Anaheim Stepper DPF11451 Users Guide

							DPF11451 
HIGH PERFORMANCE BILEVEL DRIVER ANDMANUAL PRESET INDEXER
USER’S MANUAL
Driver Features
Opto Isolated Inputs
Over Voltage Protection
500VA Power Supply
100 Volt Operation
High Start/Stop Speeds
10 Amps/phase Standstill Motor Current
Very High Power Output
Bilevel Drive Operation (No RFI or EMI Problems)
Clock and Direction or Dual Clock Operation
Short Circuit Protection
Open or Intermittent Circuit Protection
16 Amps/phase Maximum Operating Current
Fault LED
Halfstep and Fullstep Operation
Motor Turn-off Input
+5VDC Opto-Isolation Input @ 100ma
115VAC Standard Input Voltage
Indexer Features
Internal Index Count Switches
Pulse Rate Up To 14,792 Pulses per Second
CW and CCW Home, Hard, and Soft Limit Input
Clock Pulses and Step Direction Outputs
CW and CCW Jog/Run and Fast Jog Inputs
Adjustable Motion “Complete” Output
Motion “Busy” Output
Two “Go to Home Position” Modes
TTL-MOS Compatble
Pulse and Reset Ouputs and Coincidence Inputs for Interfacing With a 2 t\
o 6 Decade Thumbwheel,      
Rotary Switch Assembly or Similar Device
#L010030 
						

							COPYRIGHT 
Copyright 1996 by Anaheim Automation.  All rights reserved.  No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language, in any form or by any means, electronic,
mechanical, magnetic, optical, chemical, manual,  or otherwise, without the prior written permission of Anaheim
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, incidental, or consequential damages arising out of the use or inability to use the product or documentation.  
Anaheim Automation’s general policy does not recommend the use of its’ products in life support applications wherein a
failure or malfunction of the product may directly threaten life or injury.  Per Anaheim Automation’s Terms and Conditions,
the user of Anaheim Automation products in life support applications assumes all risks of such use and indemnifies
Anaheim Automation against all damages.
LIMITED WARRANTY
All Anaheim Automation products are warranted against defects in workmanship, materials and construction, when used
under Normal Operating Conditions and when used in accordance with specifications.  This warranty shall be in effect for
a period of twelve months from the date of purchase or eighteen months from the date of manufacture, whichever comes
first.  Warranty provisions may be voided if products are subjected to physical modifications, damage, abuse, or misuse.
Anaheim Automation will repair or replace at its’ option, any product which has been found to be defective and is within the
warranty period, provided that the item is shipped freight prepaid, with previous authorization (RMA#) to Anaheim
Automations plant in Anaheim, California. 
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 near the back of 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. 
						

							TABLE OF CONTENTS
DRIVER
General Description................................................... 4
Bilevel Drive Definition.......................................................4
Mode Select.............................................................. 4
Motor On/Off......................................................... 4
Adjusting Kick Current ...................................................... 4
Motor Driver Connections.................................................... 4
Specifications .............................................................5
Motor Compatibility Chart ....................................................6
Fault LED................................................................ 6
Terminal Description....................................................... 7
Troubleshooting........................................................... 7
Dimension Drawings ........................................................8
X250A VERSION...........................................................8
INDEXER
Description and Function .....................................................9
Manual Preset Indexer Terminal P1 Descriptions..................................9
Manual Preset Indexer Terminal P2 Descriptions.................................10
Using the Preset Indexer....................................................11
Selecting Motion Parameters............................................11
Homing Modes.......................................................13
Setting the Move Distance..............................................14
Jumpers............................................................15
Count Input Modules.......................................................15
Manual Preset Indexer Specifications..........................................17 
						

