Anaheim Stepper DPD60401 Users Guide

							SECTION 2QUICK START11 STEP 8 - Download the Program ( the Envelope Icon Button )
STEP 9 - Run the Program
To run the program just sent, select the Start Button (Traffic Signal Icon Button) which signals Green for GO.
STEP 10 - Switch Closure
After the sample program is written, you will need to close the switch on Input 1 to view the programmed
motion.  The current to the step motor will be turned off whenever it is motionless.  Once the switch has been
closed, the motor will move 400 steps, then an output will be activated for 1 second.  This will happen 4
times automatically, and then the indexer will wait for a switch closure before repeating the same cycle.Select the Send Button (Envelope Icon Button). This sends all 4 programs (Main, Programs 1, 2, & 3 to
the Driver Pack.  The programs will reside in the nonvolatile memory, and will stay there until they are
overwritten, or deleted by the software. Once the program is sent, Click OK on the prompt button
Program Sent. (Note: Place a Branch Quit Statement at the end of every program before sending.)ê ê
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							SECTION 3STEP MOTOR DRIVER12 SECTION 3 - STEP MOTOR DRIVER
MODEL – DPD72401, DPK72402, & DPK72403 (BLD72 Driver)
BILEVEL DRIVE
The basic function of a step motor driver is to provide the rated motor phase current to the motor windings in the
shortest possible time. The bilevel driver uses a high voltage to get a rapid rate of current rise in the motor
windings in the least amount of time. When reaching the preset trip current, the driver turns off the high voltage
and sustains the current from the low voltage supply.
HALF-STEP/FULL-STEP
Users have a choice of full-step operation or half-step operation.  Full-step operation occurs by energizing two
phases at a time, rotating a typical motor  1.8 degrees per step.  Half-step operation occurs by alternately
energizing one, and then two, phases at  a time, rotating the motor 0.9 degrees per step.  Full-step operation is
suggested for applications that specifically require that mode, such as when retrofitting existing full-step systems.
MOTOR ON/OFF INPUT
The motor on/off input allows de-energizing a motor without disturbing the positioning logic.  After re-energizing
the  motor,  a routine can continue. This reduces motor heating and conserves power, especially in applications
where motors are stopped for long periods and no holding torque is required.  If holding torque is required (such
as when lifting a load vertically), then this function should not be used. This output is internally connected to the
Indexer. See  Section 8 Command Descriptions for further information on Current Hold Command.
FAULT PROTECTION
There are 3 types of fault detection.  When a fault is detected, the driver turns off the motor current and the red
Fault LED indicates which type of fault occurred. (Located on the top of the driver pack.)
1LED - Slow Blinkshorted wire in the motor or cable2LED - Fast Blinkopen wire in the motor or cable3LED - ON Steadyground fault (voltage shorted to 0V)TABLE 3: FAULT LED
If the driver goes into a fault condition, the fault may be reset by turning the power OFF for at least 15 seconds or
by pulling the RESET FAULT input (terminal 4) to a logic “0 for at least 100ms.
SETTING THE KICK CURRENT
The Kick Current should be set to the Motor’s Rated Unipolar Current.  For example, a 34D309 is rated for
4.5A, so the Kick Current Potentiometer would be set somewhere between the 4A and 5A indication.
GROUNDING
The unit should be properly grounded.  Shielded cable should be used to preserve signal integrity. 
						

							SECTION 3STEP MOTOR DRIVER13 Contact factory for grounding recommendations.
MOTOR HOOKUP
The DPD72401 Series Driver Packs can drive 6-lead and 8-lead step motors rated from 1 to 7 amps/phase
(unipolar rating).  It features a unipolar bilevel (dual voltage) drive technique with short/open circuit
protection (with a Fault LED).  This Driver Pack contains a 300 Watt fan cooled power supply.
MOTOR CONNECTIONS
Refer to Section 4 on Motor Connectors for a hookup diagram for  Driver Pack applications. All motor
connections must be separated from input connections and all other possible sources of interference.
IMPORTANT NOTE: When wiring from the driver(s) to the step motor(s) that extends beyond 25 feet, it is
important to consult with the factory.
WIRING DIAGRAM 
						

