PMDX-107 User`s Manual
Contents
1. www pmdx com see the Support page for the downloads page Please refer to the plug in documentation for information on how to configure Mach3 to access the additional output signals Use of Expanded Mode with EMC requires an EMC HAL configuration that supports Expanded O utput Mode 3 2 PWM Input The PW M signal coming in to the PMDX 107 is idle at a logic low and active at a logic high The duty cycle is measured as active duration idle duration active duration The PW M frequency must be between 25 Hz and 1 000 Hz to be considered valid The PW M duty cycle should be between 5 to 99 7 The PMD X 107 considers absence of a PW M signal i e 0 or 100 duty cycle to be a stop command W hen detecting a loss of PW M there is a delay of approximately TBD of a second from the actual loss of PW M signal until the PMD X 107 commands the VSD to stop The PMDX 107 is an open loop speed control interface This type of interface has no way of knowing about or correcting for speed deviations Most applications will achieve 5 to 10 accuracy but no guarantee of accuracy can be given because of the number of factors involved The PMDX 107 is designed to provide speed commands over a range of 5 to 99 7 of full rated speed Settings below 5 may have significant error Many VSDs will enforce a minimum speed greater than 5 as much as 30 to cool and protect the motor In this case t2. 24 September 2012 Used as a daughter board on the PMD X 132 the PMD X 125 and future boards with a PMDX option connector N ot intended for use with boards that do not have a 10 pin PMDX option connector If you need a speed controller for use with the PMD X 122 or third party boards please see the PMD X 106 Sets spindle speed using PW M from CNC control software W orks with any system that can supply a 25 Hz to 1 KHz PWM signal N eeds fewer signals because PW M signal is used for both speed and O n O ff absence of pulses stops motor W orks with 5 volt analog inputs 10 volt analog inputs and most potentiometer interfaces up to 15 volts Provides isolated solid state switch to turn spindle on and off via VFD control inputs or a small relay Provides isolated solid state switch to control direction via VFD control inputs or a small relay Can be configured for VFDs that accept Forward and Reverse commands or Run and Direction commands Can remotely control the high current relay on PMDX 125 where mains switching must be used for safe spindle run stop control e g DC motor controllers like the KBIC series used by Sherline Fully isolated interface can be used with non isolating VFD s and motor drivers O perates from a single 5 volt power supply and receives its power from option jack on PMDX boards Has on board inverter to supply isolated power to interfaces as needed Provides switchable filter to
3. PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 14 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 Table 9 Status LED Flash Patterns NOTE Ifyou encounter an internal error flash code you should power off the PMD X 107 and then power it back on Pressing the Test button is not sufficient If you encounter the internal error again contact PMDX 6 0 Connectors The following sections describe the pin out and functionality of each of the PMDX 107 connectors For all connectors pin 1 is the pin closest to the reference designator i e J1 pin 1 is the pin closest to the J1 text on the circuit board In addition all connectors have square pads on pin 1 look on the bottom of the circuit board Description Speed signal to the VSD PMD X Interface H eader Table 10 Summary of PMDX 107 Connectors 6 1 Relay and Spindle Signal Connector J1 Connector J1 provides the speed control voltage from the PMD X 107 to the VSD Din Label Description _ O U OO PMD X 107 s power supply ground Spindle speed analog control voltage output from PMDX 107 3 Aref Optional Spindle speed voltage reference input to PMDX 107 from VSD This terminal is only used when the VSD is designed to connect to an extern speed control pot see section 2 3 for examples 4 IDN Common terminal for both solid
4. disaster or unauthorized alterations repairs or modifications Limitations All warranties for this product expressed or implied are limited to 90 days from the date of purchase and no warranties expressed or implied will apply after that period All warranties for this product expressed or implied shall extend only to the original purchaser The liability of Practical Micro Design Inc in respect of any defective product will be limited to the repair or replacement of such product Practical Micro Design Inc may use new or equivalent to new replacement parts Practical Micro Design Inc makes no other representations or warranties as to fitness for purpose merchantability or otherwise in respect of the product No other representations warranties or conditions shall be implied by statute or otherwise In no event shall Practical Micro Design Inc be responsible or liable for any damages arising a from the use of the product b from the loss of use of the product c from the loss of revenue or profit resulting from the use of the product or d as a result of any event circumstance action or abuse beyond the control of Practical Micro Design Inc whether such damages be direct indirect consequential special or otherwise and whether such damages are incurred by the person to whom this warranty extends or a third party PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 18 of 18 24 September 2
