Home

MA6415 6 4 1 5 Oscillator/Drive

1. 0 2V 4V 6V 8V 0 125Khz 250Khz 375Khz 500Khz Fine Resolution E2 Installed Speed Resolution 31 25Khz V 0 2V 4V 6V 8V 0 62 5Khz 125Khz 187 5Khz 250Khz 6415 Installation and Hardware Reference Manual Rev E Run Stop Command E4 RUN STOP Control IN Separate Inputs OUT Single Input With the E4 jumper installed the RUN STOP Clutch brake mode of the 6415 is controlled by two separate optically isolated inputs When the RUN opto is driven momentarily the RUN STOP latch is placed in the RUN state and the oscillator frequency ramps to the selected speed at a rate controlled by the ACCEL potentiometer When the STOP opto is driven momentarily the RUN STOP latch is placed in the STOP state and the oscillator frequency ramps to zero frequency at a rate controlled by the DECEL potentiometer The RUN STOP latch is designed to be in the STOP state after applying power to the 6415 to insure that motion does not occur unintentionally o D c E O A Single Input If the E4 jumper is removed the RUN STOP mode of the drive is E4 jumper controlled directly from the RUN input When the RUN opto is removed driven the oscillator frequency ramps to the selected speed at a rate controlled by the ACCEL potentiometer When the RUN opto is off the oscillator frequency ramps to zero frequency at a rate controlled by the DECEL potentiometer 6415 Installation and H
2. 6415 Installation and Hardware Reference Manual Rev E 4 3 Table cont d SYMPTOM CORRECTIVE ACTION Motor produces torque but does not run l No Step pulses out Check that there is a final speed command voltage at the VCO monitor test point VCO INPUT MON and the step pulses output STEP OUT is switching Also verify that El and E3 jumpers are set correctly Loss of phase current in one winding Check phase current in both phases by placing an ammeter in series with each winding If not present check for open circuit in motor phase winding by measuring resistance One motor phase not wired correctly at stepping motor Check stepping motor wiring Step pulses output STEP OUT is too high Lower step pulses output by adjusting Run Speed and Accel Decel Potentiometers Also check to make sure that the step size and frequency range jumper E2 are set correctly Motor misses steps Incorrect run speed or low speed Adjust run speed potentiometer or low speed potentiometer Incorrect accel ramp time or decel time Adjust accel potentiometer or decel potentiometer 6415 Installation and Hardware Reference Manual Rev E If the drive is defective Return procedure 6415 Installation and Hardware Reference Manual Rev E 4 5 If you cannot correct the drive problem or if it is defective return it to Pacific Scientific for repair or replacement 1
3. windings MS CONNECTOR c 9 E x CASE S B DRIVE EARTH GROUND FOUR LEAD MOTOR MS CONNECTOR A CASE B B DRIVE EARTH GROUND EIGHT LEAD MOTOR CONNECTED IN PARALLEL MS CONNECTOR CASE DRIVE EART GROUND EIGHT LEAD MOTOR CONNECTED IN SERIES 6415 Installation and Hardware Reference Manual Rev E 2 15 Power Max motor connections The figure below shows the connections required between the 6415 and Pacific Scientific Power Max Motors Power Max motors have an eight pin connector and can be configured with either parallel or series windings CONNECTOR gt CASE a DRIVE EARTH GROUND PARALLELED WINDINGS CONNECTOR CASE 74 B DRIVE EARTH GROUND SERIES WINDINGS 6415 Installation and Hardware Reference Manual Rev E 2 5 2 J2 Power Connector Introduction The J2 power cable connects the 6415 to the power supply Please refer to Appendix C for additional information on power supply considerations J2 power table S E Input Pin Explanation 7 DC J2 1 24 to 75 Vdc max at 5 amps E The negative side of the power supply DC J2 2 connected to DC should be connected to Earth ground No connection is made within the 6415 between J2 1 and J2 3 Earth Ground J2 3 Connected to 6415 Case and J3 5 Motor Ground Power Connections between the 6415 and power supply are shown in the connection diagram o
4. e 12 E 49 9K t 250 30W E i 4 02K p IN4002 i 64 9K 4 02K AAA 0 01 uF La PUN 2200PF no E 402K 4X L l 0 1 uF 499K IRF633 LM336BZ 499K K d 9 v 6415 Installation amp Hardware Reference Manual Rev E C 9 C 2 Powering the 6415 from a Regulated Supply Certain precautions should be taken when powering the 6415 drive from a regulated power supply The 6415 s bipolar chopper output stage draws current from the DC supply in the form of pulses with fast rise and fall times This may be a problem for some regulated supplies designed to drive loads having relatively constant or slowly varying current drain If a regulated supply is used and problems are encountered a 470uf capacitor should be placed across the DC and DC lines between the power supply and 6415 Ideally this capacitor is located close to the 6415 drive but it can be located near the power supply and connected to the 6415 with a twisted pair no longer than 3 feet in length The capacitor should have a 20KHz ripple current rating of at least the 6415 s current setting and a voltage rating of 1 3 times the nominal bus voltage A second precaution involves regenerated power see section C 1 5 Regulated supplies are usually not designed to absorb power This might cause their output voltage to rise during regeneration and lead to power supply and or 6415 damage The same considerations and solutions described in section C 1 5 apply C 10
5. 8 STOP p c STOP 8 5 2 OSCILLATOR 9 me DRIVE J2 ui 20 Loc 5 LOW SPD 7 B LOW SPD 19 j DC Unregulated ANALOG INPUT c 24Vdc to 75Vdc 3 Case GND t ANALOG_INPUT 18 5 GNDA 5 GNDA 17 J 3 SNDA 4 1 Phase A GNDA 16 zm EXTERNAL POT 3 2 Phase A S c 8V_REF_OUT 15 3 Phase B 48V REF OUT gt ase 8V_REF_ OUT 14 4 VCO INPUT MON 4 ME 2 Phase CHASSIS 5 asean Stepper Motor Bir 6415 Installation and Hardware Reference Manual Rev E E 7 Mechanical Outline 0 04 je 4 30 109 2 mm 0 04 1 10 27 9 mm 0 02 2 75 69 9 mm OPTIONAL SIDE MTG CLEARANCE FOR M4 or 6 32 SCREW 0 04 1 50 38 1 mm 0 02 4 75 120 7mm CUSTOMER MTG Uu I PACIFIC SOENTIFIC 0 04 5 00 127 0 mm Y 0 02 0 75 19 1 mm CUSTOMER MTG 6415 Installation and Hardware Reference Manual Rev E Address 4 5 B 2 Applications 1 7 D 1 Bipolar chopper drive 1 2 Bus overvoltage 1 2 Bus power supply 2 3 Cable J3 2 12 J2 2 19 Routing E 4 Shielding E 5 Capacitor external 2 17 motor selection C 6 CE Installation Guide E 1 Test set up E 3 Chopper frequency A 1 Clamping circuit C 9 Cleaning unit 4 1 Components system 1 7 2 3 6415 Installation amp Hardware Reference Manual
6. The drive supplies regulated phase currents for supply voltages between 24 Vdc and 75 Vdc It is designed for use with Pacific Scientific s line of hybrid stepping motors and will work with either the standard line or the enhanced performance line Note The motor winding must be compatible with the output current of the driver Bipolar chopper drive patented 4 phase PWM pulse width modulation chopping electronically controls the motor winding currents at 20 kHz frequency This combines the best of recirculating and non recirculating current regulation producing high back EMF rejection with low chopping ripple current Benefits include reduced heat dissipation low electric noise and improved current control during motor breaking Microstepping switch selectable full 1 2 1 5 1 10 1 25 1 50 1 125 and 1 250 step capability with decimal jumper installed and 1 2 1 4 1 8 1 16 1 32 1 64 1 128 and 1 256 with decimal jumper removed Digital Electonic Damping patented circuit eliminates torque loss and or motor stalling through the mid speed region that is inherent in all open loop stepper applications Short circuit protection circuitry disables the drive if a short circuit occurs on the motor outputs The drive must be power cycled to clear fault Bus overvoltage disables the drive if the voltage exceeds 83 Vdc The drive must be power cycled to clear fault MOSFET power devices allows chopper frequency of ap
7. Side View 6415 E2 Frequency Range IN LOW FREQUENCY OUT HIGH FREQUENCY E4 RUN STOP Control IN SEPARATE INPUTS OUT SINGLE INPUT E5 MIN SPEED Frequency IN DISABLED OUT ENABLED LOW SPEED r3 a c 3 D o M a Control Source E6 E7 E8 DIR Opto Analogin Rotation DIR t DIR OUT OUT OUT Driven CCW OUT OUT OUT NotDriven cw J umpers IN IN OUT Driven CCW OUT OUT OUT NotDriven cw Analog In IN OUT IN Driven Negative CCW IN OUT IN NotDriven Positive Cw E1 E3 Velocity Control Mode 1 21N 1 21N Internal RUN SPEED Potentiometer 3 4IN N A External Potentiometer 5 6IN 1 221N External Analog Input 1 2IN 3 4 1N External Analog Input scaled by internal RUN SPEED potentiometer 6415 Installation and Hardware Reference Manual Rev E es 3 1 1 Potentiometer Settings Potentiometer The 6415 has four potentiometers which adjust the output move Settings profile of the motor The acceleration rate and deceleration rate are usually adjusted and not changed for a particular motor load combination The run speed and low speed potentiometers are adjustable during operation with the velocity ramping up or down to the new velocity Adjustments for RUN SPEED LOW SPEED ACCEL RAMP and DECEL RAMP are made with 4 multi turn potentiometers LOW SPEED is typically set lower than
8. J4 Signal interface 2 19 connector 2 25 diagram 2 23 I O table 2 20 Jumper settings 3 6 E1 E3 3 6 E2 3 10 E4 3 11 E5 3 12 E6 E7 E8 3 12 L Line transformer selection C 2 6415 Installation amp Hardware Reference Manual Rev E Maintenance 4 1 Manual how to use 1 9 Microstepping 1 2 3 16 MIN SPEED frequency 3 12 MOSFET power devices 1 2 Motor 2 3 cable making your own 2 11 connector 2 11 Flying Lead 2 13 MS connectors 2 15 Power Max 2 16 Terminal Board 2 14 PacSci cable 2 9 selection 2 3 Mounting 2 4 dimensions 2 6 E 8 guidelines 2 7 E 4 Noise pickup reduction 2 9 Optically isolated connections A 2 safety 2 2 Opto supply table 2 24 Order information B 1 Oscillator board 3 1 diagram 3 2 jumper settings 3 6 potentiometer settings 3 3 specifications A 3 Overview general 1 1 Packing list 2 1 Panel mounting 2 5 Parallel connection 2 13 2 16 Phase A A 2 11 Phase B B 2 11 Potentiometers Accel ramp 3 5 Decel ramp 3 5 Run speed 3 4 Low speed 3 4 Power dissipation 2 4 Power supply considerations C 1 Motor 2 17 C 1 Power up 3 1 Problems Solutions 4 2 Ramp time A 3 Rectifier diode selection C 5 Regeneration C 7 Regulated supply C 10 Repair procedure 4 5 Resistors 2 24 Return procedure 4 5 RUN STOP Control 3 11 S1 switch location 3 15 setting 3 15 idle current reduction setup 3 18 digital elect