							SECTION 3STEP MOTOR DRIVER14 MODEL – DPD60401
The DPD60401 will deliver a peak current of 5.5 Amperes per phase at 65 Volts, providing outstanding
motor performance. This advanced technology reduces ripple current while maintaining the 20kHz
chopping frequency in the motor, causing less heat in both the motor and drive.
MODE  SELECT  SWITCHES
The MODE SELECT SWITCHES are used to select the divisor of operation from divide by 2 up to divide
by 256. Microstep operations are recommended for those applications that specifically require this drive
technique, such as retrofitting existing microstep systems. Microstep applications are mainly used for very
slow speed operations that require high resolution or very smooth performance. This enhanced resolution
can only be accountable for positioning accuracy of a step motor typically ±5% of one full step when
dividing by 20 (step angle of .09°) or less. Anaheim Automation  recommends the use of the bilevel drives
that have a divide by 2 (halfstep mode) for operations ranging in speeds higher than 2Khz, since
smoothness can easily be accomplished at this rate.
MICROSTEP SELECTION
The number of microsteps per step is selected by the dip switch(SW1).  Table 6 shows the standard
resolution values  along with the associated settings for these switches.  The standard waveforms are
sinusoidal.
ResolutionSteps/
     RevSwitch 1Switch 2Switch 3Switch 42400ONONONON4800OFFONONON81,600ONOFFONON163,200OFFOFFONON326,400ONONOFFON6412,800OFFONOFFON12825,600ONOFFOFFON25651,200OFFOFFOFFON51,000ONONONOFF102,000OFFONONOFF255,000ONOFFONOFF5010,000OFFOFFONOFF12525,000ONONOFFOFF25050,000OFFONOFFOpen    TABLE : Mode Selections
Note: The Microstep Mode Select switches are located on the top cover of the DPD60401. 
						

							SECTION 3STEP MOTOR DRIVER15 ADJUSTING  THE  RUNNING  CURRENT
The output current on the Microstep  Driver  Pack (DPD60401) is set
by the Running Current Potentiometer.  This resistance determines
the per Phase RMS output current of the driver. Refer to table on
Running Current Settings.
REDUCING  OUTPUT  CURRENT
The amount of current per Phase in the reduction mode is related to
the value of the current adjustment potentiometer (Running Current)
and the current reduction potentiometer (Reduced Current). When
the current reduction circuit is activated, the Reduced Current
resistance is paralleled with the Running Current resistance.  This
lowers the total resistance value, and thus lowers the per Phase output current by a percentage.
Pot1.4 AMPS2 AMPS3 AMPS4 AMPS5 AMPS5.5 AMPS150%42%32%26%22%21%261%53%43%36%31%30%370%64%54%46%41%39%475%70%61%54%48%46%580%75%67%59%54%52%682%78%71%64%58%56%784%81%75%68%63%61%886%84%77%71%66%64%989%88%83%78%74%72%TABLE : Percentage of I(peak) settings on Reduced Current Potentiometer
Note: To obtain a proper setting, adjust the potentiometer arrow to the setting that corresponds to the rated
current of the step motor in use. Use the resistance tables that match resistance to rated motor currents.
MOTOR  DRIVER  CONNECTIONS
Wiring from the Driver Pack to the motor should be routed away from all other wiring.  All electrical
connections are made to screw-type terminals for secure and reliable connections. Refer to Section 5,
Installation.
STEP MOTOR CONFIGURATIONS
Step motors can be purchased in configurations of 4, 6 or 8 leads.  Each configuration requires differentcurrent settings.  Different lead configurations and the procedures to determine their output current areshown below .
6 Lead Motors
When configuring a 6 lead motor in a half-coil
configuration (connected from one end of the coil to
the center tap) use the specified per Phase (or unipolar)
current rating to determine the current adjustment pot
setting.  This configuration will provide more torque at
higher speeds.Running Current
Potentiometer SettingCurrent
(Amps)11.422334444.5555.55.5 
						

							SECTION 3STEP MOTOR DRIVER16 When configuring the motor in a series configuration
(connected from end to end with the center tap floating)
multiply the per Phase (or unipolar) current rating by
0.7. Use this result to determine the current adjustment
pot setting.
4 Lead Motors
Use the specified series motor current to determine the current adjustment
resistor value.   Four-lead motors are usually rated with their appropriate
series current, as opposed to the Phase Current which is the rating for 6 and 8
lead motors.
8 Lead Motors
Series Connection: When configuring the motor windings in
series, multiply the per Phase (or unipolar) current rating by
0.7. Use this result to determine the current adjustment pot
setting.
Parallel Connection: When configuring the motor windings in
parallel, multiply the per Phase (or unipolar) current rating by 1.4.
Use this result to determine the current adjustment Output Current
pot setting.
WARNING! Step motors will run hot even when configured correctly. Damage may occur to the motor if a
higher than specified current is used.  Most specified motor currents are maximum values.  Care should be
taken to not exceed these ratings.
Note: A fault light on the DPD60401indicates a short occurred or the over temperature condition setting the
fault light. Powering down momentarily will clear the fault. 
						