5. show the status of the board and the state of the PW M and control relays FF pae Designator DS1 Fwd Run This LED is on when the Fwd Run solid state relay is energized el el W hen this LED is on the relay s contact is shorted to the relay common terminal See section 2 4 for more information This LED shows the state of the PW M signal The brightness of the LED is directly proportional to the PW M duty cycle This LED is driven by the PW M signal from the PC or other controller At slow PW M frequencies generally under 30 Hz you may see noticeable flicker on this LED This LED is on when the PMD X 107 is powered on This LED is on when the Rev Dir solid state relay is energized W hen this LED is on the relay s contact is shorted to the relay common terminal See section 2 4 for more information DS5 Status The LED indicates the status of the PMD X 107 See Table 9 below for more information Table 8 Summary of LEDs and functions 5 1 Status LED Error Codes W hen the PMD X 107 encounters a problem it uses the Status LED to display an error code The error code is a repeating pattern of 3 flashes a short pause then some number of flashes the error code followed by alonger pause Then the entire sequence repeats Table Table 9 lists the possible flash patterns Note that a repeating pattern of one slow flash is not an error but signifies that Test Mode is active see section 2 6
6. state relays pins 5 amp 6 Fwd Run Connected to the CO M terminal for the VSD s Forward or Run signal depending on the setting of DIP switches see section 4 2 Rev D ir Connected to the C O M terminal for the VSD s Reverse or Direction signal depending on the setting of DIP switches see section 4 2 Table 11 Relay and Spindle Signal Connector Pin Out J1 PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 15 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 6 2 PMDX Interface Connector J2 Connector J2 provides an interface to the PMD X option connector ona PMDX breakout board The pin out is proprietary 7 0 Mechanical Specifications 2550 1 0u s 0006 Fwd Run a UU PMDX Breakout Board 1008 NOTE This is the total required height above the top side of the base PMDX breakout board allowing for 0 3 space above the PMDX 107 for cable radius into J1 Figure 5 PMDX 107 Dimensions and Mounting Holes WARNING The PMDX 107 should be protected from liquids dirt or chips especially metal chips which can cause shorts coming in contact with the board PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 16 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 4
7. switch settings and VSD connections for this configuration 0 to 10V The VSD expects an analog voltage between 0 and 10V where 10V is full speed In this case the PMD X 107 provides the 10V reference for its analog output circuit See Figure 2 for an example of the DIP switch settings and VSD connections for this configuration Potentiometer The VSD expects to be connected to an external potentiometer or requires a max ratiometric speed voltage that is neither 10V nor 5V In this case the VSD provides the analog reference voltage to the PMD X 107 s analog output circuit See Figure 3 for an example of the DIP switch settings and VSD connections for this configuration The VSD must not apply greater than 15 volts to the PM DX 107 reference input at J1 pin 3 referenced to J1 pin 1 NOTE W hen using ratiometric mode set the PMD X 107 s DIP switch for 5V mode See section 4 5 for more information WARNING SHOCK HAZARD A The VSD s analog ground reference is NOT necessarily at earth ground potential Likewise the control signals for forward reverse etc may not be referenced to ground Any of these may be at mains potential which may be several hundred volts above ground These potentially dangerous voltages appear on PMD X 107 connector J1 and on portions of the PMD X 107 circuit board All wiring from the PMD X 107 to the VSD should be treated as HOT and suitably protected The PMDX 107 contains iso
