Anaheim Stepper DPD72451 Users Guide

							USERS MANUAL 
MODEL DPD72451
MANUAL PRESET INDEXER
DRIVER PACK 
ANAHEIM AUTOMATION
910 E. Orangefair Lane
Anaheim, CA 92801
Phone: (714) 992-6990
Fax: (714) 992-0471
http://www.anaheimautomation.com
email: [email protected]
#L010029    May 16, 2002COPYRIGHT© 1997 by Anaheim Automation.  All rights reserved.  No part of this publication may be
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Automation, 910 E. Orangefair Lane, Anaheim, CA 92801.
DISCLAIMER
Though every effort has been made to supply complete and accurate information in this
manual, the contents are subject to change without notice or obligation to inform the
buyer.  In no event will Anaheim Automation be liable for direct, indirect, special,
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or documentation.  
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LIMITED WARRANTY
All Anaheim Automation products are warranted against defects in workmanship,
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used in accordance with specifications.  This warranty will be in effect for a period of
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TECHNICAL SUPPORT
If you should require technical support or if you have problems using any of the
equipment covered by this manual, please read the manual completely to see if it will
answer the questions you have.  Be sure to look in the TROUBLESHOOTING section
located in this manual.  If you need assistance beyond what this manual can provide,
contact your local Distributor where you purchased the unit, or contact the factory direct.
TRADEMARKS
Control Link and Driver Pack are registered trademarks of Anaheim Automation. 
						

							BILEVEL
DRIVERPOWER
SUPPLYSTEP
MOTORTHUMBWHEEL SWITCHEXTERNALMANUAL
SWITCHES
PLCand/orDPD72451
(Transformer) MANUAL PRESET
INDEXER
W/ INTERNAL
INDEX COUNT
SWITCHES
12 TABLE OF CONTENTSINTRODUCTION
PAGEThumbwheel Switch is used to set the index (number of steps or move distance)
INTRODUCTION.....................................2
DESCRIPTION and FUNCTION.........................3
MANUAL PRESET INDEXER.....................3
BLD72 BILEVEL DRIVE.........................7
HOOKUP DIAGRAM............................9
WIRING DIAGRAM...........................11
USING THE MANUAL PRESET INDEXER................12
SELECTING MOTION PARAMETERS.............13
HOMING MODES.............................15
SETTING THE  MOVE DISTANCE................16
JUMPERS..................................17
COUNT INPUT MODULES............................18
SPECIFICATIONS..................................22
X250A VERSION ...................................24
TROUBLESHOOTING...............................25
FIGURE 1 The DPD72451 Driver Pack contains a Bilevel Step Motor Driver (BLD72), a
Manual Preset Indexer board,  a Transformer, and a cooling fan.  Figure 1
shows the general configuration and layout of the DPD72451 Driver Pack.  The
and the Manual switches and/or PLC are used to initiate indexing, homing or
jogging.
The Manual Preset Indexer is ideal for applications which are repetitive and
require accurate positioning.  Some areas where Manual Preset Indexers are
commonly used are:
C Robotics
C Machine Control
C Packaging
C Assembly Automation
C Fluid Control and Mixing Systems
C Table Positioning Systems
C Photographic Controls
C Custom Motion Control
C Cut - to - Length 
						

