Anaheim Stepper DPFHP451 Users Guide
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#L010035
DPFHP451 HIGH PERFORMANCE
BILEVEL STEP MOTOR / MANUAL PRESET INDEXER
DRIVER PACK
• Internal Index Count switches
• Pulse Rates up to 14,792 pulses per
second
• CW & CCW Home, Hard, & 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 & Reset Outputs & Coincidence
Inputs
•Very High Motor Power Output
•15Amps/phase Maximum Operating
Current
•10 Amps/phase Standstill motor current
•Dual Voltage Power Supply with
500VA Transformer
•High Start-Stop Speeds
•Transient Voltage Suppression
•Halfstep and Fullstep Operation
•Bilevel Drive (No RFI or EMI problems)
•TTL/CMOS Compatible Inputs
•Clockand Direction or Dual Clock
Operation
•Motor Turn-off Input
GENERAL DESCRIPTION
The Anaheim Automation DPFHP451
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 (BLHP101),
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 2 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.
#L010035
TRANSIENT VOLTAGE
SUPPRESSION
Transient Voltage Suppression (TVS)
Diodes on the motor phase outputs
allow for much longer motor cables to
be used. Normally when using long
motor cables, voltage transients and
spikes are created. These transients
often exceed the voltage ratings of
the output phase transistors, resulting
in blown transistors. The addition of
the TVS Diodes suppresses these
transients and protects the transistors
against damage.
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. Terminal
10 is the MOTOR ON/OFF Input.
MODE SELECT/+5V OUTPUT
DPFHP001 Driver Packs are shipped
from the factory with terminal 9
assigned as an excitation Mode
Select input. 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. By setting JP2 to the
1-2 position, terminal 9 becomes a
+5VDC regulated output. The driver
defaults to halfstep when the +5VDC
output is used.
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 terminals 1, 2, 3,
12, 13, and 14. 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.
OTHER HIGH PERFORMANCE
DRIVER PACKS are available. The
DPFHP451 Driver Pack includes a
PI45 Preset Indexer along with the
bilevel high performance driver and
power supply. The DPFHP401
includes a SMC40 based
Programmable Indexer. All DPFHP
Series Driver Packs are available in
250 VAC versions (add X250
suffix).
MOUNTING AND COOLING
The DPFHP451 contains an internal
fan to create airflow through the unit.
Heating considerations should
include where the unit is mounted,
the duty cycle of operation, ambient
temperature, etc. Care should be
taken so that no point on the chassis
exceeds 60 degrees Celsius.
Rated Motor
Phase Current KICK
CURRENT
1.4 - 2.4 2.0 - 3.4
2.4 - 3.3 3.4 - 4.6
3.3 - 4.3 4.6 - 6.0
4.3 - 5.4 6.0 - 7.5
5.4 - 6.3 7.5 - 8.8
6.3 - 7.2 8.8 - 10.1
7.2 - 8.1 10.1 - 11.4
8.1 - 8.9 11.4 - 12.5
8.9 - 9.6 12.5 - 13.5
9.6 - 12.5 13.5 - 15.0
Table 1: Potentiometer Settings for
Kick Current
AA MOTOR
HOLDING
CURRENT KICK
CURRENT
34D106
1.95 - 3.00 4.20
34D109
3.12 - 4.80 6.72
34D207
2.28 - 3.50 4.90
34D209
3.00 - 4.60 6.44
34D213
4.23 - 6.50 9.10
34D307
2.28 - 3.50 4.90
34D311
3.58 - 5.50 7.70
34D314
4.55 - 7.00 9.80
42D112
3.97 - 6.10 8.54
42D119
6.18 - 9.50 13.3
42D212
3.97 - 6.10 8.54
42D219
5.98 - 9.20 12.88
42D225
8.25 - 10.00 15.00
TABLE 2 Holding Current and Kick Current Settings
for AA Motors
#L010035 JUMPER DESCRIPTION JP1 JP2 JP3 TERMINAL 5 = DIRECTION 2-3 X X TERMINAL 5 = CCW 1-2 X X TERMINAL 9 = HS/FS X 2-3 X TERMINAL 9 = +5VDC OUTPUT X 1-2 X POSITIVE GOING CLOCK INPUTS X X 2-3 NEGATIVE GOING CLOCK INPUTS X X 1-2 STANDARD PRODUCT (READY TO SHIP) 2-3 2-3 1-2
#L010035 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 PIN FUNCTION DESCRIPTION 1 -HARD LIMIT When active low, this signal instructs the step motor to halt all motion in CCW direction. 2 +HARD LIMIT Same as -HARD LIMIT except in CW direction. 3 -SOFT LIMIT When 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 LIMIT Same as -SOFT LIMIT except in CW direction. 5 -HOME LIMIT Used 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 LIMIT Same as -HOME LIMIT except in CW direction. 7 -JOG/RUN A 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/RUN Same as -JOG/RUN except in CW direction. 9 -HOME A low level on this line instructs the step motor to move to the home position via the CCW direction. (See HOME SELECT) 10 +HOME Same as -HOME except in CW direction. 11 -INDEX When 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 +INDEX Same as -INDEX, but commands a CW step motion. 13 #INT/EXT This 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. 14 HOME SELECT This 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.