							SECTION 4FEATURES17 SECTION 4- FEATURES
PRODUCT HIGHLIGHTS
· Speeds from 0.1 Hz to 2,500,000 Hz
· 24 Inputs Expandable to 96 Inputs
· 24 Outputs
· 16,000 Bytes of Stored Program Memory
· Up to 4 Programs can run Simultaneously (Multitasking)
· Math Functions
· Expandable Modules including Inputs and Thumbwheel Switches
· Encoder Feedback Capabilities
· Free Windows Based Software Included
· Limit Switches
· Addressable for up to 30 Axes
· Baud Rates up to 38,400
ENCODER FEEDBACK
Enhanced encoder feedback commands have been added to allow full control of the encoders.
Refer to Section 8 on Encoder Commands for further instructions.
PLC TYPE FUNCTIONS
In the multitasking environment, four programs can run simultaneously which gives the unit a PLC like
functionality.  For instance, Program 1 can contain a program that will turn-on Output 1 when Input 1 goes
Low.  This will happen independent of everything else going on.  This function is similar to a run on the
ladder using Ladder Logic on a PLC, and is not found in most sequential programming systems.
MULTIPLE PROGRAMS
The unit can contain up to four programs.  Any combination of these programs can be run simultaneously.
VARIABLES
Variables exist in the form of Bits and Registers.
REGISTERS
The Indexer uses a register based command structure.  A register may be written to or read.  A register is
simply a name for a spot where some value is to be stored.  Every register has a default value, can be
modified, and can be read.  For instance, the Base Speed has a default value of 99.  This can be changed
to another value, and it can also be read.  The Base Speed Register is called the MB Register.
BITS
A Bit differs from a register in that its’ value may only be a 1 or a 0.  In the programming world, a bit being
0 is considered OFF, or False; a bit being 1 is considered ON, or True.  All bits can be read, but only some
can be written to. The Moving Bit can be read, but writing to that Bit has no meaning, so it is not allowed.
In this section, each Bit is described in detail. Some Bits will be affected by commands, and others will not.
Bits tell the status of a certain item.  For example, the Moving Bit, or MV Bit will give the information if the
axis is moving or not.  If the axis is moving, the Bit Value will be a 1.  If the axis is not moving, the Bit Value
will be a 0.  Bits are very useful in making information available to the user.  Bits can also be used to make
decisions, like - If the Moving Bit is ON then activate output #1 which might turn on an LED to show that
the motor is moving.  Another example would be a conditional branch - If the Moving Bit is ON then loop to
line number 10. 
						

							SECTION 4FEATURES18 MOTOR INPUT BITS
HOME TYPE BIT
This BIT sets the type of homing to execute when the HOME(+) command is issued.HARD LIMIT INPUT BIT
This BIT indicates whether the HARD LIMIT input is on or off.
HOME LIMIT INPUT BIT
This BIT indicates whether the HOME LIMIT input is on or off.
SOFT LIMIT INPUT BIT
This BIT indicates whether the SOFT LIMIT input is on or off.
MOTION STATUS BITS
MOVING BIT
This BIT indicates whether the motor is moving or stopped, thus it is an output and cannot be
written to.  A logic “1”  indicates the motor is moving.
MOTION COMPLETE BIT
Reading this BIT will indicate whether the specified motor has completed its’ motion.  A logic “1”
indicates that the motor has completed it’s move.
MOTOR DIRECTION BIT
The DIRECTION BIT will indicate which direction the motor is moving in.  A logic “1” indicates that
the motor/axis in moving in the clockwise direction.
MOTOR ERROR CODE BIT
This Bit is enabled if the unit gets a motor error.
AT BASE SPEED BIT
This BIT is read as a 1 whenever the motor/axis is moving at the designated base speed.
AT SPEED BIT
The AT SPEED BIT indicates when the motor is moving at maximum speed.
AT RAMPING DOWN BIT
This BIT is read as 1 whenever the motor/axis is ramping down (decelerating).
AT RAMPING UP BIT
This BIT is read as a 1 whenever the motor/axis is ramping up (accelerating).
AT FAST JOG BIT
This BIT will be read as a 1 if the axis has been put into a fast jog cycle.
AT SLOW JOG BIT
This BIT will be read as a 1 if the axis has been put into a slow jog cycle.
AT RETRY BIT
This BIT will be read as a 1 if the indexer is still retrying to correct for encoder/motor difference. 
						

							SECTION 4FEATURES19 EXTERNAL MODULES
External Modules offer expansion capabilities for
items that are not available in the Driver Pack and
are for additional items such as additional Inputs,
Thumbwheel Switch Modules and Remote Panel
Mount Terminal. ( Purchased Separately )
The SMC40M-24I is an expansion module for the SMC40 Programmable Indexer series. Each SMC40M-
24I module adds 24 more inputs to  the SMC40 - up to three SMC40M-24I modules can be daisy chained
for a total of 96 inputs. The expansion modules are simply connected to the SMC40 through a standard
telephone handset cable(on JP2) - no external power supply required. JP1 is the Input socket and JP2 is
the Output socket for the next  module.  All 24 inputs are TTL/CMOS compatible and are easily accessible
through two  detachable  terminal  blocks. Or  using
the  50 pin  header connector, the  input  cable  can be connected to an Opto22® board for opto-isolation.
Using the Windows based “Intelligent Indexer” utility (that comes with the SMC40), the additional inputs
are easily incorporated into SMC40 programs.  The SMC40M-24I provides the SMC40 Programmable
Indexer a versatile way of dealing with additional inputs for complex automated systems.
SMC40M-24I 
						

							SECTION 4FEATURES20        SMC40M-24I INTERNAL WIRING