							4 GENERAL DESCRIPTION
The Anaheim Automation DPF11451 Step Motor Driver Pack is designed for motor applications that require very high
power output and high start-stop step rates.  Outstanding motor performance is achieved by means of an enhanced
bilevel or dual-voltage drive technique. This Driver Pack contains a high performance driver board (BL11), a 500VA
transformer, and a dual power supply.  It may be used with six or eight lead, size 34 and 42 step motors whose phase
current ratings range from 3 to 12.5 amperes per phase.
BILEVEL DRIVE
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.  This rapid rise of current is also referred to as the kick or operating
current.  When a desired current level is reached, a low voltage is applied to maintain a suitable holding current level. 
When a motor winding is 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.
MODE SELECT
The Mode Select input is used to select either halfstep or fullstep motor operation.  Halfstep operation is generally
preferred because this mode provides better resolution, minimizes resonance effects, and reduces power consumption.
The motor steps in increments of half the natural step angle,  e.g. in 0.9 degree steps for a 1.8 degree step motor.  In
fullstep operation, the motor steps in 1.8 degree steps.
MOTOR ON/OFF INPUT
The MOTOR ON/OFF input can be used to turn off all four motor phases (de-energize the motor) in applications where
motor detent torque is sufficient to maintain the load position.  This feature can be used to reduce the load on the
power supply and the heat dissipation in the driver circuitry and motor. 
ADJUSTING THE KICK CURRENT
The kick (or operating) 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.  The kick current level should be set to approximately
1.4 times the rated phase current.  For example, a motor rated at 10 amps/phase should be kicked to 14 amps. 
Table 2 shows various kick current levels for corresponding phase currents.  When using a motor listed in Table 3, use
the recommended potentiometer setting.  WARNING:  The kick current level must be set before operating a motor.  
MOTOR DRIVER CONNECTIONS
Motor wires are connected to the driver pack through  TB1, terminals 1 through 6.  Electrical connections to control
inputs should be kept physically separated from the motor connections.  Wiring from the driver to the motor should be
routed away from all other wiring. 
MOUNTING AND COOLING
The DPF11451 contains an integral fan to create airflow through the unit.  Heating considerations should include where
the unit is mounted, the duty cycle of operation, ambient temperature, etc. No point on the Driver Pack should exceed
60 degrees Celsius. 
						

							5 SPECIFICATIONS:
POWER REQUIREMENTS
105 VAC to 125 VAC for DPF11451 Series
210 VAC to 250 VAC for DPF11451X250 Series
Opto Power Input: (TB2: 1)
Internally Connected to Indexer
Control Inputs (All) : (TB2:  2, 3, 4, 5 and 6)
Internally Connected to Indexer
Clock Input: (TB2: 2)
Internally Connected to Indexer 
Direction Control (CCW): (TB2: 3)
Internally Connected to Indexer
Excitation Mode Select: (TB2: 4)
Logic 1 (open) - Half-step
Logic 0 - 2 ö Full-step
Power ON/OFF: (TB2: 5)
Logic 1 (open) - Motor Current On
Logic 0 - Motor Current Off
Fault Reset: (TB2: 6)
Logic 1 (open) - Driver and Fault detection enabled.
Logic 0 - Resets a Fault condition (driver is disabled when this input is low). This input must be held low for at least
100ms.
Fault Output: (TB2: 7)
This opto isolated output will withstand 60 volts at 500 ma. 
0VDC: (TB2: 8)
Used as the reference (0Vdc) connection for FAULT OUTPUT power supply. 
Output Current Rating: (TB1: 1 through 6)
16 Amps/phase maximum operating current, 10 Amps/ phase maximum standstill current, over the operating voltage
and temperature range. Motor phase  ratings of 3.0 Amperes minimum are required to meet the minimum kick level.
AMBIENT TEMPERATURE: 0 to 50 degrees Celsius.
SHIPPING WEIGHT: 18 pounds 
						