8. the PMD X breakout board PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 10 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 e PC parallel port pin 16 is the PW M signal passed through the PMD X breakout board e PC parallel port pin 17 is the Charge Pump signal into the PMD X breakout board which then passes a Charge Pump OK signal to the PMD X 107 Normal mode is compatible with the PMD X 125 when in Norma mode with Charge Pump or N ormal mode without charge pump and the PMD X 132 Normal mode should also be compatible with future PMDX breakout boards 3 1 2 Expanded Mode In Expanded mode the PMD X 107 receive spindle speed and direction commands via a serial data stream that is shared with the PMD X 125 breakout board using the following parallel port pins e PC parallel port pin 16 provides the serial data stream that contains PW M speed and direction information shared with the PMD X 125 e PC parallel port pin 17 is the Charge Pump signal required NOTE Expanded mode is compatible with the PMD X 125 when the PMD X 125 is configured in Expanded UO mode or Expanded O utput mode Expanded mode is NOT compatible with the PMD X 132 Use of Expanded Mode with Mach3 requires the PMD X 107 Mach plug in which may be downloaded from our web site at http
9. whether how fast the PMD X 107 s analog spindle control voltage follows changes in the incoming PW M Some spindle controllers will not function properly when the control voltage changes rapidly This switch is read continuously and any changes to this DIP switch take effect immediately PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 13 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 Slow Description o Fast PW M filter response approximately 1 second time constant Slow PW M filter response approximately 5 second time constant Table 6 Charge Pump Mode DIP Switch Settings 4 5 Spindle Control Voltage Switch DIP Switch 6 labeled 5v 10v determines the reference voltage and the PMD X 107 uses for its analog spindle control voltage This switch is read continuously and any changes to this DIP switch take effect immediately 5v 10v 10V reference i e 10V is full speed 5V reference i e 5V is full speed Table 7 Charge Pump Mode DIP Switch Settings WARNING If you are connecting the VSD s reference voltage to the PM DX 107 s Aref input as shown in Figure 3 on page 8 you MUST configure this DIP switch in the On position Also the VSD s reference voltage must be greater than 5V and no greater than 15 volts 5 0 LED Indicators The PMD X 107 provides LEDs to
10. 012 All Rights Reserved
11. 3 0 Technical Reference s sssessenennennununnunnnnnnnnnunennunnnnnnnnnnnnnnnnunnunnnnnnnnnnnnnn nnn nnan nnana nanen nann nn annan 10 3 1 Functional Dluergleuw resenim a AE ORA A EA AEE A 10 3 1 1 Normal Moden eeuesce eessen AER 10 3 1 2 Expanded Mo Ce s dcsccsniniataerancnienninianai anieuanoninn anni T T T 11 3 2 PW Mi le 11 3 3 Power Supply Isolation a a AN 12 A0 DIP Gugtches essreEEREEEEESEEEEEEEEEEEEEREEEEEEEEEEEEEEEEEEEEEEEEEEREEEEEEEEEEEEEEEEEEEREEEEEEEEEEEEEEEEEEEEEEEEEEREEEEEEE 12 4 1 Operational Mode Switches ENNEN EEN 13 42 Relay Mode SwitChiiea esis sinc aggiahieiarcasinascidiaieagiuiiia datiaditia ana a 13 43 Charge Pump Mode awtch EENS 13 44 Fast Slow Spindle Response Switch ENEE 13 4 5 Spindle Control Voltage Switch ENEE EEN 14 5 0 LED Indi Cator scssssssceeesneesneesneeneeeceneennceoesneesounaeeoaunnseeusneysoenaeeeauaaeeoauaeseaesneesoueneeaauansnanenees 14 SE Status LED Error COdGS eier Eege Eelere 14 6 0 CONNECtOFS sssessessnnsnnnunnonnnnnnnnnnnnnnnunnunnnnnnnnnn nunn nnnnnnan nunn nnnnnnnnnnnnnnn nann annnnnan nananana ananuna nananana nanna 15 6 1 Relay and Spindle Signal Connector UI 15 6 2 BN DX Interface Connector Ri eaisrusbnniniana a a A a 16 7 0 Mechanical Specifications esseseusunnununnnnnnnnnunnununnunnnnnnnnnnnen nunnunum nnnnnnnnnnennannnnnn annnm nnmnnn nnan nnna 16 8 0 Electrical and Environmental Specifications s s ssusnsununsununnunnnnnnnnnnnnnnunnnnnnnnnnnnnnn
12. 75D Document Revision 1 2 Assembly Revision D1 8 0 Electrical and Environmental Specifications Power Power In 5V DC regulated 5 provided by the PMDX breakout boards 125 mA maximum Solid State Relay C ontact Ratings Load voltage 150 volts DC or AC maximum Load current 80 mA maximum continuous PW M Input Signal 25 Hz to 1 000 Hz with 5 to 99 7 duty cycle VSD Reference to J1 15 volts maximum on J1 pin 3 referenced to J1 pin 1 Environmental Temperature 0 to 55 C Relative Humidity 20 to 80 relative humidity non condensing PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 17 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 Appendix A Warranty Statement Practical Micro Design Inc PMD warrants that this hardware product is in good working condition according to its specifications at the time of shipment for a period of 90 days from the date it was shipped from PMD Should the product in PMD s opinion malfunction within the warranty period PMD will repair or replace the product without charge Any replaced parts become the property of PMD This warranty does not apply to the software component of a product or to a product which has been damaged due to accident misuse abuse improper installation usage not in accordance with product specifications and instructions natural or personal
