Anaheim Stepper PCL451 Users Guide

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PCL451
Manual Preset Indexer
User’s Guide
#L010074            July 2002
910 East Orangefair Lane, Anaheim, CA 92801
e-mail: [email protected](714) 992-6990  fax: (714) 992-0471
website: www.anaheimautomation.com
ANAHEIM AUTOMATION   
						

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Features
•
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 Device
•Index On The Fly
Introduction
The PCL451 contains a manual preset indexer board. Figure 1 shows the general configuration and
layout of a preset indexer system. The thumbwheel switch is used to set the index (number of steps or
move distance) and the manual switches and/or PLC are used to initiate indexing, homing or jogging.
The manual preset indexer board utilizes the PI45 preset indexer integrated circuit (IC). Available functions
include home, hard and soft limit inputs, two homing modes, jog/run, fast jog and switch selectable base
speed, maximum speed, and 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.
Figure 1: Typical Layout of a Preset Indexer System  
						

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The PCL451 Manual Preset Indexer is ideal for applications which are repetitive and require accurate
positioning. Some areas where manual preset indexers are commonly used are:
•Robotics
•Machine Control
•Packaging
•Assembly Automation
•Fluid Control and Mixing Systems
•Table Positioning Systems
•Photographic Controls
•Custom Motion Control
•Feed to Position
•Feed to Sensor
•Cut to Length
Using the Manual Preset Indexer
Selecting Motion Parameters
The velocity profile (motion speed and acceleration) is determined by the four green switches; base
speed, max speed, acceleration/deceleration, and factor. Figure 2 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 to 3611 steps/second.
Max Speed
This is the speed at which the motor ramps up to. As shown in Table 2, there are 256 choices available
ranging from 163 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.
Figure 2: Velocity Profile of a Step Motor  
						

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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.
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 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 choose 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.
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=A) and M switch setting of A (1207 steps/
second) or 9 (1173 steps/second) can be used. A speed of 13000 steps/second (F=0) requires an M
switch setting of either A (12737 steps/second) or B (13102 steps/second).
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 steps/second (F=A), the base speed can
be chosen from a range of 11 steps/second to 339 steps/second. 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 steps/second, a Factor of 9 could also be used,
giving the range of base speed 15 to 438 steps/second.
F) c e s / s p e t s ( x a MFx a MFx a MFx a M
029 7 4 1403 9 4884 5 2C82 7
146 2 9566 2 4961 8 1D48 4
256 1 7695 7 3A11 4 1E66 3
314 8 5706 3 3B64 9F64 2
Table 1: Maximum obtainable stepping rates for all F switch settings with the maximum speed F. 
						