9. PATENT OR COPYRIGHT INFRINGEMENT SHALL NOT EXCEED THE PRICE SPECIFIED OF THE PRODUCTS OR PROGRAMS GIVING RISE TO THE CLAIM AND IN NO EVENT SHALL PACIFIC SCIENTIFIC BE LIABLE UNDER THESE WARRANTIES OR OTHERWISE EVEN IF PACIFIC SCIENTIFIC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING WITHOUT LIMITATION DAMAGE OR LOSS RESULTING FROM INABILITY TO USE THE PRODUCTS OR PROGRAMS INCREASED OPERATING COSTS RESULTING FROM A LOSS OF THE PRODUCTS OR PROGRAMS LOSS OF ANTICIPATED PROFITS OR OTHER SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES WHETHER SIMILAR OR DISSIMILAR OF ANY NATURE ARISING OR RESULTING FROM THE PURCHASE INSTALLATION REMOVAL REPAIR OPERATION USE OR BREAKDOWN OF THE PRODUCTS OR PROGRAMS OR ANY OTHER CAUSE WHATSOEVER INCLUDING NEGLIGENCE The foregoing shall also apply to Products Programs or parts for the same which have been repaired or replaced pursuant to such warranty and within the period of time in accordance with Pacific Scientific s date of warranty No person including any agent distributor or representative of Pacific Scientific is authorized to make any representation or warranty on behalf of Pacific Scientific concerning any Products or Programs manufactured by Pacific Scientific except to refer purchasers to this warranty Table of Contents 1 Overview of the 6415 1 1 6415 Definition 1 2 Other System Components 1 3 How to Use th
10. low speed direction and enable inputs The use of optical isolation increases the options available for system grounding The source commanding these control signals 1s not tied directly to the motor power supply ground allowing the system ground point for these control signals to be made external to the unit UL Recognized 508C Type R File E137798 This also complies with CSA Standard for Process Control Equipment C22 2 No 142 M1987 Vibration IEC Standard 68 2 6 6415 Installation amp Hardware Reference Manual Rev E 1 3 User adjustments Using DIP switch S1 Motor current sets the motor phase current to 5 0 4 375 3 75 3 125 2 5 1 875 1 25 or 0 625 A rms Step size sets the amount of shaft rotation per pulse with the decimal jumper installed The settings are full half 1 5 1 10 1 25 1 50 1 125 and 1 250 steps per micro step This corresponds to 200 400 1000 2000 5000 10 000 25 000 and 50 000 micro steps per revolution with a standard 1 8 motor With the decimal jumper removed the settings are 1 2 1 4 1 8 1 16 1 32 1 64 1 128 and 1 256 steps per micro step This corresponds to 400 800 1600 3200 6400 12 800 25 600 and 51 200 micro steps per revolution Digital Electronic Damping enables this patented feature which eliminates loss of torque and possible motor stalling conditions when operating at mid range speeds This instability is a phenomenon of the electronic m
11. Index Connections diagram 2 8 motor 2 9 parallel 2 13 2 14 2 15 2 16 series 2 13 2 14 2 15 2 16 testing 3 20 Connectors A 8 J3 2 11 J1 2 23 Convection cooling A 7 Current input 2 3 motor C 4 output 1 1 rating A 1 C 4 C 5 Damage 2 1 Date code 2 1 Declaration of Conformity E 2 Defective unit 4 5 Definition general drive 1 1 Dimensions 2 6 A 8 Rev E 1 1 Digital electronic damping 1 2 Setup 3 17 benefits 3 17 definition 3 17 Diode selection C 5 DIR input 2 22 4 3 A 2 Drive board settings 3 15 circuit A 1 current stepsize see S1 switch features 1 2 Earth ground safety 2 2 Enable 3 13 Enabled LED 3 13 Enabling the drive 3 21 External capacitor 2 17 External step pulse 3 14 Frequency range 3 10 Fuse selection C 7 Getting help 3 22 Grounding E 5 Heatsink mounting 2 5 Help getting 3 22 Holding torque and idle current reduction 4 3 Humidity A 6 ICR see Idle current reduction Idle current reduction 1 4 3 18 benefits 3 18 definition 3 18 Input Output connections diagram 2 8 Inspecting 2 1 Installation 2 2 2 4 Interface high voltage 2 24 typical 2 23 6415 Installation amp Hardware Reference Manual Rev E J3 Motor 2 9 cable making your own 2 11 connector 2 11 diagram 2 12 PacSci cable 2 9 procedure 2 12 safety 2 2 table 2 11 J2 Power 2 17 cable 2 19 diagram 2 18 procedure 2 19 table 2 17
12. case and hence ease heat sinking requirements It is good design practice to limit the maximum junction temperature to 125 C Testing should be done to insure the power on surge current is within the diode s Irsy rating Q 2 gt o E o O a Considerations 6415 Installation amp Hardware Reference Manual Rev E C 5 C 1 3 Capacitor Selection The table below gives the minimum bus capacitance value for a single 6415 as a function of the current setting and bus voltage These values give approximately 10 peak to peak ripple voltage with a 60 Hz line increase capacitor values by 20 for use with a 50 Hz line Current Setting 30 Volt Bus 50 Volt Bus 70 Volt Bus 5 0 14 000 8300 6000 4 375 12 000 7300 5200 3 75 10 000 6300 4500 3 125 8700 5200 3700 2 5 6900 4200 3000 1 875 5200 3100 2200 1 25 3500 2100 1500 0 625 1700 1000 740 Ripple current rating Example Bus Capacitance in Micro farads The bus capacitor s 120 Hz ripple current rating should equal or exceed the 6415 s current setting The capacitor s working voltage rating must exceed the maximum bus voltage under all line load and regen conditions Select a capacitor rated for at least 1 3 times the nominal bus voltage Suppose a 6415 is operating at 70 volts and 1s set for 5 A rms motor current Assuming a 60 Hz line a bus capacitor of 6000 micro farads should be used The capacitor sho
13. enabling the drive and power stage becoming active STEP OUT 4 12 13 The VCO output step pulses rate is 24 25 proportional to the analog speed command and available to connected up to four additional 6410 drives 2 22 6415 Installation and Hardware Reference Manual Rev E Typical The figure below shows a typical interface between the user s interface electronics and the 6415 The TTL gates should have totem pole outputs and be capable of sinking at least 10 0 mA at 0 4 volts USER S eins CONTROL JA STEPPER ELECTRONICS DRIVE c eo 5VdC o Low SPD 19 TLP 621 TTL 2 21K LOW SPD 7 1K 5 S D E t ER e TLP 2601 um 221K L gt RUN 8 1K STOP 21 ETT TLP 621 S STOP 9 IK DIR a TLP 621 2 21K TTL gt DIR 10 i 1K vp ENABLE 23 een 2 21K 5 ENABLE 11 i 1K yo gt MOTION BEGINS WITHIN 50us 1 k 50 us MIN RUN iui SETUP TIME 50 us MIN DIRECTION INPUT I t fi DIRECTION DATA MUST BE STABLE OVER THIS INTERVAL 6415 Installation and Hardware Reference Manual Rev E 2 23 Higher voltage Voltages up to 30 volts can be used for the opto power input to interface the 6415 drive However a resistor must be put in series with the command inputs as shown below Values for several common supply voltages are given in the following table If the drives have open collector outputs pull u
14. for the power supply cable Use cable twisted at requirements about 3 to 4 turns per inch 1 to 1 5 turns per centimeter 2 18 6415 Installation and Hardware Reference Manual Rev E Cable diagram J2 power cable Green Earth Ground aN White DC f Installation Black DC Procedure 1 Strip the wires 0 27 inch 7mm 2 Attach the wires to the connector as indicated in the diagram Note Make sure the screws on the PCD connector are tightened down firmly on the wiring Caution Do not solder the tips of the cables going into the PCD connector This can result in a loose connection 2 5 3 J4 Signal Interface Connection Introduction The J4 control I O signal interface accepts external speed potentiometer analog input direction and enable signals from a user s control input or other sources and outputs pulse signals STEP OUTPUT which indicates the 6415 is applying current to the motor windings The control I O interface also provides 8 0 volts for external reference voltage 8V REF OUT to power an external user s speed potentiometer and a monitor test point VCO INPUT MON to monitor the accel decel motion profile 6415 Installation and Hardware Reference Manual Rev E 2 19 J4 signal table Input Output Pin s Explanation VCO INPUT MON J4 1 Accel Decel profile and final run speed command monitor point 8V REF OUT 4 2 14 8V user
15. igm o6 COME VCO POT R7 El x 130 8V 332 gt CW 6 04V E 1K DECEL cw f oo POT R17 LOW SPEED POT R43 118mV 20 Note M 4 means other connection is not shown 6415 Installation and Hardware Reference Manual Rev E External Potentiometer J4 6415 ACCEL g POT R14 65 _ 5 1M U o 5 Qo B E CW a 9 un 8 O NAA J4 15 o o X 48V REF OUT 2 20 9 Ex b 152 Speed Cmd 1 J4 3 EXTERNAL POT 3 4 and Motion Profile STEP 10K lt S gt gt gt Generator and gt zB B RUN STOP VCO OUT USER S POT E1 Controls 8V 4 16 J GND x LAAA lt 332 u 3 CW 6 04V 25K 21K DECEL cw Tz POT R17 LOW SPEED POT R43 118mV Note 20 lt means other connection is not shown Vv 6415 Installation and Hardware Reference Manual Rev E 3 7 o 2 D c E gt O A External Analog Input 8V ACCEL 5 POT R14 moo H4 MS T ot Oo sf E3 a cw E 5 79 a 8 9 gt z 10 9 zh 7 99V 10 K J 4 6415 cw Sh 2 iiec i Motion Profile 730 04 Generator and STEP 56036 RUN STOP OUT RUN SPEED 118mV C VCO POT R7 m El ontrols Speed Cm 150 8V VA ANALOG Y ec Speed INPUT 9 4 6 10K 10K 6 2K P ANA AA e 332 A a cw 25K 1 zm 0 01uF 6 04V 2 1K DECEL ANALOG k cw S POT R17 J 4 181 INPUT 10K 10K Gainzo g LOW SPE
16. motor emits a high frequency noise but the shaft is not rotating stop the motor Lower the RUN SPEED by turning the RUN SPEED potentiometer CCW Increase the ACCEL RAMP by turning the ACCEL RAMP potentiometer CW 5 After successfully establishing motion the system can be powered down and connected to a load Note A bus capacitor should be connected to the 6415 power input The bus capacitor should be connected using a twisted pair cable no longer than three feet in length For maximum voltage and current a 100 volt 5 A rms 120 Hz ripple current rating 6000 uf capacitor is recommended If you need further assistance with your installation please contact your local distributor 6415 Installation and Hardware Reference Manual Rev E 4 Maintaining Troubleshooting In this chapter This chapter covers maintenance and troubleshooting of the 6415 unit 4 1 Maintaining the 6415 Drive Introduction The 6415 drives are designed for minimum maintenance The following cleaning procedure performed as needed will minimize problems due to dust and dirt build up Procedure Remove superficial dust and dirt from the unit using clean dry low pressure air 4 2 Troubleshooting the 6415 Drive Introduction The 6415 has an enabled LED output which is on when the drive is enabled and off when the drive is disabled or faulted due to any of the following e Output overcurrent line to line or line to neutral short e Bus overvolta