13. PMDX 107 Isolated Speed Control Ki DOO NOI eae ca olated Sk Control GR 2PMDX 107 P 3 s E ro ee Power On E P Ir SEN EI zg 9 Kr User s Manual Document Revision 1 2 Date 24 September 2012 PCB Version PCB 475D Assembly Revision D1 Serial Numbers 27090 and above PMDX W eb http www pmdx com 9704 D Gunston Cove Rd Phone 1 703 372 2975 Lorton VA 22079 2366 USA FAX 1 703 372 2977 PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 1 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 Table of Contents LO e VW UE 3 11 Ordering Information part numbersl ANNER 3 Ki Drettgitiong ae Ae EE EE 3 1 3 Important Safety Info rmstign EEN EE EE 3 L Warranty SUMMALY EE EEN EE 4 IS FERUT OS a R RE SE A E AA RN 4 L6 Mog tes tecbhe Manual 2 Eerad Eet i A T e 5 20 QUICK Stat Gude ra aaa aa aa aaa A Aa A aa Aa aA aa Aaa AAA aaa Aaa pa Aad Aaaa Aaaa 5 2 1 Example Connections to PMDN UI ENNEN 5 2 1 1 Normal Mode eet EES a TE ET a 5 2 1 2 Expanded M Oden miinan tacts as Gia tend a a AA 6 2 2 Example Connections to PMD X 132 ae 6 2 3 VSD Speed Control Interface ieii a aiaia anataad ia 7 24 VSD Run Direction Interface NEEN EEN 9 25 Configuring DIP Zwitchee suerge decide aiaiai piai iaiia 9 26 VSD Speed Calibrati iniiai aai na aia enan 9 2 7 Configuring PC Control Some 10
14. ality of PMDX 107 VSD Run Direction Signals See section 6 0 for amore detailed description of the signals on each of these connectors Also see section 4 0 for a more information on setting the DIP switches 2 5 Configuring DIP Switches Set the DIP switches according to section 4 0 2 6 VSD Speed Calibration The PMD X 107 contains built in functionality to calibrate its analog speed control voltage that is output to the VSD The PMDX 107 has a trim pot that is used to set the maximum VSD speed Trim pot R3 labeled C AL sets the maximum spindle speed Use the following steps to calibrate the output voltage 1 2 Connect the PMD X 107 as described in the previous sections Set the trim pot to its full counter clockwise positions Make sure that everything is clear of the spindle gt w Apply power to the PMD X 107 and the VSD Press amp hold the push button on the PMD X 107 for at least 1 second and then release the button The PMDX 107 will enter Test mode and output its maximum PW M voltage and will command the VSD to run the spindle in the forward direction the STATUS led will blink to show that the PMD X 107 is in test mode see section 5 1 5 PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 9 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 6 Adjust the CAL trim pot R3
15. can cause injury Precautions should be taken to assure that operators are trained in their proper operation and safety procedures and that they are protected from moving parts that may be under remote control and may move unexpectedly This product may not be used in life support or other critical safety applications PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 3 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual Document Revision 1 2 1 4 Warranty Summary PCB Revision PC B 475D Assembly Revision D1 The PMD X 107 is warranted against failure due to defective parts or workmanship for 90 days from the date of sale Refer to Appendix A for complete warranty details NOTE Ifyou have an item requiring service please see the W arranty and Repairs page on the PMDX web site http www pmdx com for return instructions In general the purchaser must pay shipping to send the unit to PMDX For repairs covered under warranty and with return shipping to a USA address PMD X will ship the repaired unit back to you via ground transportation at our expense Repairs are normally completed within 10 business days See Appendix A for our complete warranty details Please see the Warranty and Repairs page on our web site http Awww pmdx com for full details of our repair and shipping policies 1 5 Features The PMD X 107 has the following features PMDX 107_Manual_12 doc
