cables

I/O 19 motor 9 RS-232C 36

pulse cut-off) switch 7

F-H

factory configuration 4

default set-up command values 30

faults (see LEDs, diagnostic) FAX number for technical support 34 feedback, e-mail address i ferrite absorbers 49 filtering the AC input supply 50 firmware, changing 48 fuses

adding line fuses 47 internal (do not replace!) 48

grounding 2

EMC guidelines 49 system diagram 7

handshaking, disabling 36 hard limits (see end-of-travel limits) harmonic, waveform 23 HCMOS-compatible switching levels 3 heat 3 helpful resources (publications) i home limit input

connections & specs 11 testing 21

humidity 3

I/O cabling 19 inductance, configuration (DMTIND) 27 inductive load, connecting outputs to

16 inertia, and active damping 27 information label 30 inputs

encoder 12

end-of-travel limits 11

problems 35

general-purpose programmable 14

problems 35

home limit 11

problems 35

P-CUT 7

problems 35 power (AC) 18 serial communication (see serial

communication)

suppressing noise 19 testing 21 trigger 13

problems 35

installation

connections (see connections) DIP switch settings (see DIP switch

settings)

EMC guidelines 49 LVD instructions 47 mounting (see mounting) precautions 2 process overview 2 test 20

interlock jumper 9, 34

J-L

jumper settings 5 LEDs, diagnostic 18, 34 limit input connections 11 line fuses, adding 47 load, coupling 25 LVD installation instructions 47

magnetic label 30 matching, ZETA6104 to motor 22 minimum air-flow space 6 motion algorithm update rate 3 Motion Architect 32 Motion Builderª 32 Motion Toolboxª 32 motor

connections 9

non-Compumotor 44, 45

protective earth 47, 50

series or parallel 9, 10 cooling 25 coupling 25 current selection 4

non-Compumotor motors 45 current standby mode 9, 25 dimensions 24 fault 34 modifying 24 motor/drive matching 22

mounting 24 peak power requirements 18 specifications 3 speed/torque curves 10 thermal safety 48

mounting

EMC compliant 50 motor 24 ZETA6104 chassis 6

multi-drop

connections 8 internal configuration 5

N-O

National Electric Code Handbook i negative-travel limits 11 noise, electrical 2, 34

suppression on I/O cables 19 offset, phase 22 opening the ZETA6104 5 outputs

general-purpose programmable 14

problems 35 OUT-A 14 testing 21

over temp fault 34

P-Q

P-clips 49 P-CUT (pulse cut-off) input

connections & specs 7

parallel motor connection 9, 10 peak power requirements 18 performance specifications 3 phase balance 22 phase offset 22 pin outs (see also back cover)

encoder connector 12 limits connector 11 motor connector 9 programmable inputs 14 programmable outputs 14

PLC connections 15 polarity

commanded direction 35 end-of-travel limit inputs 11 home input 11 programmable inputs 14 programmable outputs 14 trigger inputs 13

PORT command 18

COM 2 function 5 part of set-up program 30

position range 3 positive-travel limits 11 potentiometers 22 power supply

5V load limit 3 AC input connections & specs 18 AC input, filtering 50 for P-CUT, limit inputs, & trigger

inputs 7, 11, 13 for programmable inputs & outputs

power up auto test 4 pre-installation changes 4

54 z ZETA6104 Installation Guide

Page 61

precautions

installation 2

mounting 6 process of installation 2 product return procedure 37 programmable I/O

connections & specs 14

testing 21 programming tools available 32 pulse cut-off (P-CUT)

testing 21

reference documentation i removing the ZETA6104 chassis 5 resistors, termination/bias

calculating 8

selecting 5 resolution

drive 35

encoder 12, 35 resonance 39 return procedure 37 ringing 39 rotor inertia, zeta & OS/RS motors 3 RP240, connections 18

testing 21 RS-232C (see serial communication) RS-485 (see serial communication)

safety 2 safety stops (see end-of-travel limits) schematics, internal (see also back

cover)

encoder inputs 12

limit inputs 11

P-CUT input 7

programmable inputs and outputs

trigger inputs 13 serial communication

RS-232C

configuration 5 connections 8 daisy-chain connections 8 disable handshaking 36 specifications 3 troubleshooting 36

RS-485

configuration 5 connections 8 disable handshaking 36 multi-drop connections 8 resistor calculation 8 RP240 connections 18 specifications 3

troubleshooting 36 series motor connection 9, 10 set-up commands 30 set-up program 30 shielding 2

EMC guidelines 49

I/O cables 19 ship kit 2 sinking input device, connecting to 16

sinking output device, connecting to

13, 15 software, update from BBS 34 sonic pressure 48 sourcing input device, connecting to

16 sourcing output device, connecting to

13, 15 specifications

motor 3

peak power requirements 18 speed/torque curves 10

overall list of (see also back cover) speed/torque curves, ZETA & OS/RS

motors 10 startup (STARTP) program 30 static torque

configuration (DMTSTT) 27

ZETA & OS/RS motor specs 3 status commands (see also back

cover, and test on page 20)

axis (see TASF command)

limit switches (see TLIM command)

motor faults (see TASXF command)

P-CUT input (see TINOF command,

bit 6)

programmable inputs (see TIN

command)

programmable outputs (see TOUT

command)

trigger inputs (see TIN command) status LEDs 18, 34 stepping accuracy 3 support software available 32

technical assistance (see inside of

front cover, and HELP command)

temperature range 3 terminal emulation, set up 20 termination resistors

calculating 8

DIP switch selection 5 test

system installation 20

test panel (Motion Architect) 34

TEST program 34 thermal safety 48 third harmonic 23 thumbwheel connections 17 transformer, isolating 47 travel limits 11 trigger inputs

connections 13

testing 21 troubleshooting 34

common problems & solutions 35

diagnostic LEDs 34

serial communication 36

test panels, Motion Architect 34

test program 34 TTL-compatible switching voltage

levels 3 tuning (see matching)

U-Z

unipolar current 45 velocity accuracy 3 velocity range 3 velocity repeatability 3 VM50 adaptor 14 waveform 23 Z channel output 12 ZETA motor (see motor)

Index 55

Page 62

Page 63

ZETA6104 Indexer/Drive

Setup

Connections

Automation

parker ZETA6104 Installation Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Change Summary

Installation

Before You Begin

Recommended Installation Process

Electrical Noise Guidelines

General Specifications

Pre-installation Adjustments

Mounting the ZETA6104

Electrical Connections

Grounding System

Serial Communication

MOTOR

Encoder

Trigger Inputs

Lengthening I/O Cables

Testing the Installation

Mounting & Coupling the Motor

Configuring Active Damping

Troubleshooting

Troubleshooting Basics

Reducing Electrical Noise

Diagnostic LEDs

Test Options

Technical Support

Common Problems & Solutions

Troubleshooting Serial Communication Problems

Product Return Procedure

Resonance (Steady State Response)

Ringing (Transient Response)

Damping

Wiring Configurations

Terminal Connections

Direction of Motor Rotation

Setting Motor Current

LVD Installation Instructions

EMC Installation Guidelines

INDEX