17. object must be provided If cooling is accomplished solely through convection air flow no fan the unit can be run at 2 5 Amps RMS maximum if the ambient temperature is 25 C or less and 1 25 Amps RMS maximum if the ambient temperature is 45 C or less Again use of a fan to blow air past the side plate of the 6415 will increase the allowable current The same considerations given above for the optional heatsink apply fe Ng 7 Mounting When mounting the 6415 please refer to the dimensions below dimensions 0 04 m 4 30 109 2 mm _ CLEARANCE FOR M4 or 6 32 SCREW 0 04 0 04 1 10 27 9 mm 1 50 38 1 mm em a Ear i 6415 ce Pace SCIENTIFIC 8o 0 02 Sb 4 75 120 7mm 0 04 Cj 5 00 127 0 mm CUSTOMER MTG LED1 o tL muvsPeED CD ACCEL RAMP e DECEL RAMP s i LOW SPEED 45 ki ara DW f A fi i L o 0 02 0 02 0 75 19 1 mm 2 75 69 9 mm CUSTOMER MTG OPTIONAL SIDE MTG 2 6 6415 Installation and Hardware Reference Manual Rev E Mounting Your installation should meet the following guidelines guidelines Vertical orientation for the unit Flat solid surface capable of supporting the approximate 1 0 Ib weight 0 5 kg mass of the unit Free of excessive vibrat
18. supply output This supply is 15 for the external customer potentiometer and step output interface and is referenced directly to the internal drive module GNDA EXTERNAL POT J4 3 Connection to the wiper which is the center tap of the external customer potentiometer The voltage at this point controls the VCO oscillator frequency GNDA J4 4 5 Drive module return This return is used 16 17 in conjunction with the external customer potentiometer and step output interface and is not referenced directly to the user supply return ANALOG IN 74 18 Differential amplify analog input with customer supplied 10Vdc to 10Vdc analog input voltage for external analog ANALOG IN 14 6 input control Analog input has an input impedance of 20KQ 2 20 6415 Installation and Hardware Reference Manual Rev E Table cont d Input Output Pin s Explanation LOW SPD 14 19 LOW SPD 14 7 Optically isolated input that selects the source of the analog speed command The analog command is derived from the low speed potentiometer with low speed opto on RUN SPD 34 20 RUN SPD J4 8 Optically isolated input that initiates the move of the motor rotation In separate latched input mode the RUN opto is placed in the RUN state when the RUN opto is driven momentarily In single run mode the run opto is controlled directly from the RUN input STO
19. the following section represent common wiring practices and should prove satisfactory in the majority of applications Caution Non standard applications local electrical codes special operating conditions and system configuration wiring needs take precedence over the information included here Therefore you may need to wire the drive differently then described here fe Ng 7 Use shielded and twisted cabling for the signal and power cables as described below This precaution reduces electrical noise Refer to section 2 2 for safety information that must be followed to reduce shock hazard 2 5 1 J3 Motor Connections Introduction Pacific Scientific cable The J3 motor cable connects the drive to the motor windings and motor case J3 utilizes a plug in screw terminal type connector to simplify assembly and allow quick connect and disconnect Note Never disconnect the motor connection while the drive is enabled This may damage the drive and void the warranty Pacific Scientific makes cables that connect directly from J3 to our system motors To order the cable from Pacific Scientific use the order number SPC xxx 6410 where xxx is the length in feet one foot increments up to 50 feet For example SPC 050 6410 is a cable 50 feet long 6415 Installation and Hardware Reference Manual Rev E 2 9 Pacific Scientific If you are using Pacific Scientific motor cable with the mating cabling d
20. the initial voltage C 1s the total capacitance in farads E is the initial kinetic energy in joules 6415 Installation amp Hardware Reference Manual Rev E C 7 Example If an unloaded E34 motor rotor inertia 035 oz in sec is rotating at 1500 rpm the stored energy is 3 87 10 035 15002 3 0 joules If all this energy is transferred to a 6800 mf capacitor initially charged to 70 volts the voltage on the capacitor after the transfer is equal to 76 volts Note This exceeds the volt maximum specification of the 6415 drive In practice most or all the kinetic energy is dissipated in the motor windings or in the drive power circuitry so that voltage pump up is often not a problem However in systems running at high speeds and having large load inertia the voltage might be pumped up significantly and circuitry must be added to insure that the 75 volt limit is never exceeded Note Regeneration effects should be considered in the presence of high line conditions To find out if regenerative energy is a problem run the system while monitoring the supply voltage with a storage oscilloscope Alternatively a simple peak detector made form a diode and a capacitor can be attached to the bus and the peak voltage measured using a digital voltmeter Start the system with slow deceleration rates and monitor the motor power supply to see if the voltage rises during deceleration Slowly increase the deceleration rate sho
21. 1 SEC DELAY OUT CLOSED 0 05 SEC DELAY OUT OPEN 1 0 SEC DELAY 6415 Installation and Hardware Reference Manual Rev E a 2 D c E O A rcm pu E Id d sd u 3 2 4 Step Size Definition The step size sets the amount of rotation per input step Fifteen step sizes are available using Jumper J6 position 3 4 and DIP switch S1 positions 1 3 as shown For all Pacific Scientific stepper motors and all 1 8 step motors step size can be converted to steps per rotation using the following table Decimal Binary Full 200 Half 400 Half 400 1 4 800 1 5 1 000 1 8 1 600 1 10 2 000 1 16 3 200 1 25 5 000 1 32 6 400 1 50 10 000 1 64 12 800 1 125 25 000 1 128 25 600 1 250 50 000 1 256 51 200 Benefits Selecting a microstep size of 1 4 or smaller results in higher resolution e smoother low speed operation ability to operate in low speed resonance regions 3 16 6415 Installation and Hardware Reference Manual Rev E nnm 3 2 2 Digital Electronic Damping Control Definition Mid speed instability and the resulting loss of torque occurs in any step motor drive system due to the motor back EMF modulating the motor winding currents at certain speeds Mid speed instability can be explained as a region of potential instability that occurs as a result of the electronic magnetic and mechanical characteristics of any stepping mot
22. 6415 Installation amp Hardware Reference Manual Rev E 6415 s powered The figure below illustrates powering the 6415 from a regulated by regulated supply where both an external capacitor and regenerated power supply dump circuit are required The recommended fusing is also shown Q 2 gt o ha o O a Considerations LEEDER FUSE RESISTOR TWISTED REGULATED POWER oa 75 VOLT SUPPLY MAX ZENER 3 FEET MAX 2 6420 EARTH SAFETY GROUND 6415 Installation amp Hardware Reference Manual Rev E C 11 Appendix D Application Examples Introduction The following examples give a flavor of just a few of the myriad applications for the 6415 D 1 Standalone Operation User s Control Electronics e O9 m c o SE Co EK lu lt 6415 Installation amp Hardware Reference Manual Rev E D 2 6415 Dispensing Product onto Conveyer Belt This example shows the 6415 Oscillator Microstepping Drive Module and motor dispensing products onto a conveyor belt and into a shipping container The stepper motor supplies start stop motion to a paddlewheel ejector to dispense the product An optic sensor is used to advance the paddlewheel to the starting point An external Start signal initiates motion to eject the product the motion continues for one revolution until the paddlewheel is aligned for the next cycle Product to be Dispensed Paddlewheel
23. Call Pacific Scientific at 815 226 3100 from 8am to 6pm Eastern Standard Time to get a Returned Materials Authorization Number RMA Note Do not attempt to return the 6415 or any other equipment without a valid RMA Returns received without a valid RMA will not be accepted and will be returned to the sender 2 Pack the drive in its original shipping carton Pacific Scientific is not responsible or liable for damage resulting from improper packaging or shipment 3 Ship the drive to Pacific Scientific 110 Fordham Road Wilmington MA 01887 Attn Repair Department RMA Note Do not ship Pacific Scientific motors to the above address The correct address for motors is Pacific Scientific 4301 Kishwaukee Street Rockford IL 61105 Attn Stepper Repair Department RMA Shipment of your drive or motor to Pacific Scientific constitutes authorization to repair the unit Refer to Pacific Scientific s repair policy for standard repair charges Your repaired unit will be shipped via UPS Ground delivery If another means of shipping is desired please specify this at the time of receiving an RMA o o ta c c o S c Appendix A Specifications Electrical Input power 24 75 V dc 5 0 Amps supply Rated drive Setting current motor phase current 5A 5A t 0 25A 4 375 4 375 0 24 3 75 3 75 0 2A 3 125 3 125 0 15 A 2 5 2540 15 A 1 875 1 875 0 125 1 25 1 25 0 125 0 625 0 625 0 1 A Drive
24. ED 0 2 Tau 50usec POT R43 118mV 0 01uF 16 2K 20 Note means other connection is not shown kg v v 3 8 6415 Installation and Hardware Reference Manual Rev E External analog input with internal RUN SPEED pot 8V ACCEL S 2 E POT R14 35 4 o _ B 1M 9 E3 a cw a 6 cof gt z 2 10 9 g i 7 99V 10K a J4 6415 cw f 1 deo eet Motion Profile zo 444 R Generator and __ STEP 5 6 UN STOP OUT RUN SPEED j El Controls VGO POT R7 El eae P Speed cma lt 150 8V ANALOG v co ew peed INPUT gt H 9 4 Lany 9 J4 6 AQ X 162K a E cw 25K T zr 0 01uF 6 04V E l 1K DECEL a e gt n ANALOG cw 7 POT R17 E J4 18 INPUT 10K 10K Gain 0 81 LOW SPEED s WV vv Tau 50usec POT R43 118mV 0 0luF 16 2K 20 Note Z means other connection is not shown gt E E 6415 Installation and Hardware Reference Manual Rev E o 2 D c E gt O A Frequency Range E2 jumper sets the VCO maximum output pulses frequency range Settings There are two frequency ranges selectable by a jumper to enhance output speed resolution E2 Frequency Range IN Low Frequency 250 Khz maximum VCO output pulses OUT High Frequency 500 Khz maximum VCO output pulses Coarse Resolution E2 Removed Speed Resolution 62 5Khz V
