Anaheim Stepper DPC40501 Users Guide

							1 #L010089December 2001
DPC40501
Programmable Driver Pack
User’s Guide
910 East Orangefair Lane, Anaheim, CA 92801
e-mail: [email protected](714) 992-6990  fax: (714) 992-0471
website: www.anaheimautomation.com
ANAHEIM AUTOMATION 
						

							2 #L010089December 2001
Table of Contents
DPC40501 .......................................................................................................................1
Table of Contents ............................................................................................................ 2
Section 1: Introduction ..................................................................................................... 4
Description ....................................................................................................................... 4
Ordering Information ........................................................................................................ 5
Axis Selection ..................................................................................................................5
Baud Selection ................................................................................................................ 6
Baud Rates ......................................................................................................................6
Methods of Communication ............................................................................................. 6
RS232 to RS485 Protocol ............................................................................................... 6
RS485 Protocol ............................................................................................................... 7
Two Wire Configuration ................................................................................................... 7
Four Wire Configuration .................................................................................................. 7
Terminating Resistor ....................................................................................................... 8
Status LED ......................................................................................................................8
Technical Support ............................................................................................................ 8
Electrical Specifications ................................................................................................... 9
Terminal Descriptions ...................................................................................................... 9
Dimensions .................................................................................................................... 10
Wiring Diagram .............................................................................................................. 11
Microstep Selection (SW1 Settings) .............................................................................. 11
Motor Selection .............................................................................................................. 12
Step Motor Selection Guide ........................................................................................... 12
Setting the Output Current ............................................................................................. 13
Reducing Output Current ............................................................................................... 13
Determining Output Current .......................................................................................... 13
Step Motor Configurations ............................................................................................. 13
6 Lead Motors ................................................................................................................ 14
4 Lead Motors ................................................................................................................ 14
8 Lead Motors ................................................................................................................ 15
Connecting the Step Motor ............................................................................................ 15
Mis-Wire Detection ........................................................................................................ 15
Section 2: Controller Functions ..................................................................................... 16
Section 3: SMC50WIN Software ................................................................................... 19
Installation ..................................................................................................................... 19
Getting Started .............................................................................................................. 19
“The Unit is Connected” / “The Unit is NOT Connected” ............................................... 20
File Menu .......................................................................................................................20
Setup Menu ................................................................................................................... 20
Toolbar .......................................................................................................................... 21
Tab Sheets .................................................................................................................... 21
Motion Tab Sheet .......................................................................................................... 21
Motion Tab Sheet Tutorial ............................................................................................. 22
Program Tab Sheet ....................................................................................................... 23 
						

							3 #L010089December 2001
Current Program Filename ............................................................................................ 23
SMC50 Memory Available ............................................................................................. 24
Currently Selected Line ................................................................................................. 24
Add/Change/Insert Commands ..................................................................................... 24
Motion Command Tab Sheet ......................................................................................... 25
Program Parameters ..................................................................................................... 27
Calculator ......................................................................................................................28
Section 4: Direct Talk Mode .......................................................................................... 29
COM Port Settings ......................................................................................................... 29
Unit Selection ................................................................................................................ 29
Instructions ....................................................................................................................29
Section 5: Troubleshooting ............................................................................................ 34
Error Codes ................................................................................................................... 35
Section 6: Tutorial .......................................................................................................... 36
Sample Program 1: ........................................................................................................ 36
Sample Program 2: ........................................................................................................ 37
Appendix 1: ASCII Table for Direct Mode ...................................................................... 39
Legal Information ........................................................................................................... 40 
						