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M Switch Setting Chart
B Switch Setting Chart
F012 3 456 7 8 9A B CDEF
F
25 0151914272237304447405356595
E
37 4122926314844506561757973878
D
401918283844546279768399950 101 151 1
C
64192347527187990 102 103 114 105 195 166 147 1
B
8917365574960 162 114 175 107 138 159 170 261 272 2
A
1 182654821 104 195 198 121 243 245 247 229 290 342 393 3
9
5 1733790 154 118 150 244 247 230 392 355 377 399 381 483 4
8
1 22530 145 150 265 209 294 378 382 446 410 533 546 509 591 6
7
8 29683 160 237 214 368 395 451 596 581 666 670 794 748 712 8
6
1 38755 113 270 338 343 461 587 504 649 684 759 714 808 822 9
5
5 39877 146 205 383 459 498 595 603 719 735 860 995 930 0 125 0 1
4
2 440 160 280 380 401 577 568 686 794 812 939 945 0 161 1 176 1 132 2 1
3
0 542 174 207 398 401 609 612 891 951 0 110 1 178 1 106 2 133 3 149 3 106 4 1
2
2 645 190 306 401 616 706 812 0 134 1 146 2 186 3 147 4 156 5 155 6 103 7 121 8 1
1
3 860 211 421 690 890 0 114 1 125 3 131 5 117 6 190 8 174 9 166 0 218 1 218 2 298 3 2
0
4 2 101 371 691 961 2 191 5 171 7 183 0 228 2 202 5 203 7 293 9 202 1 375 9 284 4 311 6 3
Table 3
F012 3 456 7 8 9A B CDEF
F
3 6 166 107 147 197 138 188 139 199 140 201 271 232 213 283 264 2
E
2 4 284 235 295 266 227 297 278 259 230 331 322 323 324 345 366 3
D
0 2 372 353 324 315 306 396 308 309 310 421 452 483 425 476 448 4
C
1 8 439 440 571 592 534 575 527 588 540 632 614 616 628 650 782 7
B
6 2 614 665 627 698 660 752 744 746 768 790 833 895 868 851 964 9
A
6 3 975 908 940 0 182 0 145 0 128 0 111 1 114 1 137 1 170 2 124 2 118 2 122 3 156 3 111 4 1
9
7 0 2 143 2 136 2 139 2 152 3 185 3 149 3 113 4 107 4 111 5 144 5 110 6 105 6 120 7 175 7 161 8 1
8
9 9 6 173 7 177 7 102 8 146 8 111 9 195 9 111 0 266 0 232 1 248 1 284 2 261 3 288 3 266 4 284 5 2
7
8 4 2 289 2 215 3 270 4 266 4 262 5 219 5 285 6 203 7 250 8 248 8 286 9 275 0 325 1 325 2 306 3 3
6
0 2 5 267 5 253 6 279 6 226 7 203 8 220 9 277 9 275 0 314 1 392 2 332 3 322 4 372 5 304 6 395 7 3
5
6 6 8 203 9 279 9 276 0 314 1 381 2 399 2 348 3 347 4 386 5 396 6 347 7 368 8 350 0 423 1 466 2 4
4
2 2 3 379 3 347 4 345 5 393 6 382 7 312 8 391 9 322 0 423 1 464 2 476 3 459 4 413 6 477 7 403 9 4
3
3 5 9 304 0 413 1 472 2 462 3 413 4 404 5 455 6 477 7 440 9 493 0 518 1 523 3 519 4 516 6 514 8 5
2
8 7 8 458 9 459 0 511 2 523 3 595 4 529 5 523 7 597 8 533 0 669 1 686 3 615 5 634 7 684 9 656 1 7
1
9 6 3 640 5 664 6 639 7 684 9 601 1 797 2 765 4 724 6 783 8 754 0 836 2 829 4 843 7 819 9 846 2 9
0
8 6 9 909 1 0 122 4 0 146 6 0 181 9 0 158 1 1 146 4 1 185 7 1 176 0 2 139 3 2 173 7 2 120 1 3 178 4 3 159 8 3 103 3 4 129 7 4 1
Table 2 
						

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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; making the flag is necessary.
1: Max Speed To Home
2: Starts To Decelerate to Base Speed
Figure 3
Figure 4
Figure 5    
						

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3: Decelerate to Base Speed and Change Direction
4: Run at Base Speed Until the Soft Limit Switch Is No Longer Closed
Setting the Move Distance
The index count or move distance for the PCL451 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
section on Count Index Boards).
Jumpers/Connectors
There are two 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.
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 P1 is for the forward count; the connector P2 is for the
reverse count. When using two modules for different forward and reverse indexes, jumper JP2 must be in
the “2-3” position.
Figure 6
Figure 7   
						

