Anaheim Stepper DPC50501 Users Guide
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September 2012 L0101941 DPC50501 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
September 2012 L0101942 Table of Contents Section 1: Introduction.................................................................................................................................3 Description.....................................................................................................................................................3 Ordering Information.......................................................................................................................................4 Axis Selection.............................................................................................................................................4 Baud Selection............................................................................................................................................5 Baud Rates.................................................................................................................................................5 Methods of Communication.......................................................................................................................5 RS232 to RS485 Protocol...........................................................................................................................5 RS485.........................................................................................................................................................6 Two Wire Confi guration..................................................................................................................................6 Four Wire Confi guration...............................................................................................................................6 Terminating Resistor......................................................................................................................................7 Status LED (Controller)...................................................................................................................................7 Technical Support...........................................................................................................................................7 Electrical Specifi cations..............................................................................................................................8 Terminal Descriptions.................................................................................................................................8 Dimensions.................................................................................................................................................9 Wiring Diagram............................................................................................................................................9 Motor Selection..........................................................................................................................................10 Step Motor Selection Guide.......................................................................................................................11 Reducing Output Current............................................................................................................................11 Determining Output Current...........................................................................................................................11 Step Motor Confi gurations.........................................................................................................................12 Connecting the Step Motor........................................................................................................................13 Short-Circuit, Mis-Wire, and Over-Current Conditions...................................................................................13 Section 2: Controller Functions................................................................................................................14 Section 3: SMC50WIN Software...............................................................................................................17 Installation.................................................................................................................................................17 Getting Started...........................................................................................................................................17 “The Unit is Connected” / “The Unit is NOT Connected”....................................................................................18 File Menu..................................................................................................................................................18 Setup Menu...............................................................................................................................................18 Toolbar........................................................................................................................................................18 Tab Sheets................................................................................................................................................19 Current Program Filename.............................................................................................................................21 Add/Change/Insert Commands..................................................................................................................21 Calculator..................................................................................................................................................25 Section 4: Direct Talk Mode..................................................................................................................26 COM Port Settings....................................................................................................................................26 Unit Selection...........................................................................................................................................26 Instructions...............................................................................................................................................26 Section 5: Troubleshooting....................................................................................................................31 Error Codes..................................................................................................................................................32 Section 6: Tutorial...................................................................................................................................33 Sample Program 1:......................................................................................................................................33 Sample Program 2:......................................................................................................................................34 Appendix 1: ASCII Table for Direct Mode........................................................................................ .............36 Copyright ..................................................................................................................................................37
September 2012 L0101943 Introduction The DPC50501 is a single axis programmable controller, a 5 amp bipolar microstep driver, and a 48VDC 65W power supply package. It provides fl exible, independent control of bipolar step motors with a current range from 0.5 to 5.0 amps and microstepping resolutions of 1, 2, 5, 8, 10, 16, 32 and 64. The easy to use software, SMC50WIN, can be used to directly control motion and to program the controller. The DPC50501 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 DPC50501 has 20 commands which are easy to remember for direct movement and uses the RS485 communication protocol so up to 32 units can be networked together from one com- munications port on your PC or PLC (programmable logic controller). The DPC50501 also has 2 programmable “open drain” outputs and 4 TTL compatible inputs and can be powered from 105 VAC to 130VAC. The DPC50501 is direct replacement in size and connections with Anaheim Automation’s DPC40501. The upgrades to this unit include higher resolution and higher motor currents. Section 1: 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 DPC50501 provides independent programming of acceleration/deceleration, base speed (start up speed), max speed (running speed), and the number of steps to 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 defi nes. 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. Four testable inputs and 2 programmable outputs are provided per axis. 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 DPC50501 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 store in the con- troller 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 DPC50501 has an output current capability of 0.5 amp minimum to 5.0 amps maximum (peak rating). The driver offer motor cur- rent ON/OFF capabilities. The Reduce Current Enabled automatically reduces motor current to 50% of the set value after the last step is made (20msec delay). With the DPC50501, various step resolutions can be implemented by the onboard dip switch. These divisions range from 200 steps per revolution to 12800 steps per revolution. The bipolar driver confi guration handles 4, 6, and 8 lead motors. Protection devices have been added to this driver for phase to phase short-circuit conditions.
September 2012 L0101944 Ordering Information The table below lists a variety of products available from Anaheim Automation. These products include those covered by this manual, analog with supporting cables and devices. We are con- tinually adding new products to our line, so please consult Anaheim Automation representatives for information on the latest releases. Part Number Description DPC50501 Featured PCL501 RS485 compatible controller (Up to 32 unit multidrop compatible) PCL501PC RS232 compatible controller (Not mulitdrop compatible) 485SD9TB RS232 to RS485 converter MBC05641 0.5-5 Amp Microstep Driver PSAM24V1.2A-5V3.5APower supply for PCL501 and PCL501PC ([email protected], [email protected]) 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 DPC50501. The table below shows how to confi gure the jumpers for a given axis. JP8 is the LSB (Least Signifi cant Bit) and JP4 is the MSB (Most Signifi cant Bit). Axis SelectedJumper SettingAxis SelectedJumper Setting 0 00000 16 10000 1 00001 17 10001 2 00010 18 10010 3 00011 19 10011 4 00100 20 10100 5 00101 21 10101 6 00110 22 10110 7 00111 23 10111 8 01000 24 11000 9 01001 25 11001 10 01010 26 11010 11 01011 27 11011 12 01100 28 11100 13 01101 29 11101 1 4 0 111 0 3 0 1111 0 1 5 0 1111 3 1 11111
September 2012 L0101945 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 confi gure the jumpers for a given baud rate. JP3 is the LSB and JP1 is the MSB. Baud Rate Jumper Setting 1200 000 2400 001 4800 010 9600 011 19200 100 38400 101 57600 110 115200 111 Baud Rates A term used frequently in serial data communications. A “baud” is defi ned 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 DPC50501’s controller. One is to directly talk to the controller by using Direct Talk Mode. This is usually used with a computer or PLC (Pro- grammable 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 write and send programs. This method is used when the controller is the main controller. For example: A DPC50501 can replace simple motion control and replace I/O functional when minimal quantities of I/O are required to control specifi c machinery. Simple motion profi les that can operate with 4 or less inputs and 2 or less outputs can utilize a DPC50501 controller. 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 for- mat. Only one converter box is needed per serial port. Contact the factory for RS485 converter information and sales.