25. Ejector 6415 Drive and motor functioning in a clutch brake application Shipping Container D 2 6415 Installation amp Hardware Reference Manual Rev E rns D 3 6415 Clutch Brake Cut and Seal Machine uses 6415 Oscillator Microstepping Drive Module to accurately index pinch rolls so plastic web is in position for cutting and sealing into bags Feed spool Photoelectric Separate Run Stop position sensor Thermal cutter sealer Pa Plastic Pacific Scientific Model 6415 Oscillator Micro Stepping Drive Module Application Examples 6415 Installation amp Hardware Reference Manual Rev E D 3 D 4 6415 Shingle Catcher Roofing shingle machine uses 6415 Oscillator Microstepping Drive Module to catch and stack fast moving shingles and then place them in a bundle forming chamber shingles Start wheels Right angle gearboxes Pacific Scientific Model 6415 Oscillator Micro Stepping Drive Module Bundle P4 D 4 6415 Installation amp Hardware Reference Manual Rev E Appendix E CE Installation Guide Introduction Customer Responsibility The information contained in this appendix applies to the 6415 ONLY The 6415 is designed for use within machines that require compliance with European Safety and EMC Directives The standards that the 6415 complies with are described in the Declaration of Conformity on the following page Note The informa
26. P 34 21 STOP J4 9 Optically isolated input that terminates motor rotation In separate latched input mode the STOP opto is placed in the STOP state when the STOP opto is driven momentarily In single STOP mode the STOP opto is controlled directly from the STOP input The 6415 is designed to be in the STOP state after applying power to insure that motion does not occur unintentionally 6415 Installation and Hardware Reference Manual Rev E 21 z fe Ng 7 Table cont d Input Output Pin s Explanation DIR J4 22 Optically isolated input that determines DIR 34 10 the direction of motor rotation If standard motor wiring is followed the motor will turn clockwise if the opto current 1s zero The sense of the DIR input can be reversed by reversing the connection of either but not both motor phase connectors i e switching A and A OR B and B Refer to the figure at the end of the table for timing and circuit information ENABLE J4 23 Optically isolated input used to enable or disable the 6415 s power stage With the enable sense J6 5 6 jumper out factory ENABLE J4 11 default the power stage is enabled if the opto current is zero and disabled if the opto is driven Inserting the jumper reverses this functionality See figure at the end of the table for circuit information There is a delay of approximately 500ms after
27. Pacific SCIENTIFIC HIGH PERFORMANCE MOTORS amp DRIVES 110 Fordham Road Wilmington MA 01887 978 988 9800 Fax 978 988 9940 Part MA6415 List Price 25 U S December 1998 RevE MA6415 6415 Oscillator Drive Installation amp Hardware Reference Manual This document 1s copyrighted by Pacific Scientific Company It 1s supplied to the user with the understanding that it will not be reproduced duplicated or disclosed in whole or in part without the express written permission of Pacific Scientific Company Copyright 1996 1998 WARRANTY AND LIMITATION OF LIABILITY Includes software provided by Pacific Scientific Pacific Scientific warrants its motors and controllers Product s to the original purchaser the Customer and in the case of original equipment manufacturers or distributors to their original consumer the Customer to be free from defects in material and workmanship and to be made in accordance with Customer s specifications which have been accepted in writing by Pacific Scientific In no event however shall Pacific Scientific be liable or have any responsibility under such warranty if the Products have been improperly stored installed used or maintained or if customer has permitted any unauthorized modifications adjustments and or repairs to such Products Pacific Scientific s obligation hereunder is limited solely to repairing or replacing at its option at its factory any Products or
28. RUN SPEED to allow for accurate stopping It can also be used as a second RUN SPEED ACCEL RAMP is typically set to minimize time to reach RUN SPEED without allowing the motor to stall The DECEL RAMP is linear and stable allowing a more precise repeatable stopping Q i 5 position 92 The figure below shows the typical velocity pulse frequency profile in response to separate RUN STOP and RUN LOW o commands A Separate command signals RUN SPEED DECEL src RAMP ACCEL RAMP 4 LOW SPEED y MIN SPEED 0 RUN gt lt 50 mSEC MIN DENARII ERE ET Nacsa LOW SPD CT LOW STOP 50 mSEC MIN 0 Riis Shs fac Sind a ws is ld 6415 Installation and Hardware Reference Manual Rev E 3 3 Single Command The figure below shows the typical velocity pulse frequency Signal profile in response to a single RUN STOP command RUN SPEED ACCEL DECEL RAMP RAMP MIN SPEED du Mcd ap STOP STOP RUN 0 Acceleration rate is non linear resulting in an exponential velocity ramp Deceleration rate is constant resulting in a linear velocity ramp Accel Ramp Potentiometer R14 and Decel Ramp Potentiometer R17 adjust the time for acceleration and deceleration With fixed accel potentiometer and step size settings the acceleration rate is a function of speed control inputs For example increasing the run speed command by a factor of two will result in t
29. X j EARTH SAFETY GROUND 6420 6415 Installation amp Hardware Reference Manual Rev E AN Warning Power supply design must insure that the voltage between J2 2 and J2 1 never exceeds 75 volts under any operating conditions These conditions include high line voltage transformer regulation effects voltage spiking due to current switching within the module and regeneration Failure to do this can result in permanent damage to the 6415 C 1 1 Line Transformer Selection Primary voltage and frequency rating Secondary voltage rating Make sure that the transformer is guaranteed to operate at the highest line voltage combined with the lowest line frequency that will ever be used to power your system Failure to do so can result in saturation large current increases and winding failure Maximum motor speed performance will be achieved by using as high a motor supply voltage as possible without ever exceeding 75 volts Of course lower voltages can also be used so long as the voltage is greater than the minimum specified value of 24 volts but motor torque will drop more rapidly as speed increases The peak bus voltage excluding any spiking due to current switching in the drive module or any regeneration effects is approximately equal to 1 414 Actual Secondary rms voltage 1 5 Note This assumes a 0 75 volt drop across each rectifier diode To insure this as well as to discharge the bus capacitor whe
30. agnetic and mechanical characteristics of a stepping motor system The compensation circuit damps mid range oscillations by advancing or delaying switching of the output current relative to the incoming pulse train Idle current reduction ICR enables or disables idle current reduction which reduces motor winding current by 50 of its rated value during motor dwell periods ICR begins 0 1 second after the last input step pulse occurs This delay can also be set to 0 05 seconds or 1 second using a plug on jumper Note The current will return to 100 at the next step pulse 6415 Installation amp Hardware Reference Manual Rev E Using plug on jumpers Step filter when enabled jumper installed rejects noise pulses on step input less than 500ns wide Useful if maximum step rate is 500 KHz D e o gt o Enable sense allows the polarity of the enable input to be reversed With the jumper installed the enable input opto isolator must be driven to enable the drive With the jumper removed enable input opto isolator must be driven to disable Run and or Stop controls allows for independent inputs or a single input for Run Stop With separate input control mode E4 jumper installed the 6415 1s controlled by two separate optically isolated inputs This separate input control mode is useful for functioning in a clutch brake application In the single input mode E4 jumper removed the drive run or stop is controlled di
31. apter 3 1 4 Warranty The Pacific Scientific 6415 drive has a two year warranty against defects in material and assembly Products that have been modified by the customer physically mishandled or otherwise abused through miswiring incorrect switch settings and so on are exempt from the warranty plan 6415 Installation amp Hardware Reference Manual Rev E 1 9 2 Installing the 6415 In this chapter This chapter explains how to install the 6415 stepper motor drive Topics covered are e Unpacking and inspecting the 6415 Installing and using the 6415 unit safely e Selecting other system components e Mounting the 6415 in your installation fe im Ng io 7 e Connecting input output cables 2 1 Unpacking and Inspecting Unpacking 1 Remove the 6415 from the shipping carton Make sure all procedure packing materials are removed from the unit 2 Check the items against the packing list A label located inside the chassis of the unit identifies the unit by model number serial number and date code Inspection Inspect the unit for any physical damage that may have been procedure sustained during shipment If you find damage either concealed or obvious contact your buyer to make a claim with the shipper Do this within 10 days of receipt of the unit Storing the unit After inspection store the drive in a clean dry place The storage temperature must be between 55 degrees C and 70 degrees C To prev
32. ardware Reference Manual Rev E 3 11 Minimum Speed E5 jumper sets the VCO minimum output pulses frequency Threshold threshold depending on the E2 jumper configuration Steps below Setting this frequency are inhibited to insure no movement at end of decel ramp This functionality can be disabled by inserting jumper E5 ES MIN SPEED Frequency IN Disable minimum speed OUT Enable minimum speed Min Speed Threshold 4 Khz Max for high frequency range 2 Khz Max for low frequency range Direction Command Setting DIR DIR This optically isolated input controls the direction of motor rotation when the E6 E7 and E8 jumpers are removed Motor rotation is CCW if the opto is driven and CW otherwise The direction of motor rotation can also be controlled by the analog input or plug on jumpers as shown Control Jumper Jumper Jumper DIR Opto Analog In Rotation Source E6 E7 ES DIR DIR Out Out Out Driven CCW Out Out Out Not Driven CW Jumpers In In Out Driven CCW Out Out Out Not Driven CW Analog In In Out In Driven Negative CCW In Out In Not Driven Positive CW 3 12 6415 Installation and Hardware Reference Manual Rev E Oscillator The 6415 Enable input factory default is the drive is enabled Enable unless the Enable opto is driven However this functionality can be reversed by inserting jumpe