#L010035 15 FAST When active low, it is used in conjunction with JOG/RUN to cause a fast run (base speed) operation in the specified direction. 16 BUSY This 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). 17 CLOCK This 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. 18 0VDC Ground (0Vdc). 19 DIRECTION Clockwise (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. 20 COMPLETE This 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 3). 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). SETTING PULSE WIDTH SETTING PULSE WIDTH 1 12 ms 6 79.5 ms 2 25.5 ms 7 93 ms 3 39 ms 8 106.5 ms 4 52.5 ms 9 120 ms 5 66 ms -- -- TABLE 3: Pulse Width Settings TYPICAL HOOK-UPS FOR BUSY AND COMPLETE OUTPUTS: 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 PIN FUNCTION DESCRIPTION 1 +5VDC +5VDC Regulated Voltage Supply Output 2 +12VDC Unreg +12VDC Unregulated Voltage Supply Output 3 0VDC Ground (0Vdc). 4 0VDC Ground (0Vdc). 5 9 - 12VAC IN 9 - 12VAC Voltage Supply Input for PCL451 version. 6 9 - 12VAC IN 9 - 12VAC Voltage Supply Input for PCL451 version.
#L010035 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 6. They range from 2 steps/second to 3,611 steps/second. MAX SPEED As shown in Table 5, 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 4 lists the maximum obtainable stepping rates for all F switch settings with the maximum speed F. F Max(steps/sec) F Max F Max F Max 0 14792 4 4930 8 2548 C 728 1 9264 5 4266 9 1816 D 484 2 7165 6 3759 A 1411 E 366 3 5841 7 3360 B 946 F 246 TABLE 4: Maximum 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.
#L010035
SETTING THE M SWITCH
Now that we have selected the F switch setting, we can find the value for M from Table 5. 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 4 lists the maximum speed values for each switch setting of F. Looking at the M values in
Table 5 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=A) and M switch setting of 9 (1173 sps) or A (1207 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).
M SWITCH SETTING
0 1 2 3 4 5 6 7 8 9 A B C D E F
F 163 166 170 174 179 183 188 193 199 204 210 217 223 231 238 246
E 242 248 253 259 266 272 279 287 295 303 313 322 332 342 354 366
D 320 327 335 342 351 360 369 380 390 401 412 425 438 452 467 484
C 481 493 504 517 529 543 557 572 588 604 623 641 661 682 705 728
B 626 641 656 672 689 706 725 744 764 786 809 833 859 886 915 946
A 936 957 980 1004 1028 1054 1082 1111 1141 1173 1207 1242 1281 1322 1365 1411
9 1207 1234 1263 1293 1325 1358 1394 1431 1470 1511 1544 1601 1650 1702 1757 1816
8 1699 1737 1777 1820 1864 1911 1959 2011 2066 2123 2184 2248 2316 2388 2466 2548
7 2248 2298 2351 2407 2466 2526 2591 2658 2730 2805 2884 2968 3057 3152 3252 3360
6 2520 2576 2635 2697 2762 2830 2902 2977 3057 3141 3229 3323 3422 3527 3640 3759
5 2866 2930 2997 3067 3141 3218 3299 3384 3474 3568 3669 3774 3886 4005 4132 4266
4 3322 3397 3474 3554 3639 3728 3821 3919 4022 4132 4246 4367 4495 4631 4777 4930
3 3953 4040 4131 4227 4326 4431 4540 4655 4777 4904 5039 5181 5332 5491 5661 5841
2 4878 4985 5095 5211 5332 5459 5592 5732 5879 6033 6196 6368 6551 6743 6948 7165
1 6369 6504 6646 6793 6948 7110 7279 7456 7642 7838 8045 8263 8492 8734 8991 9264
0 9968 10190 10422 10664 10918 11185 11464 11758 12067 12393 12737 13102 13487 13895 14330 14792
TABLE 5: Max Speed (Factor Setting vs. Max Setting)
#L010035
SETTING THE B SWITCH
By choosing an F value, we restrict our choice of Base Speed to 16 possible values (see Table 6). 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=A), the Base speed can be chosen from a range of 11 sps to 339 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 9 could also be used, giving the
range of Base Speed 15 to 438 sps.
B SWITCH SETTING
0 1 2 3 4 5 6 7 8 9 A B C D E F
F 2 5 10 15 19 24 27 32 37 40 44 47 50 53 56 59
E 3 7 14 22 29 36 41 48 54 60 65 71 75 79 83 87
D 4 10 19 28 38 48 54 64 72 79 86 93 99 105 110 115
C 6 14 29 43 57 72 81 97 109 120 130 141 150 159 166 174
B 8 19 37 56 75 94 106 126 141 157 170 183 195 207 216 227
A 11 28 56 84 112 140 159 189 212 234 254 274 292 309 324 339
9 15 37 73 109 145 181 205 244 274 303 329 355 377 399 418 438
8 21 52 103 154 205 256 290 349 387 428 464 501 533 564 590 619
7 28 69 138 206 273 341 386 459 515 569 618 666 707 749 784 821
6 31 78 155 231 307 383 434 516 578 640 694 748 795 841 880 922
5 35 89 177 264 350 438 495 589 659 730 791 853 906 959 1003 1052
4 42 104 206 308 408 510 577 686 768 849 921 993 1054 1116 1167 1223
3 50 124 247 370 489 610 690 821 919 1015 1101 1187 1260 1333 1394 1460
2 62 154 309 460 610 761 860 1021 1143 1264 1368 1474 1565 1655 1730 1812
1 83 206 411 612 809 1009 1141 1352 1513 1671 1809 1947 2066 2181 2281 2389
0 124 310 617 919 1216 1519 1717 2038 2282 2520 2730 2939 3120 2957 3448 3611
TABLE 6: Base Speed (Factor Setting vs. Base Setting)
#L010035
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.
Figure 7: H1 Homing Mode