							34 DESCRIPTION AND FUNCTION
MANUAL PRESET INDEXER BOARD
The Manual Preset Indexer board utilizes the PI45 Preset Indexer integrated
circuit (I.C.). Functions available are Home, Hard and Soft Limit inputs, two
Homing modes, Jog/Run, Fast Jog and switch selectable Base Speed,
Maximum Speed, Acceleration/Deceleration. 
This board  includes the necessary buffering and other circuitry for the PI45 chip
that makes indexing easy.  The board can be operated manually or with a
Programmable Logic Controller (PLC) to index a set of pulses determined by the
internal count switches or an external count module, such as the AA1760-5 or
similar device.
Indexer board features include:
 Internal Index Count switches
 Pulse Rates up to 14,792 pulses per second
 CW and CCW Home, Hard, and Soft Limit inputs
 Adjustable Motion Complete output
 Motion Busy output
 Clock pulses and step direction outputs
 CW and CCW Index inputs
 CW and CCW Jog/Run and Fast Jog inputs
 Two Go to Home Position modes
 TTL-MOS Compatible
 Pulse and reset outputs and coincidence inputs for interfacing with a 
  2 to 6 decade thumbwheel, rotary switch assembly or similar deviceMANUAL PRESET INDEXER TERMINAL (P1) DESCRIPTION
PINFUNCTIONDESCRIPTION1-HARD LIMITWhen active low, this signal instructs the step motor to
halt all motion in CCW direction.
2+HARD LIMITSame as -HARD LIMIT except in CW direction.
3-SOFT LIMITWhen active low, this signal instructs the step motor to
ramp down to  base speed and complete the move.
Input active during a -Index or  -Home function.
4+SOFT LIMITSame as -SOFT LIMIT except in CW direction.
5-HOME LIMITUsed in H0 Homing mode in conjunction with -Soft
Limit.  Giving -Home command (active low) causes
motor to ramp to high speed in the CCW direction until
-Soft Limit is contacted.  At contact, motor will
decelerate to base speed and run until the -Home Limit
is contacted, at which time the motor will stop.
6+HOME LIMITSame as -HOME LIMIT except in CW direction.
7-JOG/RUNA low level on this line causes the step motor to take
one step in the CCW direction.  Normally, the
JOG/RUN inputs are manipulated by external
pushbutton switches.  A single depression of the switch
causes a jog operation, while holding the switch down
for 0.5 seconds causes a slow run condition.  This
command may be used with FAST to perform a fast
run at the base speed rate.
8+JOG/RUNSame as -JOG/RUN except in CW direction.
9-HOMEA low level on this line instructs the step motor to move
to the home position via the CCW direction.  (See
HOME SELECT)
10+HOMESame as -HOME except in CW direction.
11-INDEXWhen low, this signal causes the PI45 chip to read the
current motion parameters and number of steps from
the thumbwheel switches and command the motor to
step the indicated distance in the CCW direction.  (See
-SOFT LIMIT).   NOTE :  If -SOFT LIMIT is
encountered during an Index, the motor will decelerate
to base speed and complete the Index. 
						

							56 12+INDEXSame as -INDEX, but commands a CW step motion.section on Jumpers).
13#INT/EXTThis input determines which set of switches will be
used for counting.  A logic “1 or open selects the
Internal Index Count Number.  A logic “0 selects the
count of an external counter module.
14HOME SELECTThis input selects the type of Home operation to
perform:  When active low, H0 Homing Mode is
selected.  It is a standard deceleration and stop on
switch operation.  In essence, type H0 is a combination
of the HOME and SOFT limit commands.  When active
high, H1 Homing Mode is selected.  H1 is used for anti-
backlash protection.  It performs a decelerate, reverse,
return off switch operation.  NOTE: the switch must
remain closed during deceleration, reverse, and return
in H1 Mode.
15 FASTWhen active low, it is used in conjunction with
JOG/RUN to cause a fast run (base speed) operation
in the specified direction.
16BUSYThis open collector switch output is ON when the motor
is moving.  This output can sink 0.5A and stand off
40Vdc maximum.  A 10k ohm pullup resistor can be
jumpered in place to provide TTL levels (see section
on Jumpers).
17CLOCKThis output is an open collector output, 15
microseconds wide (minimum) that is the clock input
for the motor driver. It is buffered to assure adequate
drive for an LS-TTL input. This signal is internally
connected to the driver. 
180VDCGround (0Vdc).
19DIRECTIONClockwise (CW) motion causes this output to be active
high i.e. logic “1.  Counterclockwise motion causes
this output to be active low i.e. logic “0. This output
tells the motor driver which direction to run. This signal
is internally connected to the driver.
20COMPLETEThis open collector switch output turns on after the
indexing cycle is executed.  The pulse width (time that
this output is on) is adjustable from about 12ms to
120ms (see Table). This output can sink 0.5A and
stand off 40Vdc maximum.  A 10k ohm pullup resistor
can be jumpered in place to provide TTL levels. (seeFIGURE 2 SETTINGPULSE WIDTHSETTINGPULSE WIDTH
112 ms679.5 ms
225.5 ms793 ms
339 ms8106.5 ms
452.5 ms9120 ms
566 ms--
--
TYPICAL HOOK-UPS FOR BUSY AND COMPLETE OUTPUTS OF THE
MANUAL PRESET INDEXER BOARD:
K1 will energize immediately after completion of an index cycle and remain
energized for approximately an amount of time set by the “COMPLETE PULSE
WIDTH” POT.  K2 will be energized throughout an index cycle.
MANUAL PRESET INDEXER TERMINAL (P2) DESCRIPTION
PINFUNCTIONDESCRIPTION
1+5VDC+5VDC Regulated Voltage Supply Output
2       +12VDC Unreg+12VDC Unregulated Voltage Supply Output
30VDCGround (0Vdc).
40VDCGround (0Vdc).
59 - 12VAC IN 9 - 12VAC Voltage Supply Input for PCL451 version.
69 - 12VAC IN9 - 12VAC Voltage Supply Input for PCL451 version.
BLD72 BILEVEL DRIVER
The BLD72 step motor driver employs a bilevel drive technique for high-
performance operation of step motors.  The driver is designed to operate  4-
phase, 6 or 8 lead step motors, providing high torque output and higher start-
stop speeds.  This driver is rated for output currents of 10 Amps/phase when
running and 7 Amps/phase at standstill. The BLD72 includes fault protection 
						