33. ation vs output current Figure 1 WATTS 25 20 15 10 0 625 1 25 1 875 2 5 3 125 3 75 4 375 5 0 AMPS RMS 0 fa fe 2 o E O D Q o 6415 Installation and Hardware Reference Manual Rev E A 7 Mechanical Dimensions Weight Connectors Power Supply Signal Motor Refer to Section 2 4 1 0 Ib nominal PCD ELVH0310 connector Mating connector PCD ELVP03100 25 contact female D connector Mating connector ITT Cannon DB 255 with ITT Cannon DB110963 3 Hood PCD ELVH0510 connector Mating connector PCD ELVP05100 6415 Installation and Hardware Reference Manual Rev E Appendix B Ordering Information fe a i z E fe i Background This appendix lists 6415 part numbers and gives information on ordering 6415 part number table Pacific Scientific Part Order Comment Stepper Drive 6415 Connector Kit CK6415 25 pin D connector 5 pin PCD 3 pin PCD Installation and MA6415 Hardware Manual Motor Cable SPC xxx 6410 Xxx represents length in feet for example SPC 005 6410 is a cable 5 feet long For lengths over 50 feet contact Pacific Scientific The connectors are MS on the motor end and PCD on the drive end to connect to Pacific Scientific motors Heatsink HS6410 Heatsink with mounting hardware Cover CV6415 Cover with mounting hardware 6415 Installation amp Hardware Reference Manual Rev E How
34. circuit Chopper frequency Two phase bipolar chopper current regulated 20 KHz nominal 6415 Installation and Hardware Reference Manual Rev E A 1 o fe 2 o o o Q o Step size Switch settable Steps motor revolution 1 8 stepper motor Full 1 2 200 400 1 2 1 4 400 800 1 5 1 8 1000 1600 1 10 1 16 2000 3200 1 25 1 32 5000 6400 1 50 1 64 10000 12800 1 125 1 128 25000 25600 1 250 1 256 50000 51200 Signal input See circuit diagram Section 2 5 3 requirements Optically Isolated Inputs Input Min Input Current Max Input Max Reverse Opto ON Current Voltage J4 19 J4 7 Low Speed 3 0 mA 4 5 mA 5 volts J4 22 J4 10 Direction 3 0 mA 4 5 mA 5 volts J4 23 J4 11 Enable 3 0 mA 4 5 mA 5 volts J4 20 J4 8 Run 3 0 mA 4 5 mA 5 volts J4 21 J4 9 Stop 3 0 mA 4 5 mA 5 volts A 2 6415 Installation and Hardware Reference Manual Rev E Signal output See circuit diagram Section 2 5 3 characteristics J4 1 100KQ Input Impedance VCO Input Monitor J4 2 J4 14 50 mA max 25 C Ambient J4 15 25 mA max 50 C Ambient 8 V Ref Out J4 3 IMQ Input Impedance External Pot J4 12 J4 13 100 ma Max Max Reverse voltage 50 Vdc 25 C Ambient J4 24 J4 25 50 ma Max Max Reverse voltage 50 Vdc 50 C Ambient Step Out Maximum 500 KHz step rate Run Direction The figure below show the required timing relatio
35. closed during operation Braided cable shields should be connected to protective earth ground Mount the drive to a conductive surface of the machine chassis to ensure a good high frequency ground If the chassis is painted or coated with another nonconductive coating remove the coating from the mounting location prior to mounting the drive To avoid the risk of crosstalk motor and command I O cables should be kept away from sensitive signal cables such as telephone and intercommunication lines 6415 Installation and Hardware Reference Manual Rev E Cable shielding The following information is not required for CE compliance of a and grounding single axis installation When planning a multi axis installation or im ae 7 LL oO if extra high frequency noise reduction is required Pacific Scientific suggests n addition to the cable requirements given in this manual the motor and signal interface cables should have a braided shield which can be grounded to reduce high frequency disturbances The motor cable shield must be grounded near the drive with a suitable high frequency ground Such a ground connection 1s made by removing the cable s outer insulation to expose the braided shield then clamping the exposed braid to a conductive surface of the machine chassis If the chassis is painted or coated with another nonconductive coating remove the coating from the clamping location prior to clampin
36. d by multiplying the specified secondary voltage Volts rms by the rated secondary current Amps rms For example a 24 Vac transformer with a rated secondary current of 1 Amp has a VA of 24 6415 Installation amp Hardware Reference Manual Rev E C 3 Current Rating Example Based upon these considerations the table below gives the highest allowable rated secondary voltage when using a line with 10 voltage tolerance Transformer VA Maximum Rated Rating Secondary Voltage 1 100 44 7 Vac 100 350 45 5 Vac gt 500 46 8 Vac The average current load of the 6415 is a function of the motor used as well as motor speed and torque To optimize the power supply design the supply current can be measured using a DC current meter when the motor is producing the highest shaft power If it is difficult to make this measurement assume the maximum average load current equals the selected phase current Thus if the DIP switch is set for 5 Amps RMS assume the maximum average power supply current is 5 amps The average transformer secondary current equals the sum of the average currents for all 6415s powered by the supply Because the transformer supplies pulses of current to charge the bus capacitor s on the other side of the diode bridge the rms current is higher than the average current The transformer should have a rated secondary rms current of at least 1 8 times the average current T
37. ectronic damping enabled Idle current reduction enabled 5 Arms motor current Warning If the motor is rated at less than 5 A rms winding current set positions 6 7 amp 8 accordingly 3 20 6415 Installation and Hardware Reference Manual Rev E Procedure cont d Warning Make sure power is removed before proceeding 3 Check that Jumper J6 is set as follows These settings reflect the following Idle Current Reduction Enabled 0 1 second delay 6415 enabled without enable input driven Decimal step size selected o D c E gt O A Step input filter enabled 4 Switch On power Signals test 1 Connect the motor leads and power supply wires to the 6415 Oscillator Board connectors as shown in Section 3 1 Note J on the lower board is not used 2 Wire the control signals for the independent RUN STOP and DIRECTION control into connector J4 3 Pull the RUN signal Low J4 8 and the motor will ramp up to speed Pull the STOP signal low J4 9 and the motor decelerates to a stop When the DIRECTION signal is pulled low J4 10 the motor will run in the CCW direction looking at the motor shaft If the desired rotation for a low signal is CW swap the connections of the motor leads on pins J3 1 and J3 2 Note Remove power from the drive before swapping the leads 6415 Installation and Hardware Reference Manual Rev E 3 21 Procedure cont d Getting help 3 22 4 If the
38. ejes Place Date Wilmington MA USA 10 29 98 Legally binding Signature E 2 6415 Installation and Hardware Reference Manual Rev E CE Test Set Up The 6420 was determined to be the noisiest configuration for the 64xx family Therefore it was used for all EMC testing Motor N32 HCHJ LNK NS 00 All mounting surfaces are free of paint Metal Plate Motor Cable SPC 020 6410 All other cables are in accordance with Chapter 2 of this manual All D Sub connectors have metallic hoods z Wire to Earth Ground Rail AWG 3 0 or larger 24 75 VDC Power Supply T lal 0 Li2 3 4 pem o oed Eg fe To Earth Ground rail To Mains 6415 Installation and Hardware Reference Manual Rev E E 3 im EI Eg 7 LL oO Safety Drive mounting Cable Routing In addition to the safety guidelines given in Section 2 2 observe the following Electronic drives contain electrostatic sensitive devices which can be damaged when handled improperly Qualified personnel must follow ESD protection measures For example wear grounded heel and wrist straps when contacting drive Follow IEC 536 2 and IEC 1140 for installation protection against electric shock Installation shall be performed in accordance with local electric codes local accident prevention rules and EN 61800 3 All covers shall be
39. ent damage during storage replace the unit in the original shipping carton 6415 Installation and Hardware Reference Manual Rev E 2 1 2 2 Installing and Using the 6415 Unit Safely Your responsibility LN Safety guidelines As the user or person applying this unit you are responsible for determining the suitability of this product for any application you intend In no event will Pacific Scientific Company be responsible or liable for indirect or consequential damage resulting from the misuse of this product Note Read this manual completely to effectively and safely operate the 6415 unit Warning The circuits in the 6415 drive are a potential source of severe electrical shock Follow the safety guidelines to avoid shock To avoid possible personal injury whenever you are working with the 6415 unit Do not operate the drive without the motor case tied to earth ground Note This is normally done by connecting the motor s case to J3 5 of the 6415 and connecting J2 3 of the 6415 to earth ground e Do not make any connections to the internal circuitry The input and output signals are the only safe connection points e Always remove power before making or removing connections from the unit e Be careful of the J3 motor terminals when disconnected from the motor With the motor disconnected and power applied to the drive these terminals have high voltage present even with the motor disconnected e Do not use t
40. g the shield It is important that the clamp chosen be conductive and provide a full 360 degree connection 69999 40mm gt 15mm Wrap the end of the shielding in wire and solder it x Shielding L Motor connector I max 40 cm Note Ground shield to machine chassis with a metal clamp providing a 360 degree termination cable Motor Clamp cable Machine Chassis 6415 Installation and Hardware Reference Manual Rev E E 5 The signal interface cable shield should be grounded to the drive through the 9 pin D sub connector s conductive hood If the cable connector does not provide a 360 degree ground connection to the shield the signal interface cable should be grounded in accordance with the instructions given in the previous paragraph for the motor cable For additional information please contact the factory to request e Application Note 106 Reducing Motor Drive Line Noise e Application Note 107 Reducing Motor Drive Radiated Emissions 6415 Installation and Hardware Reference Manual Rev E o 2 5 o Connection Diagram im Eg i 7 i LL oO J4 J1 STEP OUT 43 STEP OUT 25 2 STEP OUT 4 3 STEP_OUT 24 ENABLES 11 PaciFic 5 NOT USED ENABLE 23 SCIENTIFIC 6 DIR 49 gt o 6415