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Jumper Location/Function
Terminal Pin Descriptions (P1)
n i Pn o i t c n u Fn o i t p i r c s e D
1TI M I L D R A H -. n o i t c e r i d W C C n i n o i t o m l l a t l a h o t r o t o m p e t s e h t s t c u r t s n i l a n g i s s i h t , w o l e v i t c a n e h W
2TI M I L D R A H +.n o i t c e r i d W C n i t p e c x e T I M I L D R A H - s a e m a S
3TI M I L T F O S -d n a d e e p s e s a b o t n w o d p m a r o t r o t o m p e t s e h t s t c u r t s n i l a n g i s s i h t , w o l e v i t c a n e h W
E M O H - r o X E D N I - a g n i r u d e v i t c a t u p n I . n o i t c e r i d W C C e h t n i e v o m e h t e t e l p m o c
. n o i t c n u f
4TI M I L T F O S +.n o i t c e r i d W C n i t p e c x e T I M I L T F O S - s a e m a S
5TI M I L E M O H -d n a m m o c E M O H - g n i v i G . T I M I L T F O S - h t i w n o i t c n u j n o c n i e d o M g n i m o H 0 H n i d e s U
T F O S - l i t n u n o i t c e r i d W C C e h t n i d e e p s h g i h o t p m a r o t r o t o m s e s u a c ) w o l e v i t c a (
e h t l i t n u n u r d n a d e e p s e s a b o t e t a r e l e c e d l l i w r o t o m , t c a t n o c t A . d e t c a t n o c s i T I M I L
. p o t s l l i w r o t o m e h t e m i t h c i h w t a , d e t c a t n o c s i T I M I L E M O H -
6TI M I L E M O H +.n o i t c e r i d W C n i t p e c x e T I M I L E M O H - s a e m a S
7NU R / G O J -. n o i t c e r i d W C C e h t n i p e t s e n o e k a t o t r o t o m p e t s e h t s e s u a c e n i l s i h t n o l e v e l w o l A
A . s e h c t i w s n o t t u b h s u p l a n r e t x e y b d e t a l u p i n a m e r a s t u p n i N U R / G O J e h t , y l l a m r o N
n w o d h c t i w s e h t g n i d l o h e l i h w , n o i t a r e p o  g o j  a s e s u a c h c t i w s e h t f o n o i s s e r p e d e l g n i s
T S A F h t i w d e s u e b y a m d n a m m o c s i h T . n o i t i d n o c  n u r w o l s  a s e s u a c s d n o c e s 5 . 0 r o f
. e t a r d e e p s e s a b e h t t a n u r t s a f a m r o f r e p o t
Figure 8: Jumper Locations
1 P Je c n u o b e D
y a l e D t u p n I
2 - 1sm 5 . 2 1
3 - 2sm 3 . 0
Table 4
2 P Js e l u d o M t n u o C l a n r e t x E
2 - 1)e s r e v e R d n a d r a w r o F e m a S ( e l u d o M e n O
3 - 2es r e v e R d n a d r a w r o F r o f s e l u d o M e t a r e p e S
Table 5  
						