							4 #L010089December 2001
Section 1: Introduction
The DPC40501 is a single axis programmable controller, a 4 amp bipolar microstep driver, and a 48VDC
65W power supply package. It provides flexible, independent control of bipolar step motors with a current
range from 1.0 to 4.0 amps and microstepping resolutions of 1, 2, 5, 10 and 16. The easy to use software,
SMC50WIN, can be used to directly control motion and to program the controller. The DPC40501 also
has the ability for real time functions. A “direct mode” is used to directly control motion for real time
movements through serial communication. The DPC40501 has 20 commands which are easy to remem-
ber for direct movement and uses the RS485 communication protocol so up to 32 units can be networked
together from one communications port on your PC or PLC (programmable logic controller). The DPC40501
also has 2 programmable “open drain” outputs and 4 TTL compatible inputs and can be powered from
105VAC to 130VAC.
Description
Generally step motor controllers are open-loop systems, meaning that no information is sent back to the
controller from the motor to verify the number of steps that were taken. A step motor is essentially a digital
device - you give the step motor driver 10 step pulses, and the motor moves 10 steps. The DPC40501
provides independent programming of acceleration/deceleration, base speed (start up speed), max speed
(running speed), and the number of steps to be taken in both relative and absolute positioning modes. On
absolute positioning moves, the controller automatically determines the proper direction to go and the
number of steps to take. The relative positioning will move a number of steps in the direction that the user
defines. The controller has a high level command set including: looping, conditional statements, time
delays, and I/O. Hard, soft, and home limit switch inputs are provided for each axis. These features are
generally required in most machine control designs. 4 testable inputs and 2 programmable outputs are
provided per axis. These I/O may be used for monitoring and controlling machine operation and/or interaxis
coordination. These I/O are accessible independent of the busy state of the axis controls. The 4 inputs are
TTL/CMOS compatible. The 2 outputs are current sinking, open drain FETs. The controller in the DPC40501
has a built-in programmable reset circuit. Reset is automatic on power-up or by pressing the external
reset button. A CD is provided when you purchase the unit. This CD contains software that allows you to
write and change programs that are to be stored in the controller for autostart use. This CD also allows
you to save the programs onto your computer hard drive, and easily retrieve them when needed. The
clock and direction outputs of the controller are internally wired to the driver. The “microstep driver” in the
DPC40501 has an output current capability of 1.0 amp minimum to 4.0 amps maximum (peak rating). The
driver offers motor current ON/OFF capabilities. The Reduce Current Enabled automatically reduces
motor current to 70% of the set value after the last step is made (20msec delay). With the DPC40501,
various step resolutions can be implemented by the onboard dip switch. These divisions range from 200
steps per revolution to 3200 steps per revolution. The bipolar driver configuration handles 4, 6, and 8 lead
motors. Protection devices have been added to this driver for phase to phase short-circuit and motor mis-
wire conditions. 
						

							5 #L010089December 2001
Ordering Information
The table below lists a variety of products available from Anaheim Automation. These products include
those covered by this manual along with supporting cables and devices. We are continually adding new
products to our line, so please consult your nearest authorized Anaheim Automation distributor or
representative for information on the latest releases.
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C P 1 0 5 L C P)e l b i t a p m o c p o r d i t l u m t o N ( r e l l o r t n o c e l b i t a p m o c 2 3 2 S R
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Axis Selection
Each controller will be addressed using 5 jumpers (JP4 - JP8) allowing the PC to address up to 32
controllers from one port.  The jumpers are considered ON (1) when they are in position “1-2” and OFF (0)
when they are in position “2-3”. The jumpers are located on the side of the DPC40501. The table below
shows how to configure the jumpers for a given axis. JP8 is the LSB (Least Significant Bit) and JP4 is the
MSB (Most Significant Bit).
s i x A
d e t c e l e Sr e p m u J
g n i t t e Ss i x A
d e t c e l e Sr e p m u J
g n i t t e S
000 0 0 06 100 0 0 1
110 0 0 07 110 0 0 1
201 0 0 08 101 0 0 1
311 0 0 09 111 0 0 1
400 1 0 00 200 1 0 1
510 1 0 01 210 1 0 1
601 1 0 02 201 1 0 1
711 1 0 03 211 1 0 1
800 0 1 04 200 0 1 1
910 0 1 05 210 0 1 1
0 101 0 1 06 201 0 1 1
1 111 0 1 07 211 0 1 1
2 100 1 1 08 200 1 1 1
3 110 1 1 09 210 1 1 1
4 101 1 1 00 301 1 1 1
5 111 1 1 01 311 1 1 1 
						