41. ge Low voltage supply out of tolerance 6415 Installation and Hardware Reference Manual Rev E 4 o o ta c o S c Use the troubleshooting table to diagnose and correct most problems If you are unable to achieve satisfactory operation contact your local Pacific Scientific Distributor or the Applications Engineering Department IMPORTANT NOTE If you suspect that the 6415 drive has been damaged DO NOT simply replace it with another and apply power Re check the power supply design and verify that it meets all requirements Improper supply design is the most common cause for damaged drives Corrective action table SYMPTOM CORRECTIVE ACTION Motor produces no torque enabled LED not lit Ensure that the J6 5 6 jumper is out or if in that the enable input opto is driven with at least 3 mA Disconnect the motor cable and cycle the J2 power supply Off and On If the enabled LED lit check the step output and VCO input monitor point Also check motor cable and motor for shorts across the windings or between the windings and the motor case Check that the J2 power supply voltage is 2 24 Volts and lt 75 Vdc If possible check with an oscilloscope to verify that this is true on a transient basis Motor produces no torque enabled LED lit Verify that DIP Switch S1 position 6 7 and 8 current select are set correctly Re check that the motor cable is wired correctly and proper
42. gital electronic damping ON OFF e Idle current reduction e Enable sense e Step filter response time Oscillator Board MPR swi _Drive Board Side View 6415 ENABLE SENSE J UMPER IN OPTO ON TO ENABLE OUT OPTO OFF TO ENABLE IDLE T JUMPER SELECT IDLE CURRENT REDUCTION TIME SEE TABLE BELOW J6 DEC JUMPER SEE SW1 TABLE BELOW IN SELECT DECIMAL STEP SIZES OUT SELECT BINARY STEP SIZES STEP BW JUMPER REMOVED AT FACTORY 5 JUMPERS 3 4 amp 7 8 INSTALLED AT FACTORY 8 4 PC CARD EDGE S1SIDE VIEW FACTORY DEFAULT POSITIONS SHOWN FACTORY DEFAULTS 5 0 AMPS RMS STEPSIZE 1 25 IDLE CURRENT REDUCTION ENABLED 0 1 SEC DIGITAL ELECTRONIC DAMPING CONTROL ENABLED DRIVER ENABLED UNLESS ENABLE OPTO DRIVEN SW1 POSITION 1 2 3 STEP SIZE DEC DEC MPR J MPR N OUT CLOSED CLOSED CLOSED CLOSED CLOSED OPEN CLOSED OPEN CLOSED OPEN OPEN CLOSED CLOSED CLOSED OPEN OPEN CLOSED OPEN OPEN CLOSED OPEN OPEN OPEN OPEN SW1 POSITION 7 CLOSED CLOSED OPEN OPEN CLOSED CLOSED OPEN OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN SWI swi IDLE CURRENT POSITION 4 DIGITAL ELECTRONIC DAMPING JUMPER POSITIONS REDUCTION IN CLOSED DISABLED CLOSED DISABLED OPEN ENABLED IN OPEN 0
43. he ENABLE input as a safety shutdown Always remove power to the drive for a safety shutdown 6415 Installation and Hardware Reference Manual Rev E 2 3 Selecting Other System Components Selecting external The 6415 drive requires an external 5Vdc 0 25 logic power analog input and supply for all user s control inputs and 0 to 10Vdc 0 10 logic input analog input power supply if the analog speed command is derived power supplies from external input source configuration Selecting a The 6415 is designed for use with Pacific Scientific s line of motor hybrid stepper motors or most other 2 phase stepper motors The drive works with either the standard line or the enhanced high performance line of stepper motors The motor winding current rating must be compatible with the output current of the drive package Refer to the Torque Speed Curves in the Pacific Scientific Motion Control Solutions Catalog or contact your local Pacific Scientific distributor for sizing and motor compatibility assistance Selecting bus A single power supply is required to operate the 6415 unit power supply Note n multi axis applications it is preferable to run each power connection from supply to drive and not daisy chain the power connections The power supply can vary from 24 to 75 Volts maximum at a maximum current of 5 amps It does not have to be a regulated supply Note The supply voltage cannot exceed 75 volts The bus overvol
44. he transformer used to supply three 6415 drive modules each set for 5 Amps rms should have a rated secondary rms current of 1 8 5 5 5 27 amps or greater Note t is generally not advisable to significantly oversize the transformer because this will increase rectifier surge current during turn on as well as capacitor ripple current 6415 Installation amp Hardware Reference Manual Rev E C 1 2 Rectifier Diode Selection Voltage rating For the bridge rectifier configuration shown the peak inverse voltage PIV equals 1 414 times the secondary rms voltage For example a 40 Vrms secondary will develop 1 414 40 56 6 PIV across the rectifier diodes To allow for line variation and spiking allow at least a 50 safety factor in the diode rating Therefore the PIV rating of the rectifier diodes should be at least twice the rated secondary rms voltage Current Rating Since each diode conducts only on alternate cycles the average diode current will be half the supply s average DC current load on the supply When power is first applied there is a surge of current to charge the capacitor s which must be less than the diode s peak one cycle surge current Ips rating Typically diodes are chosen with an average current rating of at least twice the average current load of the supply It is often advisable to select diodes with an even greater average current rating because they have lower thermal resistance between junction and
45. iagram connectors already attached install as follows Ol 00999 3 JACKET A 1 A BLK A MOTOR z 5 E B PHASES g 3 uk B snc P CASEGND 5 KG E 5 Pin PCD SPC XXX 6410 5 Pin MS Connector 6415 MOTOR Note All wires are 16 AWG 2 10 6415 Installation and Hardware Reference Manual Rev E Making your To make your own motor cable follow the guidelines given below own cable for wiring to the J3 mating connector Depending on your motor configuration refer to the appropriate diagram at the end of this section to determine the motor connections required J3 connection table o S Output Pin Explanation T EI 7 Motor Phase A J3 1 Motor Phase A excitation Motor Phase A J3 2 Todsted Pain Motor Phase B J3 3 Motor Phase B excitation Motor Phase B J3 4 Puede Drive Case J3 5 Connected to the motor case Earth Ground ground Mating The J3 motor connector on the 6415 mates to a PCD 5 pin screw connector cable connector The mating cable connector is type ELVP05100 Cable The mating connector terminals will accept 16 to 28 AWG wire requirements However use 16 AWG or heavier for motor phase excitations For the motor cable use cable with two twisted pairs twisted at about 3 to 4 turns per inch 1 to 1 5 turns pe
46. ion or shock Minimum unobstructed space of 4 inches 10 cm above and below the unit Maximum ambient temperature of 50 C and maximum 6415 chassis temperature of 60 C 2 5 Connecting to the 6415 Introduction The four input output I O connectors are JI Not used J2 Power connector J3 Motor connector J4 Signal connector These inputs and outputs are shown on the following page 6415 Installation and Hardware Reference Manual Rev E 2 z fe Ng T 7 Connection diagram J4 STEP OUT 45 STEP OUT 25 STEP OUT 45 STEP OUT 24 ENABLE 11 ENABLE 23 DIR 10 DIR 22 STOP 9 5 STOP 21 B RUN 9 o me RUN 20 5 LOW_SPD 7 5 c LOW SPD4 19 o O ANALOG INPUT 6 p ANALOG _INPUT 18 Qo u GNDA 5 2 GNDA 17 GNDA 4 GNDA 16 EXTERNAL POT 3 8V_REF_OUT 15 8V_REF_OUT 5 8V REF OUT 14 VCO INPUT MON 1 Pacific SCIENTIFIC 6415 OSCILLATOR DRIVE J1 1 2 3 4 5 NOT USED 6 7 8 9 J2 DC 1 DC Unregulated E 24Vdc to 75Vdc 3 Case GND 3 1 Phase A 2 Phase A 3 Phase B 4 Phase B 5 Case GND 6415 Installation and Hardware Reference Manual Rev E Wiring is application specific Noise pickup reduction Shock hazard reduction Wiring sizes wiring practices and grounding shielding techniques described in
47. is Manual 1 4 Warranty 2 Installing the 6415 2 1 Unpacking and Inspecting 2 2 Installing and Using the 6415 2 3 Selecting Other System Components 2 4 Mounting the 6415 Unit 2 5 Connecting to the 6415 2 5 1 J3 Motor Connections 2 5 2 J2 Power Connector 2 5 3 J4 Signal Interface Connector 3 Powering Up the 6415 Drive 3 1 Oscillator Board Settings 3 1 1 Potentiometer Settings 3 1 2 Jumper Settings 3 2 Drive Board Settings Switch S1 amp Jumper J6 3 2 1 Step Size 3 2 2 Digital Electronic Damping Control 3 2 3 Idle Current Reduction 3 2 4 Setting Motor Current 3 2 5 Enable Sense Control 3 2 6 Step Bandwidth Adjustment 3 3 Testing the Installation 6415 Installation amp Hardware Reference Manual Rev E 4 Maintaining Troubleshooting 4 1 4 1 Maintaining the 6415 Drive ee 4 1 4 2 Troubleshooting the 6415 Drive 2 2 a ee 4 1 Appendix A Specifications A 1 Appendix B Ordering Information B 1 Appendix C Power Supply Considerations C 1 Appendix D Application Examples D 1 Appendix E CE Installation E 1 Index Rev E 6415 Installation amp Hardware Reference Manual 1 Overview of the 6415 In this chapter This chapter introduces the 6415 stepper drive Topics covered are e 6415 definition Other system components e System diagram e How to use this manual e Warranty information 1 1 6415 Definition Overview The Pacific Scientific 6415 Oscillator Microstepping Drive Module is an economical
48. jumper installed the enable input must be driven current in opto for the 6415 power stage to be enabled o D c E o gt O A 3 2 6 Step Bandwidth Adjustment A digital filter can be enabled which reduces susceptibility to noise on the step input at the expense of a lower limit on maximum step frequency With Jumper J6 positions 1 2 installed the filter is enabled and step pulses must have a minimum width of one microsecond Pulses less than 0 5 microseconds in width will be rejected With the filter disabled Jumper J6 position 1 2 removed step pulses must be a minimum of 0 25 microseconds wide 6415 Installation and Hardware Reference Manual Rev E 3 19 3 3 Testing the Installation Background The following procedure verifies that the 6415 is installed properly and that it was not damaged during shipment Procedure After installing the 6415 as described in Chapter 2 test your installation as follows Warning Perform this initial power up with the motor shaft disconnected from the load Improper wiring or undiscovered shipping damage could result in undesired motor motion Be prepared to remove power if excessive motion occurs Connections test 1 Check all wiring and mounting to verify correct installation 2 With the power Off check that S1 is set as follows factory default settings These settings reflect the following Step size of 1 25 Digital el