16. e spindle control signals and interfacing to the PMD X 107 through either a PMD X 125 in Run Normal mode or PMD X 132 then configure your software to output the following signals on the given parallel port pins PC Parallel Port Pin Description Spindle direction 0 Forward 1 Reverse PW M pulse width modulation See section 3 2 for details of this signal Charge 17 Charge Pump signal This signal should be a rough approximation of a Pump square wave The PMD X 125 and PMD X 132 can be configured to use this signal to enable their outputs and in turn send a logic high to the PMDX 107 CPO K input If your software does not support the charge pump function then you must set the PMD X 107 s Ignore CPO K DIP Switch to on see section 4 0 Table 2 PC Parallel Port Signals for PMDX 107 the parallel port pin numbers are based on the standard PC 25 pin D parallel port connector If you are using something other than a PC to generate the spindle control signals or are using a breakout board other than aPMDX breakout board then configure your controller and breakout board according to their directions 3 0 Technical Reference 3 1 Functional Overview This section will be filled in later 3 1 1 Normal Mode In Normal mode the PMD X 107 receives the spindle speed controls via the following parallel port pins e PC parallel port pin 14 is the Spindle Direction signal passed through
17. ection 2 3 regarding potentially hazardous voltages 3 Connect the PMDX 107 to the VSD s Run Direction or Forward Reverse controls see section 2 4 4 Set the PMD X 107 DIP switches see section 4 0 5 Plug the PMD X 107 into the PMD X 125 see section 2 1 or PMD X 132 see section 2 2 6 Connect the parallel port cable to the PMD X 125 or PMD X 132 board and apply power to the VSD and PMD X boards 7 Calibrate the PMD X 107 speed control output voltage see section 2 6 8 Configure the PC or other controller to generate the proper spindle control signals see section 2 7 2 1 Example Connections to PMDX 125 The PMDX 107 can plug directly into a PMD X 125 Multi Mode Breakout Board via the O ption Card Connector J18 All power supply and control signals are brought in to the PMD X 107 via this connector No external power supply is required W hen connected to a PMD X 125 the PMD X 107 can operate in one of two modes as described in the following sections 2 1 1 Normal Mode In Normal mode the PMD X 107 receives the spindle speed controls via the following parallel port pins e PC parallel port pin 14 is the Spindle Direction signal passed through the PMD X 125 e PC parallel port pin 16 is the PW M signal passed through the PMD X 125 e PC parallel port pin 17 is the Charge Pump signal into the PMD X 125 which then passes a Charge Pump OK signal to the PMD X 107 PMD X 125 DIP Switch settings Configure
18. harge pump enabled Set the relay mode DIP switch and 5V 10V DIP switch as appropriate for your VSD See section 4 0 for information on DIP switch settings If you are not using a charge pump signal configure the boards as follows PMD X 132 jumper settings Configure the PMD X 132 s jumper JP1 Output Enable for not EStop and jumper JP2 Pin 17 Mode for normal See the PMD X 125 User s Manual for more information PMD X 107 DIP Switch settings Configure the PMD X 107 for Normal mode with ignore charge pump Set the relay mode DIP switch and 5V 10V DIP switch as appropriate for your VSD See section 4 0 for information on DIP switch settings PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 6 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 2 3 VSD Speed Control Interface The VSD speed control interface on the PMD X 107 generates an analog voltage proportional to the desired VSD speed This voltage is the result of an incoming PW M signal or when in Expanded mode from the serial command data from the PC The PMD X 107 supports three different analog speed control interfaces 0 to 5V The VSD expects an analog voltage between 0 and 5V where 5V is full speed In this case the PMD X 107 provides the 5V reference for its analog output circuit See Figure 1 for an example of the DIP
19. he motor will not start until the PW M reaches a suitable value The PMD X 107 uses the absence of a valid PW M signal to stop the spindle motor A valid PW M signal must always be pulsing on and off A true 0 or 100 duty cycle signal does not pulse and will therefore turn off the spindle motor Most control software including MACH will provide the proper signal formatting PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 11 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 WARNING Mach3 Spindle Linearization Table Based on versions of Mach3 available to us at the time this manual was updated Lockdown version R3 042 040 PMD X recommends not using the spindle speed calibration function in Mach Many systems do not stabilize fast enough and result in faulty data in the linearization table Instead PMD X recommends using the adjustment pot on the PMD X 107 for speed compensation see section 2 6 VSD Speed Calibration for more information NOTE If you have ever run the auto calibration in Mach3 you will need to remove the existing linearization table The table isstored in a file named Linearity dat located in the Mach3 macros X XXX directory where Mach3 is the directory into which you installed the Mach software usually C Mach3 and XXX X is the name of the configuration For example if