							1
2
31 2 31
2
3FAULT
POWER
78 against shorted and open motor wires.  If any type of fault is detected, the driverFAULT PROTECTION
will turn off current to the motor, and the Fault LED will indicate which type of
fault occurred.There are three types of fault detection.  When a fault is detected, the driver
BILEVEL DRIVEoccurred.  See the Troubleshooting section for more information.
The basic function of a step motor driver is to control the motor winding
currents.  Motor performance is determined by how fast the driver can increase
and decrease the winding currents. A rapid rise in winding current is achieved
by applying a high voltage directly to a motor winding until a desired current
level is reached.  Then a low voltage is applied to maintain a suitable holding
current level.  When a motor winding is de-energized (turned off), a rapid
decrease in winding current is achieved by routing the energy in the collapsing
field back to the power supply through a high voltage path.  The high voltage
supply furnishes the energy necessary to maintain motor output torque at high
step rates thus providing high mechanical power output.  The low voltage supply
provides much of the current needed at low step rates and all of the holding
current.  
Bilevel drivers do not use high frequency switching techniques as chopper
drivers do.  Consequently, they do not create the EMI, RFI, and motor heating
problems that are associated with chopper drivers.
ADJUSTING THE KICK CURRENT
The kick current level is the desired phase current level that the high voltage
provides each time a step is taken.  The high voltage is turned off when this
level is reached.    To obtain a proper setting, refer to the silkscreen on the side
of the unit and adjust the potentiometer to the rated phase current of the motor.
This internally sets the kick current 40% over the rated phase current.  
 WARNING: The kick current level must be set before operating a motor.FUNCTIONJP1JP2JP3
NEGATIVE GOING CLOCKS1-2XX
POSITIVE GOING CLOCKS2-3XX
TERMINAL 5 = CCWX1-2X
TERMINAL 5 = DIRECTIONX2-3X
GROUND FAULT DETECTION ENABLEDXX2-3
GROUND FAULT DETECTION DISABLEDXX1-2
TABLE1: JUMPERS SETTINGS  turns off the motor current and the red Fault LED indicates which type of fault
1LED - Slow Blinkshorted wire in the motor or cable
2LED - Fast Blinkopen wire in the motor or cable
3LED - ON Steadyground fault (voltage shorted to 0V)
 
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.  
JUMPER FUNCTIONS/LOCATIONS 
						