49. llator The Oscillator board mounts on the Drive board and is separated by standoffs Drive The drive has an eight position DIP switch S1 and a group of four jumpers J6 controlling drive current digital electronic damping idle current reduction and binary or decimal step size The DIP switch S1 is easily accessible without removing the Oscillator card The default factory set jumpers are usually suitable for most applications but can be modified if necessary The jumpers J6 may be removed using needle nose pliers To reinstall the jumper loosen the screws on the oscillator board If the oscillator board must be removed it must be re aligned properly before tightening the screws o D c O A Warning When installing the oscillator board make sure the 20 pin connector is aligned properly Misalignment will seriously damge the drive Oscillator The Oscillator has four multi turn potentiometers R7 R14 R17 and R43 and eight plug on jumpers E1 through E8 controlling motor run speed low speed accel decel high low frequency range min speed threshold enable or disable run stop command separate latched input or single input mode and direction control 6415 Installation and Hardware Reference Manual Rev E 3 1 3 1 Oscillator Board Settings Location of Note Default settings are in bold jumpers and pots Oscillator Board i MPR SW1 I
50. ly plugged into the drive Motor produces torque but does not turn Make sure that the STEP output 1s switching 6415 Installation and Hardware Reference Manual Rev E Table cont d SYMPTOM CORRECTIVE ACTION Motor rotates in Check polarity of the DIRECTION input Also verify that the the wrong direction selection jumpers E6 E7 E8 are set correctly direction Reverse the A and motor phases Motor does not Check that the step size setting of the drive and speed reach expected potentiometer are set correctly position Verify that the motor does not stall If it does 1 Re check sizing calculations Be sure that the power supply voltage is high enough for the required torque vs speed curve 2 Use a finer step size to avoid low speed resonance problems 3 Enable Digital Electronic Damping S1 position 4 OFF Enabled LED not 1 Turn the bus power off lit drive is 2 Disconnect the motor winding from the drive disabled Turn the bus power back to on If the Enabled LED is still not lit check that the 8V reference output 8V REF OUT is within specifications 4 Remove any external connections to the enable input opto ENABLE and check to see that the enable sense jumper J6 5 6 is removed factory default 5 Reapply the power If ENABLED LED is still not lit drive has an internal short o2 o o ta c c o S c
51. microstepping drive with an integral ramped oscillator card The ramped card contains a stable wide range voltage controlled oscillator VCO and associated control circuitry which provides step pulses and direction command signals to the drive card The drive card converts step and direction command signals into motor winding currents to control a two phase stepper motor Principal features include independent acceleration and deceleration profiles which enable the motor to be operated at high speed in a reasonable time In addition microstepping and digital electronic damping provide for high resolution and smooth operation through both the low speed and mid speed resonance regions Run speed pulse frequency is controlled by an on board potentiometer an external user s potentiometer or a bipolar external analog input voltage Acceleration and deceleration ramps are also potentiometer controlled When a bipolar analog voltage is used as the input the direction command is derived from a polarity detector on the ramped oscillator card Deceleration can include a slow speed adjustable potentiometer before stopping to enhance accuracy of stopping position Control signals are optically isolated 6415 Installation amp Hardware Reference Manual Rev E 1 1 D e o gt Oo Drive features The output current of the 6415 is dip switch selectable from 5A rms 7 1A peak in microstep mode to 0 625A rms 0 88A peak in microstep mode
52. n AC power is removed it is recommended that a bleed resistor be placed across each bus capacitor as shown 6415 Installation amp Hardware Reference Manual Rev E Example If for example the secondary rms voltage is 40 Vac the peak bus voltage will be 1 414 40 1 5 55 volts A transformer with 115 Vac primary and 40 Vac secondary would produce 55 volts peak bus voltage under nominal line conditions and at rated loading However if the line voltage increases 10 the peak bus voltage increases to 1 414 1 1 40 1 5 60 7 volts at rated transformer loading gt 2 Q O Load regulation must also be accounted for when selecting the Qa 5 transformer Transformers are designed to produce their specified E secondary voltage when loaded by their rated current For currents less than rated the secondary voltage will increase 7 Signal Transformer gives the following load regulation data for e 5 its line of rectifier transformers eS VA Rating Load Regulation 1 100 10 100 350 8 gt 500 5 or less This means that the secondary voltage of a 100 VA transformer will increase 10 over the specified voltage if the load current is reduced from rated current to zero Since the stepper drive s might sometimes be disabled the full regulation effect as well as maximum line voltage should be considered when selecting the transformer 1 The VA product is obtaine
53. n the following page A simple non regulated supply is used for this example DC and DC should be run from the power supply s capacitor to the 6415 as a twisted pair no longer than 3 feet in length shielding with the shield connected to earth ground can reduce noise emissions A Buss MDA 10 A slow blow fuse or equivalent should be included in the power supply between the rectifier and capacitor as shown IMPORTANT NOTE It is extremely important that the supply voltage never exceed 75 volts even on a transient basis This is one of the most common causes of drive failures Wiring inductance between the 6415 power input and the external capacitor is significant because a PWM chopper drive requires pulse currents Therefore it is extremely important that the two be connected by a twisted pair no longer than three feet in length 6415 Installation and Hardware Reference Manual Rev E 2 17 Connection diagram BUSS MDA 10 FUSE 2 TWISTED Ld Ld AC IN n f EARTH 3FEET MAX w HN m GROUND SINGLE AXIS 3 FEET MAX BUSS 3 MDA 10 2 3 RUSE TWISTED e hd e 2 1 AC IN 3 ee e J1 e o 77 EARTH GROUND BUSS MDA 10 PESE FUSE TWISTED e e 2 1 ep 3 o e e TO OTHER AXES MULTIPLE AXES Cable Use 16 AWG
54. nship between timing the RUN and DIRECTION inputs requirements MOTION BEGINS WITHIN 50us 4 k 50 us MIN RUN ESA SETUP TIME 50 us MIN DIRECTION NOT DA ft DIRECTION DATA MUST BE STABLE OVER THIS INTERVAL o fa fe 2 o o o Q o 6415 Installation and Hardware Reference Manual Rev E A 3 Minimum ramp 50 milliseconds This restriction only applies with digital time for step electronic damping circuit enabled rate Accel Decel Driver state 1 With digital electronic damping circuit enabled at pulse generator frequencies less than 500 full steps sec delay is less than 500 transition delay usec At frequencies greater than 500 full steps sec delay is oo to input less than 270 of the input pulse period 2 With digital electronic damping circuit disabled delay is less than 10 usec at all step frequencies RUN SPEED Control Analog Input Analog Input 10 Vdc Range Also controllable with internal or external potentiometers Analog Input 20 KQ differential amp Impedance High Frequency Range RUN SPEED 8 KHz to 500 KHz Control LOW SPEED 8 KHz to 370 KHz Control A 4 6415 Installation and Hardware Reference Manual Rev E Low Frequency Range RUN SPEED Control LOW SPEED Control RUN SPEED LOW SPEED Stability Over Temp Range ACCEL RAMP exponential accel pot fully CW accel pot fully CCW DECEL RAMP linear decel pot fully CW decel
55. on board direction controls jumpers are removed Motor rotation is CCW if the opto is driven and CW otherwise The direction of the motor can also be controlled by the analog input or on board plug on jumpers E6 E7 and E8 Acceleration and deceleration controls Acceleration rate is non linear resulting in an exponential velocity ramp Constant deceleration rate resulting in a linear velocity ramp Accel Ramp Pot R14 and Decel Ramp Pot R17 adjust the initial acceleration and deceleration rate of the motor from 0 4 msec to 0 4 sec accel single time constant and 6 0 msec to 1 4 sec decel time Run speed and low speed controls Run Speed Potentiometer R7 and Low Speed Potentiometer R43 both independent speed potentiometers set the steady state run speed of the motor when the optically isolated input RUN STOP or LOW_SPD opto is driven The motor speed ramps up from the selectable MIN SPD threshold enable or disable with E5 jumper until it reaches the final speed Run Speed Potentiometer adjusts the final motor speed from 8 KHz to 500 KHz and 4 KHz to 250 KHz for high and low frequency range operation Unlike the Low Speed Potentiometer which is adjustable from 8 KHz to 370 KHz and 4 KHz to 180 KHz for high and low frequency ranges 6415 Installation amp Hardware Reference Manual Rev E Typical applications Typical applications for 6415 include e X Y tables and slides e Packaging machinery e Robotics e Specialt
56. onsiderations apply as for back mounting Power dissipation vs current 15 10 0 625 1 25 1 875 2 5 3 125 3 75 4 375 5 0 AMPS RMS 2 4 6415 Installation and Hardware Reference Manual Rev E Heatsink mounting Panel mounting 6415 Installation and Hardware Reference Manual Rev E 2 5 If a cooling plate is not provided the optional heatsink available from Pacific Scientific can be mounted to the side of the 6415 and the combined unit mounted to a panel using the slots on the back of the 6415 as described above bookcase mounting With a minimum unobstructed space of four inches above and below the unit and cooling accomplished solely through convection no fan the 6415 can be run at 5 Amps RMS maximum for ambient temperatures of 25 C or less and 2 5 Amps RMS maximum for ambient temperatures of 45 C or less Using a fan to blow air past the heatsink will increase the allowable current significantly It is always required that the 6415 s chassis temperature not exceed 60 C It is best to confirm this by direct measurement with a temperature probe during system operation Any difference between the ambient temperature during the measurement and the worst case should be added to the measured chassis temperature The resulting sum must be under 60 C If the 6415 is mounted to a panel with no cooling plate and no heat sink a minimum unobstructed space of four inches above and below and one inch between the side plate and any other