							6 #L010089December 2001
RS232 to RS485 Protocol
The controller can be connected to your PC serial port via an RS485 or RS422 converter box. The RS232
converter will convert the RS232 communication format to the RS485 or RS422 format. Only one converter
box is needed per serial port. Contact the factory for RS485 converter information and sales.
Baud Rates
A term used frequently in serial data communications. A “baud” is defined as the reciprocal of the shortest
pulse duration in a data word signal, including start, stop, and parity bits. This is often taken to mean the
same as “bits per second”, a term that expresses only the number of “data” bits per second. Very often,
the parity bit is included as an information or data bit. The PCL501 accepts the following baud rates:
1200, 2400, 4800, 9600, 19200, 38400, 57600, 115200
Methods of Communication
There are two methods for sending commands to the DPC40501’s controller. One is to directly talk to the
controller by using Direct Talk Mode. This is usually used with a computer or PLC (Programmable Logic
Controller), where the computer or PLC gives the controller serial commands to off-load its processor. For
example: A PLC can utilize its outputs to toggle the controller’s inputs and gain control of variable speeds,
variable programs, variable distances, etc. Simply using the controller as the intelligent pulse generator a
PLC can remove some of the tasks that were not meant for ladder logic or any PLC processing time. The
second way to give commands to the controller is to use the software program SMC50WIN to either
manually control or to write and send programs. This method is used when the controller is the main
controller. For example: A DPC40501 can replace simple motion control and replace I/O functional when
minimal quantities of I/O are required to control specific machinery. Simple motion profiles that can oper-
ate with 4 or less inputs and 2 or less outputs can utilize a DPC40501 controller.
Baud Selection
The baud rate is selected using 3 jumpers (JP1 – JP3). They are selected the same way that the address
jumpers are selected. The table below shows how to configure the jumpers for a given baud rate. JP3 is
the LSB and JP1 is the MSB.
e t a R d u a Bg n i t t e S r e p m u J
0 0 2 100 0
0 0 4 210 0
0 0 8 401 0
0 0 6 911 0
0 0 2 9 100 1
0 0 4 8 310 1
0 0 6 7 501 1
0 0 2 5 1 111 1 
						

							7 #L010089December 2001
RS485 Protocol
The RS485 protocol is as follows, on board receivers will remain in active mode indefinitely. Transmitters
must be turned off when the unit is not sending data to prevent the line from sending and receiving data at
the same time. Therefore when the PC is transmitting data its driver will be turned on and each of the units
connected will have their drivers off. If they are requested to send data back to the PC, the selected unit
will turn it’s driver on to send the data then turn it off after it has completed transmission. Note: The above
protocol is done internally between the converter and the controller. The RS485 method of communica-
tion allows increased noise immunity and increased communication distance of up to 4000 feet without
repeaters. RS485 repeaters allow an additional 4000 feet per repeater.
Four Wire Configuration
Devices configured for four wire communications use TX and RX connections for both the transmit and
the receive pairs. The user can connect the transmit lines to the receive lines to create a two wire configu-
ration flexibility. Note that the signal ground line should also be connected in the system. This connection
is necessary to keep the VCM common mode voltage at the receiver within a safe range. From the
diagram below, it can be seen that all wires are run directly from the converter to the controller. For
example TX+ from the converter goes to TX+ on the controller and so on.
Two Wire Configuration
The two wire configuration reduces cabling costs by requiring only three wires. A, B and ground. The
DPC40501 is designed to allow either the two or four wire configuration. To use the 2 wire configuration
simply wire TX+ to RX+, and TX- to RX- on your converter box. Then run a wire from ground, a wire from
TX+/RX+ and a wire from TX-/RX-, to the first controller in the network. Finally do the same on the
terminal block of the controller to the converter box. The diagram below illustrates how this configuration
is connected. RS422 systems require a dedicated pair of wires for each signal, a transmit pair, a receive
pair, and an additional pair for each handshake/control signal used (if required). The tristate capabilities of
RS485 allow a single pair of wires to share transmit and receive signals for half duplex communications.
This “two wire” configuration (note that an additional ground conductor should be used) reduces cabling
cost. RS485 devices may be internally or externally configured for two wire systems. Internally configured
RS485 devices simply provide “A” and “B” connections (sometimes labeled “-” and “+”). 
						