							9 n i P
n o i t c n u Fn o i t p i r c s e D
8NU R / G O J +.n o i t c e r i d W C n i t p e c x e N U R / G O J - s a e m a S
9EM O H -e h t a i v n o i t i s o p e m o h e h t o t e v o m o t r o t o m p e t s e h t s t c u r t s n i e n i l s i h t n o l e v e l w o l A
) T C E L E S E M O H e e S ( . n o i t c e r i d W C C
0 1EM O H +.n o i t c e r i d W C n i t p e c x e E M O H - s a e m a S
1 1XE D N I -d n a s r e t e m a r a p n o i t o m t n e r r u c e h t d a e r o t p i h c 5 4 I P e h t s e s u a c l a n g i s s i h t , w o l n e h W
e h t p e t s o t r o t o m e h t d n a m m o c d n a s e h c t i w s l e e h w b m u h t e h t m o r f s p e t s f o r e b m u n
s i T I M I L T F O S - f I : e t o N . ) T I M I L T F O S - e e S ( . n o i t c e r i d W C C e h t n i e c n a t s i d d e t a c i d n i
e t e l p m o c d n a d e e p s e s a b o t e t a r e l e c e d l l i w r o t o m e h t , x e d n i n a g n i r u d d e r e t n u o c n e
. x e d n i e h t
2 1XE D N I +.n o i t c e r i d W C n i t p e c x e , X E D N I - s a e m a S
3 1TX E / T N I #r o  1  c i g o l A . g n i t n u o c r o f d e s u e b l l i w s e h c t i w s f o t e s h c i h w s e n i m r e t e d t u p n i s i h T
n a f o t n u o c e h t s t c e l e s  0  c i g o l A . r e b m u N t n u o C x e d n I l a n r e t n I e h t s t c e l e s n e p o
. e l u d o m r e t n u o c l a n r e t x e
4 1TC E L E S E M O H0 H , w o l e v i t c a n e h W : m r o f r e p o t n o i t a r e p o  e m o H  f o e p y t e h t s t c e l e s t u p n i s i h T
. n o i t a r e p o h c t i w s n o p o t s d n a n o i t a r e l e c e d d r a d n a t s a s i t I . d e t c e l e s s i e d o M g n i m o H
n e h W . s d n a m m o c T I M I L T F O S d n a E M O H e h t f o n o i t a n i b m o c a s i 0 H e p y t , e c n e s s e n I
t I . n o i t c e t o r p h s a l k c a b - i t n a r o f d e s u s i 1 H . d e t c e l e s s i e d o M g n i m o H 1 H , h g i h e v i t c a
t s u m h c t i w s e h T : e t o N . n o i t a r e p o h c t i w s f f o n r u t e r , e s r e v e r , e t a r e l e c e d a s m r o f r e p
. e d o M 1 H n i n r u t e r d n a , e s r e v e r , n o i t a r e l e c e d g n i r u d d e s o l c n i a m e r
5 1TS A Fe s a b ( n u r t s a f a e s u a c o t N U R / G O J h t i w n o i t c n u j n o c n i d e s u s i t i , w o l e v i t c a n e h W
. n o i t c e r i d d e i f i c e p s e h t n i n o i t a r e p o ) d e e p s
6 1YS U Bk n i s n a c t u p t u o s i h T . g n i v o m s i r o t o m e h t n e h w N O s i t u p t u o h c t i w s r o t c e l l o c n e p o s i h T
. m u m i x a m C D V 0 4 f f o d n a t s d n a A 5 . 0
7 1KC O L Ce h t s i t a h t ) m u m i n i m ( , e d i w s d n o c e s o r c i m 5 1 , t u p t u o r o t c e l l o c n e p o n a s i t u p t u o s i h T
L T T - S L n a r o f e v i r d e t a u q e d a e r u s s a o t d e r e f f u b s i t I . r e v i r d r o t o m e h t r o f t u p n i k c o l c
. t u p n i
8 1CD V 0)C D V 0 ( d n u o r G
9 1NO I T C E R I Do t t u p t u o s i h t s e s u a c n o i t o m ) W C ( e s i w k c o l C . t u p t u o r o t c e l l o c n e p o n a s i t u p t u o s i h T
e b o t t u p t u o s i h t s e s u a c n o i t o m ) W C C ( e s i w k c o l c r e t n u o C .  1  c i g o l . e . i , h g i h e v i t c a e b
. n u r o t n o i t c e r i d h c i h w r e v i r d r o t o m e h t s l l e t t u p t u o s i h T .  0  c i g o l . e . i , w o l e v i t c a
0 2ET E L P M O Ce h T . d e t u c e x e s i e l c y c g n i x e d n i e h t r e t f a n o s n r u t t u p t u o h c t i w s r o t c e l l o c n e p o s i h T
e e s ( s m 0 2 1 o t s m 2 1 t u o b a m o r f e l b a t s u j d a s i ) n o s i t u p t u o s i h t t a h t e m i t ( h t d i w e s l u p
. m u m i x a m C D V 0 4 f f o d n a t s d n a A 5 . 0 k n i s n a c t u p t u o s i h T . ) e l b a t
g n i t t e Sh t d i W e s l u Pg n i t t e Sh t d i W e s l u P
1sm 2 16sm 5 . 9 7
2sm 5 . 5 27sm 3 9
3sm 9 38sm 5 . 6 0 1
4sm 5 . 2 59sm 0 2 1
5sm 6 6- ---
Table 6 
						

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n i Pn o i t c n u Fn o i t p i r c s e D
1CD V 5 +)t u p n I / t u p t u O ( y l p p u S e g a t l o V d e t a l u g e R C D V 5 +
2ge r n U C D V 2 1 +)t u p n I / t u p t u O ( y l p p u S e g a t l o V d e t a l u g e r n U C D V 2 1 +
3CD V 0)C D V 0 ( d n u o r G
4CD V 0)C D V 0 ( d n u o r G
5NI C A V 2 1 - 9tu p n I y l p p u S e g a t l o V C A V 2 1 - 9
6NI C A V 2 1 - 9tu p n I y l p p u S e g a t l o V C A V 2 1 - 9
Terminal Pin Descriptions (P2)
PCL451 Dimensions
Note: Refer to specifications section for power requirements.
Figure 8: PCL451 Dimensions Drawing