							910 MOTOR/DRIVER CONNECTIONSBLD72 DRIVER TERMINAL DESCRIPTION
Figure 3 shows the proper connection of the step motor.  The CLOCK (pin 6)PINFUNCTIONDESCRIPTION
and DIRECTION (pin 5) inputs on the driver terminal block are internally
connected to the CLOCK and DIRECTION outputs of the indexer (nothing
should be connected to these inputs).
Table 2: Driver Terminal Block
Figure 3: Step Motor
Phases  1PHASE 1MOTOR PHASE 1 (Red motor wire)
2PHASE 3MOTOR PHASE 3 (Red/White motor wire)
3COMMON 1,3MOTOR PHASE 1,3 COMMON (Black motor wire)
4FAULT RESETIf this input is momentarily pulled low after a fault
condition occurs, then the fault is reset and the driver
can run again.
5DIRECTIONThis input is the direction control input.  It is internally
connected to the Direction control output of the
Manual Preset Indexer.  A logic 1 selects CW(+)
direction.  A logic 0 selects CCW (- ) direction.
6CLOCK INA negative going pulse on this input causes the
motor to step.  The Clock output of the Manual
Preset Indexer is internally connected to this  input.
70VDCThis 0Vdc is internally connected to the 0Vdc on the
Manual Preset Indexer.
8HS/FSThis is the excitation mode select input.  A logic 1
selects HALF-STEP excitation.  A logic 0 selects
dual phase FULL-STEP excitation.
9ON/OFFThis input may be used to turn off the motor current
while standing still.  This will reduce heating in the
driver and motor.  The motor is energized when this
input is a logic 1.  The motor is de-energized when
this input is a logic 0.
10No connection 
11COMMON 2,4MOTOR PHASE 2,4 COMMON (White motor wire)
12PHASE 2MOTOR PHASE 2 (Green motor wire)
13PHASE 4MOTOR PHASE 4 (Green/White motor wire) 
						

							DRIVER
TERMINAL
BLOCK
See Figure 3
INDEXER
TERMINAL
BLOCK
External Connectors for Count Input BoardsReverseForward BLD DRIVER
Manual Preset Indexer 115 VACP1
P2P4
P3TIME SPEED
BASE SPEED MAXIMUM SPEED ACCELERATION
DECELERATION1112 FIGURE 4: INTERNAL WIRING DIAGRAM DPD72451 INTERNAL WIRING DIAGRAM
FIGURE 5:  Velocity Profile USING THE MANUAL PRESET INDEXER
SELECTING MOTION PARAMETERS
The velocity profile (motion speed and acceleration) is determined by the four
green switches; the Base Speed, Max Speed, Acceleration/Deceleration, and
Factor.  Figure 5 shows a typical velocity profile of a step motor. 
BASE SPEED
This is the speed at which the motor starts to run.  There are 256 choices of
Base Speeds as shown in the Table 3.  They range from 2 steps/second to
3,611 steps/second.
MAX SPEED
As shown in Table 2, there are 256 choices available ranging from 163
steps/second to 14792 steps/second.
ACCELERATION/DECELERATION
The step motor starts to accelerate after taking 4 steps at the base speed and
continues until it reaches the selected maximum speed taking the number of
steps set by A/D at each speed in the internally generated ramp table.  A/D=0
is no acceleration (run at BASE speed only), A/D=1 is the fastest (minimum
ramp time), and A/D=F is the slowest (maximum ramp time).  The step motor
starts to decelerate at the calculated point and continues until it reaches the
selected base speed and stops.  
 
FACTOR
The F switch should be set first because it directly affects the Base and Max
speed.  Table 1 lists the maximum obtainable stepping rates for all F switch
settings with the maximum speed F. 
						