							8 #L010089December 2001
Technical Support
Everyone needs help on occasion. If you have problems using any of the equipment covered by this
manual, please read the manual to see if it will answer the questions you have. Be sure to look in the
troubleshooting section located near the back of this manual. If you need assistance beyond what this
manual can provide, you can call the factory direct for application assistance. If possible, have this manual
in hand. It is often helpful to have the unit connected to a computer with the software installed.
Terminating Resistor
To eliminate noise on the transmission lines a terminating resistor may need to be used. If needed the
termination resistor need only be added to the last (furthest from the converter box) controller in the
network. A termination resistor with a value of 120 ohms is needed in certain conditions; when using a
4000 ft. or longer cable and a baud rate of 38400 or when using a 2000 ft. or longer cable and a baud rate
of 57600. If you need to add a terminating resistor, contact the factory for the exact location on the board.
Status LED
When powered and operated properly, the status LED will be green.  When an error occurs, the LED will
change to RED and an error code will be generated in the error code register.  To read and clear the error
with the software, click on the “Verify Parameters” button located in the “Motion Tab”. To read and clear
the error while in “Direct Mode” use the ! command. Once the error has been read and cleared, the LED
will return to green and the error code register will be cleared. Refer to the table in section 5 for a list of the
error codes. 
						

							9 #L010089December 2001
Electrical Specifications
Power Requirements:
110VAC Single Phase
Operating Temperature:
0º to 60º C
Pulse Output Range:
77 to 15000 pps
Inputs (TTL-CMOS):
Logic “0”: 0 to 0.8VDC
Logic “1”: 3.5 to 5.0VDCData Format:
Half-Duplex, 1 start bit, 8 data bits,
no parity, 1 stop bit
Outputs (2 programmable I/O):
Open Drain Type
40V, 75mA
Note: For inductive loads, customers must connect a clamping diode
to protect from fly back voltage spikes.Driver Ratings:
Output Current 4.0 amps peak
Baud Rate:
1200 to 115200 BAUD
m e t In i Mx a Ms t i n U
t n e r r u C t u p t u O e s a h P7. 08. 2)S M R ( A
t n e r r u C t u p t u O e s a h P0. 10. 4)k a e P ( A
Terminal Descriptions
# n i Pn o i t p i r c s e D
1+X T
2-X T
3+X R
4-X R
5dn u o r G 5 8 4 S R
TB1:
# n i Pn o i t p i r c s e Ds t n e m m o C
11T U Oni a r D n e p O
22T U Oni a r D n e p O
31N I1= w o L e v i t c A
42N I2= w o L e v i t c A
53N I4= w o L e v i t c A
64N I8= w o L e v i t c A
7CD V 0ec n e r e f e R
TB2:
# n i Pn o i t p i r c s e Ds t n e m m o C
1+G O Jwo L e v i t c A
2-G O Jwo L e v i t c A
3GO J Fwo L e v i t c A
4+T F O Swo L e v i t c A
5-T F O Swo L e v i t c A
6+D R A Hwo L e v i t c A
7-D R A Hwo L e v i t c A
8EM O Hwo L e v i t c A
9KL Cni a r D n e p O
0 1RI Dni a r D n e p O
1 1CD V 0ec n e r e f e R
TB3:
# n i Pn o i t p i r c s e D
1.C D V 5 o t d e t c e n n o c y l l a n r e t n I : ) + ( e d o n A t u p n I k c o l C p e t S
2.d e t c e n n o c y l l a n r e t n I : ) - ( e d o h t a C t u p n I k c o l C p e t S
3.C D V 5 o t d e t c e n n o c y l l a n r e t n I : ) + ( e d o n A n o i t c e r i D
4.d e t c e n n o c y l l a n r e t n I : ) - ( e d o h t a C n o i t c e r i D
5.C D V 5 o t d e t c e n n o c y l l a n r e t n I : ) + ( e d o n A F F O / N O
6a e s u y l p m i s , n o i t c n u f e l b a n e o T : ) - ( e d o h t a C F F O / N O
e z i g r e n e - e d l l i w s i h T . e t a v i t c a o t C D V 0 o t e r u s o l c t c a t n o c
. e t a v i t c a o t y r a s s e c e n e b y a m t u p t u o n A . s g n i d n i w r o t o m e h t
TB5:
# n i Pn o i t p i r c s e D
1ro t o m p e t s e h t f o 1 e s a h P : A e s a h P
2ro t o m p e t s e h t f o 3 e s a h P : A e s a h P
3ro t o m p e t s e h t f o 2 e s a h P : B e s a h P
4ro t o m p e t s e h t f o 4 e s a h P : B e s a h P
5dn u o r G r o t o M : D N G M
TB4: 
						

							10 #L010089December 2001
Dimensions
TB2
TB3
TB1 TB4
TB5