20. in a manner consistent with applicable safety requirements Practical Micro Design Inc does not control how this board is integrated into the purchaser s system and cannot be responsible for guaranteeing the safety of your system The PMDX 107 is not guaranteed to be fail safe The system into which the PMD X 107 is installed should provide fail safe protection and emergency stop capability WARNING SHOCK HAZARD A The VSD s analog ground reference is NOT necessarily at earth ground potential Likewise the control signals for forward reverse etc may not be referenced to ground Any of these may be at mains potential which may be several hundred volts above ground These potentially dangerous voltages appear on PMD X 107 connector J1 and on portions of the PMD X 107 circuit board All wiring from the PMD X 107 to the VSD should be treated as HOT and suitably protected Care must be taken that user cannot come in contact with these voltages An enclosure that allows for adequate ventilation but prevents intrusion by operator s hands and foreign objects especially conductive byproducts of machining operations should be utilized with this board Interlock switches on power circuits should remove power when the enclosure is opened Always disconnect mains power from BOTH the CNC control system and the VSD before working on the wiring connected to either Automated machine tools into which the PMD X 107 may be integrated
21. ke effect Config 3 Solid state relays operate as Forward and Reverse control signals Solid state relays operate as Run and Direction control signals Table 4 Relay Mode DIP Switch Settings 4 3 Charge Pump Mode Switch DIP Switch 4 labeled C onfig4 determines whether the PMD X 107 pays attention to the Charge Pump OK signals that may optionally be provided by the PMDX breakout boards This switch is read only at power up or when the Test push button is pressed This means that if you change the settings on these switches you must either press amp release the Test push button or power the PMD X 107 off and back on or in order for the change to take effect Config 4 Description Require a Charge Pump O K signal from the PMD X breakout boards In this mode the PMDX 107 will ignore any PW M signal until the C harge Pump O K signal is asserted from the PMDX breakout board usually associated with an O utputs Enabled LED on the breakout board Ignore the Charge Pump O K signal from the PMDX breakout boards In this mode the PMD X 107 always looks for valid PW M signals This mode can be used for example when you are using a PMD X 132 board and need to use parallel port pin 17 for some function other than a charge pump Table 5 Charge Pump Mode DIP Switch Settings 4 4 Fast Slow Spindle Response Switch DIP Switch 5 labeled Slow determines
22. lation circuitry between the VSD interface and the low voltage control inputs DO NOT connect any terminal on connector J1 to any other connector on the PMDX 107 or on the PMDX breakout board Specially do not connect any terminal to any ground GND signal At best doing so will defeat the isolation provided by the PMDX 107 At worst it will destroy the electronics in your system PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 7 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual Document Revision 1 2 PMDX 107 Rev Dir Fwd Run COM Aref Aout Agnd PCB Revision PC B 475D Assembly Revision D1 VSD Analog In 0 5VDC COM Figure 1 Example OV to 5V VSD Connections amp DIP Switch Settings PMDX 107 Rev Dir Fwd Run COM Aref Aout Agnd Figure 2 Example OV to 10V VSD Connections amp DIP Switch Settings PZO TBD Config1 TBD nat Config2 TBD co Config3 TBD la Config4 TBD la Slow Elo 5v 10v PMDX 107 Rev Dir Fwd Run COM Aref Aout Agnd sccce AW PMDX 107_Manual_12 doc 24 September 2012 VSD Reference Figure 3 Example Ratiometric VSD Connections amp DIP Switch Settings 2010 2012 Practical Micro Design Inc All Rights Reserved Page 8
23. le 1 Example 2 Figure 4 Sample DIP Switch Settings Example 1 shows the DIP switches as shipped from the factory All switches are off Example 2 shows the DIP switches set so that Config 1 and Slow are on and all other switches are closed PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 12 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 4 1 Operational Mode Switches The O perational Mode switches are read only on power up or when the Test push button is pressed This means that if you change the settings on these switches you must either press amp release the Test push button or power the PMD X 107 off and back on or in order for the change to take effect Config 1_ Config 2 Normal Mode see section 3 1 1 Expanded Mode see section 3 1 2 Unused will flash an error code on the STATUS LED Unused will flash an error code on the STATUS LED Table 3 Operational Mode DIP Switch Settings 4 2 Relay Mode Switch DIP Switch 3 labeled C onfig3 determines how the two solid state relays behave This switch is read only at power up or when the Test push button is pressed This means that if you change the settings on these switches you must either press amp release the Test push button or power the PMD X 107 off and back on or in order for the change to ta