							1314 FMax(steps/sec)FMaxFMaxFMax
0147924493082548C728
192645426691816D484
2716563759A1411E366
3584173360B946F246
TABLE 3:  MAXIMUM MAX RATES FOR FACTOR SETTINGS
EXAMPLE :
Assume that the motor is to run at a Max Speed of 4500 steps/second.  It can
be seen from the table above that this speed can only be obtained with the F
switch setting of 0 through 4.  Any of these switch settings could provide
speeds in excess of 4500 steps/second.  The rule of thumb is to always
chose the highest F switch setting that will provide the desired Max Speed,
and also give the widest range for Base Speeds.  In this example, F with a
switch setting of 4 is the best choice.  For a desired speed of 1200
steps/second, set F switch to A.  For a desired speed of 13000 steps/second,
only an F switch setting of 0 will suffice.
SETTING THE M SWITCH
Now that we have selected the F switch setting, we can find the value for M
from Table 2.  The factor setting is in the left hand column, and the Max
Speed setting is along the top row.  In example 1 for the desired M of 4500
steps/second, we set the F switch at 4.  Table 1 lists the maximum speed
values for each switch setting of F.  Looking at the M values in Table 2 for an
F switch setting of 4, the closest speeds are 4495 (M=C) and 4631 (M = D). 
For the desired maximum speed of 1200 steps/second (F=9) and M switch
setting of 0 (1207 sps) or A (1173 sps) can be used.  A speed of 13000 sps 
(F=0) requires an M switch setting of either A (12737 sps) or B (13102 sps).
SETTING THE B SWITCH
By choosing an F value, we restrict our choice of Base Speed to 16 possible 
values (see Table 3).  In example 1, from maximum speed of 4500
steps/second
(F = 4) we can select Base speeds ranging from 42 to 1223 steps/second. 
For
the desired maximum speed of 1200 sps (F=9), the Base speed can be
chosen 
from a range of 15 sps to 438 sps.  If due to the selection of the factor we are 
       limited to a low Base Speed, it is possible to choose a lower Factor and
then 
choose the appropriate Base and Max settings.  Thus, for maximum speed of
 1200 sps, a Factor of A could also be used, giving the range of Base Speed 
11 to 339 sps.M SWITCH SETTING
F0123456789ABCDEF
F163166170174179183188193199204210217223231238246
E242248253259266272279287295303313322332342354366
D320327335342351360369380390401412425438452467484
C481493504517529543557572588604623641661682705728
B626641656672689706725744764786809833859886915946
A9369579801004102810541082111111411173120712421281132213651411
91207123412631293132513581394143114701511154416011650170217571816
81699173717771820186419111959201120662123218422482316238824662548
72248229823512407246625262591265827302805288429683057315232523360
62520257626352697276228302902297730573141322933233422352736403759
52866293029973067314132183299338434743568366937743886400541324266
43322339734743554363937283821391940224132424643674495463147774930
33953404041314227432644314540465547774904503951815332549156615841
24878498550955211533254595592573258796033619663686551674369487165
16369650466466793694871107279745676427838804582638492873489919264
09968101901042210664109181118511464117581206712393127371310213487138951433014792
TABLE 4: MAX SPEED (FACTOR SETTING VS MAX SETTING)
B SWITCH SETTING
F0123456789ABCDEF
F251015192427323740444750535659
E371422293641485460657175798387
D4101928384854647279869399105110115
C614294357728197109120130141150159166174
B81937567594106126141157170183195207216227
A11285684112140159189212234254274292309324339
9153773109145181205244274303329355377399418438
82152103154205256290349387428464501533564590619
72869138206273341386459515569618666707749784821
63178155231307383434516578640694748795841880922
5358917726435043849558965973079185390695910031052
4421042063084085105776867688499219931054111611671223
3501242473704896106908219191015110111871260133313941460
262154309460610761860102111431264136814741565              1655     17301812
18320641161280910091141135215131671180919472066               2181     22812389
0124310617919 121615191717203822822520273029393120               2957    34483611
 TABLE 5: BASE SPEED (FACTOR SETTING VS BASE SETTING) 
						