September 2012 L0101946 RS485 Protocol The RS485 protocol is as follows, onboard receivers will remain in active mode indefi nitely. Transmitters must be turned off when the unit is not sending data to prevent the line from send- ing 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 controller. The RS485 method of communication allows increased noise immunity and increased communication distance of up to 4000 feet without repeaters. RS485 repeaters allow an additional 4000 feet per repeater. Two Wire Confi guration The two wire confi guration reduces cabling costs by requiring only three wires. A, B and ground. The DPC50501 is designed to allow either the two or four wire confi guration. To use the 2 wire confi guration 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 fi rst 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 confi guration 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” confi guration (note that an additional ground conductor should be used) reduces cabling cost. RS485 devices may be internally or externally confi gured for two wire systems. Internally confi gured RS485 devices simply provide “A” and “B” connections (sometimes labeled “-” and “+”). Four Wire Confi guration Devices confi gured 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 confi guration fl exibility. 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 control- ler and so on.
September 2012 L0101947 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 4000ft. or longer cable and a baud rate of 38400 or when using a 2000ft. 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 (Controller) When powered and operated properly, the status LED will 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. 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.
September 2012 L0101948 Electrical Specifi cations Power Requirements: 110VAC Single Phase Operating Temperature: 0° to 60° C Pulse Output Range: 77 to 15000 pps Inputs (TTL-CMOS): Logic “0”: 0 to 0.8VDC Logic “1”: 3.5 to 5.0VDC Baud Rate: 1200 to 115200 BAUDDriver Ratings: Output Current 5.0 amps peak Data 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 fl y back voltage spikes. Pin # Description 1 TX+ 2 TX- 3 RX+ 4 RX- 5 RS485 Ground Terminal Descriptions TB1: Pin # Description Comments 1 OUT1 Open Drain 2 OUT2 Open Drain 3 IN1 Active Low = 1 4 IN2 Active Low = 2 5 IN3 Active Low = 4 6 IN4 Active Low = 8 7 0VDC Reference TB2: Pin # Description 1 Phase A: Phase 1 of the step motor 2 Phase Ā: Phase 3 of the step motor 3 Phase B: Phase 2 of the step motor 4 Phase B: Phase 4 of the step motor 5 MGND: Motor Ground TB4: Pin # Description Comments 1 JOG+ Active Low 2 JOG- Active Low 3 FJOG Active Low 4 SOFT+ Active Low 5 SOFT- Active Low 6 HARD+ Active Low 7 HARD- Active Low 8 HOME Active Low 9 CLK Open Drain 10 DIR Open Drain 11 0VDC Reference TB3: Pin # Description 1 Step Clock Input Anode (+): Internally connected to 5VDC. 2 Step Clock Input Cathode (-): Internally connected. 3 Direction Anode (+): Internally connected to 5VDC. 4 Direction Cathode (-): Internally Connected. 5 ON/OFF Anode (+): Internally connected to 5VDC. 6ON/OFF Cathode (-): To enable function, simply use a con- tact closure to 0VDC to activate. This will de-energize the motor windings. An output may be necessary to activate. TB5: Item Min Max Units Phase Output Current 0.35 3.5 A (RMS) Phase Output Current 0.5 5.0 A (Peak)
September 2012 L01019410 Microstep Selection (SW1 Settings) Switches 2, 3 and 4, of the DIP switch select the number of microsteps per step. The table below shows the standard resolution values along with the associated positions for the select switches. The standard waveforms are sinusoidal. Switch 1 selects the auto reduce current enable or dis- able. With Switch 1 On, reduce current is enabled, with Switch 1 Off, reduced current is disabled. Resolution Steps/Rev Select 2 Select 3 Select 4 1 200 ON ON ON 2 400 ON ON OFF 5 1000 ON OFF ON 8 1600 ON OFF OFF 10 2000 OFF ON ON 16 3200 OFF ON OFF 32 6400 OFF OFF ON 64 12800 OFF OFF OFF Motor Selection The DPC50501’s bipolar microstep driver is compatible with both bipolar and unipolar motor confi gurations, (i.e. 8 and 4 lead motors, and 6 lead center tapped motors). Step motors with low current ratings and high inductance will perform better at low speeds, pro- viding higher low-end torque. Motors with high current ratings and low inductance will perform better at higher speeds, providing more high-end torque. Since the DPC50501 is constant current source, it is not necessary to use a motor that is rated at the same voltage as the supply voltage. What is important is that the driver is set to the ap- propriate current level based on the motor being used. Anaheim Automation offers a comprehensive line of step motors in 17, 23, 34 and 42 frame sizes. Contact the factory to verify motor/drive compatibility.