24. limit speed ramp rate for sensitive motor drivers reduces probability of blown fuses Provides safety interlock for charge pump OK input monitoring and detection of missing PW M Provides speed calibration pot for setting maximum speed Has push button for self test and calibration modes LED s for PO W ER Status PW M active FW D Run and REV Dir Manual run stop speed and direction control are possible using an external pot relays and or switches NOTE The PMDX 107 is not suitable for use with universal motor controllers such as consumer grade wood routers whose motors have brushes 2010 2012 Practical Micro Design Inc All Rights Reserved Page 4 of 18 PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 1 6 Updates to this Manual Check the PMD X web site http www pmdx com for revisions or updates to this manual and related application notes The latest revision of this manual is available on the PMD X 107 page follow the links from the main page 2 0 Quick Start Guide The following sections show the steps necessary to install configure and use the PMD X 107 In general the steps are 1 Power off your VSD and PMD X 125 or PMDX 132 boards and unplug the parallel port cable from the PMDX 125 or PMDX 132 2 Connect the PMD X 107 to the VSD s speed control interface see section 2 3 WARNING SHOCK HAZARD A Please see the warning in s
25. nn nnan nnna 17 Appendix A Warranty sss sssssssunennenennunnunnnnnnnnnnnennunun nunnunum nnmnnn nnen nunnnnnnnnn annn nenn nnan nnnnn annann nannaa nnn 18 PMDX 107_Manual_12 doc 2010 2012 Practical Micro D esign Inc Page 2 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 1 0 Overview This document describes the configuration and operation of the PMD X 107 Isolated Speed Control This document pertains to the following versions of the PMD X 107 Circuit Board Revision PCB 475D marked on the bottom of the board Assembly Revision D1 marked on silk screen block next to the serial number Serial N umber Range 27090 and above 1 1 Ordering Information part numbers The PMD X 107 can be built with or without components that allow the board to be mounted to an operator s panel as designated by the full part numbers Part Number Features PMDX 107 Normal version with one mounting bracket 1 2 Definitions PWM Pulse width modulation a digital signal that represents an analog voltage as a pulse stream VFD Variable Frequency Drive used with 3 phase AC motors VSD Variable Speed Drive either aDC motor speed control or aVFD 1 3 Important Safety Information The PMDX 107 is intended for integration by the purchaser into industrial control systems It is solely the purchaser s responsibility to assure that the system is configured
26. of 18 PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 2 4 VSD Run Direction Interface The PMD X 107 provides two sets of solid state relay contacts to control the running and direction of the VSD There is a single common terminal and two normally open terminals WARNING SHOCK HAZARD The VSD s analog ground or common reference is NOT necessarily at earth ground potential It may be at mains potential or it may be several hundred volts These potentially dangerous voltages appear on PMDX 107 connector J1 and on portions of the PMDX 107 circuit board The PMD X 107 contains isolation circuitry between the VSD interface and the low voltage control inputs DO NOT connect any terminal on connector J1 to any other connector on the PMDX 107 Specially do not connect to any terminal on J1 to any ground GND signal At best doing so will defeat the isolation provided by the PMDX 107 At worst it will destroy the electronics in your system r p DIP Switch 8 off DIP Switch 3 on Contacts Fwd Rev mode Run Dir mode jipind na Common terminal for J1 pins 5 amp 6 Common terminal for J1 pins 5 amp 6 _ VSD hated Cd closed VSD running forward yep ee running to J1 pin 4 direction determined by J8 J1 pin 6 VSD halted VSD direction forward closed VSD running reverse VSD direction reverse to J1 pin 4 Table 1 Function