							STOPS SLOWS
DOWN
SCREWHOME
LIMIT SOFT
LIMIT NUT
STEP
MOTOR1516 HOMING MODES
There are two Homing Modes that may be initiated, H0 and H1.
H0 HOMING MODE:  This mode causes the motor to run at Max Speed in
the direction selected.  The motor runs until the nut encounters the SOFT
limit switch, at which time the motor decelerates to the Base Speed.  The nut
continues to run at Base Speed until it hits the Home limit switch.  This may
be illustrated by using a step motor driving a leadscrew as shown below. 
CAUTION: The two limit switches should be placed such that the nut after
hitting the Soft limit switch has enough time to get to Base Speed before
encountering the Home limit switch.
H1 HOMING MODE: When this homing mode is selected, the nut seeks
home at Max speed.  It decelerates to Base speed when the soft limit switch
is encountered.  The Soft limit switch must remain closed until the motor
completely decelerates to Base speed, at which time the controller causes
the motor to reverse direction and run at Base speed until the Soft limit
switch is no longer closed.  This mode is illustrated below.  This Homing
mode uses only one switch, but a flag is required to keep the switch closed
during the deceleration cycle.  If only a momentary switch closure is made,
the motor will decelerate to Base speed and stop.  This stopping point may
not be accurate or repeatable; so, the flag is necessary.SETTINGTHE
MOVE DISTANCE
The index count or move distance for the DPD72451 can be accomplished by
a number of methods.  The easiest way is to use the red switches labeled
“Internal Index Number” on the unit; these switches are used by default. 
External Count Modules may also be used.    These include the Click Pot
Module, AA1748, the Thumbwheel Module, AA1760,  the BCD Input Module,
AA2210, and the Quad Board, AA1754.  These modules set the distance of
the move, but will allow for different variations in interfacing (see descriptions
in next section).
JUMPERS
There are four jumpers on the Manual Preset Indexer board.  The first
jumper, JP1, is used to set the debounce delay time for the JOG, HOME, and
INDEX inputs.  When JP1 is in the “1-2 position, the debounce delay is
approximately 12.5 milliseconds.  When JP1 is in the “2-3 position, the
debounce delay is approximately 0.3 milliseconds.  The active low signal on
these inputs must be wider than the debounce delay time. 
						

							1718 FIGURE  6 To use an external Count Module, the INT/EXT input (pin 13) must be pulled
low to a logic  “0.  The on-board switches will be ignored.  External Count
Modules plug into either connector labeled “EXTERNAL COUNT MODULE
CONNECTOR”(P1 or P2).  When only using one module for both FORWARD
and REVERSE indexes, jumper JP2 must be in the “1-2 position.
When using external Count Modules, it is possible to use one module for
FORWARD indexing and another module for REVERSE indexing.  The
connector on the side of the unit is the FORWARD count; the connector on
the top (of front face) is the REVERSE count.  When using two modules fordifferent FORWARD and REVERSE indexes, jumper JP2 must be in the “2-3 position.
JUMPER LOCATION / FUNCTION
JP1DEBOUNCE INPUT
DELAY
1-212.5 ms
2-30.3 ms
JP2EXTERNAL COUNT MODULES
1-2ONE MODULE (SAME FORWARD AND REVERSE)
2-3SEPARATE MODULES FOR FORWARD AND REVERSE
FIGURE  7
FIGURE  8  COUNT INPUT BOARDS
All of the Count Input Boards or Modules set the number of steps the motor
will move when an Index is initiated, but each Module allows for a different
variation in interfacing.
AA1748 - CLICK POT MODULE
A CLICK POT module consists of 10 position (0 - 9) digital pots mounted on
a printed circuit board.  One pot is used per each decade (digit).  These units
are available in 2, 4, or 6 decades.  The user dials in the step count on the
pots.  Any time the motor is indexed, it will move the number of steps set on
the pots.  One module is required per axis.  The module is connected to the
Manual Preset Indexer via a supplied 5 lead cable.
AA1760 - THUMBWHEEL SWITCH MODULE
These thumbwheel switches provide an attractive way to input a step count. 
The user dials in the desired count on the thumbwheels, which can be
mounted on an enclosure face.  The module is available in 3, 4, 5, or 6
decades.  The module is connected via a supplied 5-lead cable.