							6 AA MOTORHOLDING CURRENTKICK
CURRENT
34D109 - 34N1093.12 - 4.806.72
34D209 - 34N2093.00 - 4.606.44
34D213 - 34N2144.23 - 6.509.10
34D3113.58 - 5.507.70
34D314 - 34N3144.55 - 7.009.80
42D112 - 42N1123.97 - 6.108.54
42D1196.18 - 9.5013.3
42D2123.97 - 6.108.54
42D2195.98 - 9.2012.88
42D2258.25 - 10.0015.00
TABLE 2:  Holding Current  and Kick Current Settings for Standard AA Motors.
Fault
Detection Sensitivity
Figure 1 shows the location of the 2 position dip switch used for selecting the sensitivity mode by the user.
SW1SW2FUNCTION
OFFOFFNo Protection
ONOFFPower-up Tests, No Running Tests
OFFONLow Sensitivity Fault Protection
ONONMaximum Fault Sensitivity Protection
Fault Protection
There are five types of fault detection provided for on the BL11 High Performance Driver. When a fault is detected, the driver
turns off the motor current and the red Fault LED will flash to indicate which type of fault has been detected.
FaultLED FlashesFault Detected
11 TimePower-up Open Circuit
22 TimesPower-up Short Circuit
33 TimesHigh Voltage to High
44 TimesRunning Open
55 TimesRunning Short
TABLE 1: Fault LED Operation 
						

							7 Figure 2: Sense Resistors, Fault Detection Sensitivity        
              Switch and Jumper Locations
6 PIN TERMINAL DESCRIPTION
TERMINALDESCRIPTION
1Motor, Phase 1
2Motor, Phase 3
3Common 1,3
4Common 2,4
5Motor, Phase 2
6Motor, Phase 3
TABLE 2:  TB1 6-PIN TERMINAL 
8 PIN TERMINAL DESCRIPTION
TERMINALDESCRIPTION
1+5Vdc Input 
2Clock Input
3Direction Control Input/CCW
4Half-step/Full-step
5Power On/Off
6Fault Reset
7Fault Output
80Vdc
TABLE 3: TB2 8-PIN TERMINAL  
						

							8 TROUBLESHOOTING
If a Fault occurs, reset the Fault by applying a logic “0 to the Reset Fault Input (terminal 4) for at least 100ms (or by
cycling power OFF for at least 15 seconds).  After resetting, try to run the motor again.  If the driver faults again then
check the conditions listed below.
Is the LED Blinking One time (Power-up Open)? 
This indicates that the driver has detected a open circuit condition on power-up. An open connection exists in one of
the motor windings or in the motor cable or wiring.  Check the motor and the wiring for opens.
Is the LED Blinking Two times (Power-up Short)?
This indicates that the driver has detected a short circuit condition on power-up. The motor may have a shorted phase
or there is a short in the motor cable or wiring.  Check the motor and the wiring for shorts. If the driver continues to
sense “shorts” after the motor and wiring are determined to be good, then the output transistors should be checked
(see below).
Is the LED Blinking Three times?
This indicates that an over voltage condition exists on the high voltage input. Check the incoming AC power line for a
high level. For 115Vac operation the line voltage should be between 105 and 125Vac. For 230Vac operation the line
voltage should be between 210 and 250Vac. If the line voltage is high you need to lower it to the correct level.
Is the LED Blinking Four times (Running Open)? 
This indicates that there is an open connection in one of the motor wires.  Check the motor and the wiring for opens. 
Another condition that may cause this type of fault is when a large motor is ramped down too quickly so that it loses
it’s positioning. If this fault is detected randomly and the unit is in sensitive protection mode switch to moderate
protection mode or power-up only protection mode. As a last resort switch to no protection and call the factory for
further information.
Is the LED Blinking Five times (Running Short)?
This indicates that the motor has a phase shorted or there is a short in the motor cable or wiring.  Check the motor and
the wiring for shorts. If the driver continues to sense “shorts” after the motor and wiring are determined to be good, then
the output transistors should be checked (see below).
Checking Output Transistors
1.Remove the side plate.
2.Set the multimeter to Diode Test.
3.Place the RED meter lead on (between) the Sense Resistors (labeled R29 and R71 in Figure 2).
4.Touch the BLACK meter lead to each phase (TB1 terminals 1, 2, 5 and 6).
5.This should give readings between 0.450V and 0.550V.
6.If any  readings are significantly less than 0.450V, then the unit has been damaged.  To send the unit in for
repair, contact the factory for an RMA#. 
						

							9 
						

							10 X250A Hookup
INDEXER 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.
MANUAL 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.
12+INDEXSame as -INDEX, but commands a CW step motion.
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,