27. rectly in to the PMD X 132 Breakout Motherboard s Expansion Connector J23 All power supply and control signals are brought in to the PMD X 107 via this connector No external power supply is required NOTE The PMDX 107 must be configured for Normal mode when plugged into a PMD X 132 The PMDX 107 s Expanded mode is not compatible with the PMD X 132 and it will interfere with the PMD X 132 s functionality W hen connected to a PMD X 132 the following PC parallel port signals are used to control the spindle interface e PC parallel port pin 14 is the Spindle Direction signal passed through the PMD X 132 e PC parallel port pin 16 is the PW M signal passed through the PMD X 132 e OPTIONALLY PC parallel port pin 17 is the Charge Pump signal into the PMD X 132 which then passes a Charge Pump O K signal to the PMD X 107 The PMDX 132 and PMD X 107 configurations depend on whether you are using a charge pump signal with your PMD X 132 Please refer to the PMD X 125 User s Manual for more information about the charge pump feature If you are using a charge pump signal configure the boards as follows PMD X 132 jumper settings Configure the PMD X 132 s jumper JP1 Output Enable for CP O K and jumper JP2 Pin 17 Mode for CP OK See the PMD X 125 User s Manual for more information PMD X 107 DIP Switch settings Configure the PMD X 107 for Normal mode with c
28. the PMDX 125 for Run in Normal Mode or Run in Normal Mode with Charge Pump See the PMDX 125 User s Manual for more information PMD X 107 DIP Switch settings Configure the PMD X 107 for Normal mode with charge pump enabled Set the relay mode DIP switch and 5V 10V DIP switch as appropriate for your VSD See section 4 0 for information on DIP switch settings PMDX 107_Manual_12 doc 2010 2012 Practical Micro Design Inc Page 5 of 18 24 September 2012 All Rights Reserved PMDX 107 User s Manual PCB Revision PC B 475D Document Revision 1 2 Assembly Revision D1 2 1 2 Expanded Mode In Expanded mode the PMD X 107 shares the serial data stream with the PMD X 125 and receives the spindle speed controls via the following parallel port pins e PC parallel port pin 16 provides PW M speed and direction information shared with the PMD X 125 e PC parallel port pin 17 is the Charge Pump signal required Use of Expanded Mode with Mach requires the PMD X 107 Mach3 plug in which may be downloaded from our web site at http www pmdx com see the Support page for the downloads page Please refer to the plug in documentation for information on how to configure Mach3 to access the additional output signals Use of Expanded Mode with EMC requires an EMC HAL configuration that supports Expanded O utput Mode 2 2 Example Connections to PMDX 132 The PMDX 107 is designed to plug di
29. until the spindle motor just reaches its maximum speed Do not increase the setting of R3 above the point at which the motor reaches maximum speed as this will distort the speed control curve NOTE The PMDX 107 will exit Test mode on its own after 30 seconds at which point you will have to restart Test mode if you have not completed the calibration 7 Press amp release the push button on the PMD X 107 again The PMD X 107 will set the speed control output to 30 of full speed with the VSD commanded in the forward direction The 30 speed is intended to be above the low speed cutoff threshold imposed by some VSD units If your VSD does not run at this test speed please contact us for further advice 8 Observe that your VSD is running at 30 full speed There is no adjustment for this speed 9 Press amp release the push button on the PMD X 107 one more time to exit the Test mode and return to normal operation KA 2 The speed control provided by the PMD X 107 is open loop There is no compensation by the PMD X 107 for motor loading or other factors because there is no speed feedback on which to base a compensation Normal expectations should be for control within 5 of target speed under no load conditions Speeds below 30 of full speed will likely suffer greatly under load Speeds below 10 of full speed may track speed commands poorly 2 7 Configuring PC Control Signals If you are using a PC to generate th
30. you installed Mach in the default directory and are using the Mach3Mill configuration the file would be C Mach3 macros Mach3Mill Linearity dat You can either delete this file or rename it to something like Linearity O Id dat 3 3 Power Supply Isolation The VSD interface is isolated from the low voltage PC and PMD X breakout board interface and power supply Do not connect the VSD s interface to the computer interface or power supply by any method other than connector J1 on the PMDX 107 Doing so will defeat the isolation 4 0 DIP Switches The PMD X 107 contains 6 DIP switches that determine various aspects of its behavior The DIP switches are numbered 1 through 6 These numbers also appear on the DIP switch The functional labels shown in the table below also appear on the circuit board s silkscreen next to the DIP switch In the descriptions that follow the switch positions are described as on or off The on position is with the raised portion of the switch positioned towards the silk screen labels The off position is with the raised portion of the switch positioned away from the silkscreen labels The DIP switch also has an arrow pointing to the ON position 5 5 z a D D 5 6 5 6 FZO CH Config1 ICH n Config2 J Ja Config3 J aj Config4 FZO CA Configi ICH n Config2 CH Je Config3 IC J aj Config4 Examp
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