57. or 1 0 second using DIP switch S1 position 5 and Jumper J6 position 7 8 With the jumper installed factory default ICR is disabled when DIP Switch S1 position 5 is in the closed position and enabled with a delay of 0 1 second current is reduced by 50 when no step command is received for 0 1 second when the switch is open With the jumper removed ICR is enabled and the delay can be set to 0 05 second or 1 0 second by placing DIP Switch S1 position 5 in the closed or open position respectively Note When ICR is active both the holding torque generated by the motor and the motor stiffness around the holding position are reduced by approximately 50 The ICR function e Reduces motor and drive heating during stand by operation 6415 Installation and Hardware Reference Manual Rev E 3 2 4 Setting Motor Current Motor current can be set using DIP Switch S1 positions 6 7 and 8 as shown Current should be compatible with motor current ratings Note Power dissipation in the 6415 drive increases as the output current is increased so that more cooling is required at high motor currents 3 2 5 Enable Sense Control The polarity of the enable input can be changed using Jumper J6 position 5 6 With the jumper removed factory default the drive is enabled when the enable input is not driven and disabled when driven current flows in enable opto This allows the 6415 to be used with no connection to the enable input With the J6 5 6
58. or system The circuitry used to control this phenomenon does so by advancing or delaying the switching of the output current with respect to the incoming pulse train This should be taken into account if the user is attempting to employ pulse placement techniques Enable the digital electronic damping function by placing DIP switch S1 position 4 in the open position as shown This is the default position and should be used for most applications 1f your application is affected by loss of torque at mid range speeds If pulse placement techniques are being used disable the digital electronic damping function by placing DIP switch S1 position 4 in the open position o D c E o O A Benefit This feature controls torque loss at mid range speeds When enabled the motor maintains torque at mid range operation provided the torque load does not exceed motor torque ratings 6415 Installation and Hardware Reference Manual Rev E 3 17 3 2 3 Idle Current Reduction Definition Benefits The Idle Current Reduction ICR function reduces the phase current at times when no motion is commanded Motor current is reduced when no step commands are received for a given time This time can be set to 0 05 seconds 0 1 seconds or 1 0 second Current to both motor windings is reduced by one half The ICR function can be enabled disabled and the time delay between the last step command and current reduction can be set to 50 ms 0 1 seconds
59. p resistors R2 should be added as shown A typical value of R2 is 2 7K Opto Supply to 6415 R1 12 Vdc 1 5K 15 Vdc 22K 30 Vdc 6 8 K USER S 6415 CONTROL j4 STEPPER ELECTRONICS DRIVE OPTO SUPPLY o LOW_SPD 19 TLP 621 2 21K TTL im LOW SPD 7 1K y gt R1 RUN 20 TLP 2601 TTL R2 SE id RUN 8 1K R1 STOP 21 i xx TLP 621 m je STOP 9 T ew R1 DIR 22 TLP 621 221K TIL gt m e DIR 10 K R1 ENABLE 23 pez 2 21K mr ENABLE 11 i 1K ye gt R1 6415 Installation and Hardware Reference Manual Rev E Mating The J4 signal interface connector is 25 contact female D connector connector The mating cable connector is an ITT Cannon DB 255 with ITT Cannon DB110963 3 Hood z fe u9 7 6415 Installation and Hardware Reference Manual Rev E 3 Powering Up the 6415 Drive In this chapter This chapter explains how to power up the 6415 drive after installation Topics covered are e Oscillator Board potentiometers and Jumpers El E8 e Setting up functions using switch S1 and Jumper J6 This section is intended to familiarize the 6415 user with the hardware adjustments and settings required to power up and operate the 6415 drive Introduction The 6415 drive is a two board assembly incorporating a Drive and an Oscillator card set The topmost visible board is the Osci
60. parts thereof which prove to Pacific Scientific s satisfaction to be defective as a result of defective materials or workmanship in accordance with Pacific Scientific s stated warranty provided however that written notice of claimed defects shall have been given to Pacific Scientific within two 2 years after the date of the product date code that is affixed to the product and within thirty 30 days from the date any such defect is first discovered The products or parts claimed to be defective must be returned to Pacific Scientific transportation prepaid by Customer with written specifications of the claimed defect Evidence acceptable to Pacific Scientific must be furnished that the claimed defects were not caused by misuse abuse or neglect by anyone other than Pacific Scientific Pacific Scientific also warrants that each of the Pacific Scientific Motion Control Software Programs Program s will when delivered conform to the specifications therefore set forth in Pacific Scientific s specifications manual Customer however acknowledges that these Programs are of such complexity and that the Programs are used in such diverse equipment and operating environments that defects unknown to Pacific Scientific may be discovered only after the Programs have been used by Customer Customer agrees that as Pacific Scientific s sole liability and as Customer s sole remedy Pacific Scientific will correct documented failures of the Program
61. pot fully CCW 4 KHz to 250 KHz 4 KHz to 180 KHz 1 of full scale typical 0 4 sec single time constant 0 4 msec single time constant 1 4 sec 6 0 msec 6415 Installation and Hardware Reference Manual Rev E A 5 o fe 2 o o o Q o MIN SPEED 4 Khz Maximum high frequency range 2 KHz Maximum low frequency range Steps below this frequency are inhibited to insure no movement at end of decel ramp This functionality can be disabled by inserting jumper E5 Note Motor rpm 0 3 Freq Hz step size For example If frequency 500 000 Hz and step size 125 rpm 1200 Environmental Operating Full rated current 0 to 50 C ambient air with or without cover Temperature provided chassis properly mounted so as not to exceed 60 C Storage 55 C to 70 C Temperature Maximum 60 C chassis temperature Humidity Range Note For optimal thermal performance mount the 6415 chassis back or side to a cooling plate or heatsink Use a thermal pad or grease if surface is irregular A fan or idle current reduction may be employed to keep chassis below 60 C 10 to 90 non condensing 6415 Installation and Hardware Reference Manual Rev E Convection 6415 not mounted on cooling plate Cooling With optional heat Full rating 5 A at 25 C Ambient sink 2 5 A max at 45 C Ambient Without heat sink 2 5 A max at 25 C Ambient 1 25 A max at 45 C Ambient See Figure 1 for plot of driver power dissip
62. proximately 20 KHz eliminating acoustical noise often associated with choppers 6415 Installation amp Hardware Reference Manual Rev E Acceleration and deceleration circuitry Acceleration rate is non linear which produces an exponential velocity ramp profile This method improves the acceleration profile since at low motor speed a higher acceleration rate 1s produced and a lower acceleration rate at high speeds Constant deceleration rate resulting in a linear velocity ramp allowing a more precise and repeatable stopping position The acceleration and deceleration rates are adjustable with the on board potentiometers to optimize system performance D e o gt o Two independent run speeds selected by using the Low Spd input The motor high speed range is controlled by the Run Speed potentiometer low speed range is controlled by the Low Speed potentiometer Low speed setting is typically selected prior to stopping the motor to improve stopping position repeatability It can also be used as an independent secondary speed Internal and or external speed command allows for stand alone and or speed following operation Separate latched and or single RUN STOP inputs allows for direct clutch brake replacement application Enabled LED indicator LED lit when drive is enabled and not lit when the drive is disabled or faulted Optically isolated signal interface connection optical isolation is provided on the RUN STOP
63. r J6 5 6 so that the opto must be driven to enable the drive Minimum opto current opto on 3 ma Maximum opto current opto on 4 5 ma USER S CONTROL ELECTRONICS JA 6415 m 5Vdc OPTO SUPPLY 5 T 23 ENABLE 9 221K TLP 621 s o Do 11 ENABLE 1K 3 ENABLE a DISABLE Oscillator LED is lit when drive is enabled A fault is indicated if the drive is Enabled LED commanded enabled but the LED is not lit 6415 Installation and Hardware Reference Manual Rev E 3 13 Oscillator The step pulse output from the VCO is available on J4 12 J4 13 External Step J4 24 and J4 25 This can be connected to up to four additional Pulse 6410 drives 6415 Step Pulse Out ya 6410 Stepper Drive 1 Step Input 8V_REF_OUT 4 2 _ Im 2 21K MZ ZU J4 12 J 1 6 464 TLP 2601 6410 Stepper Drive 2 Step Input J 1 1 e 221K SZ AU Step Output J 4 13 J 1 6 464 M TLP 2601 4 64K 6410 Stepper Drive 3 Step Input J 1 1 e vco MMBT2907 ALT1 221K SZ ZU J 4 24 J 1 6 464 t TLP 2601 6410 Stepper Drive 4 Step Input J 11 2 21K MZ A J4 25 J 1 6 464 TLP 2601 3 14 6415 Installation and Hardware Reference Manual Rev E 3 2 Drive Board Settings Switch S1 amp Jumper J6 Introduction Location of S1 DIP switch S1 and Jumper J6 on the drive board set the following e Step size e Motor current level e Di
64. r centimeter for the motor phase excitations and a fifth wire for the case ground As an option the cable may be shielded to reduce radiated noise A single shield can be used around both phase excitations and the ground wire or each phase excitation twisted pair can be individually shielded as in the Pacific Scientific cables Connect shields to pin 5 of the mating connector 6415 Installation and Hardware Reference Manual Rev E Cabling diagram J3 motor Motor Case K 2 Gnd Green Lu 7mm 5 To B Yellow ae 4 Motor B Red Q 7 mm A Orange 3 7 mm A Black 2T in M 7 mm 1 S Salie Note The colors in the diagram follow the Pacific Scientific stepper motor cable color code Procedure 1 Strip the wires to 0 27 in 7mm 2 Attach wires to connector as indicated in the diagram To Drive Note Make sure the screws on the PCD connector are tightened down firmly on the wiring Do not solder the tips of the cables before insertion into the Caution connector Solder can contract and cause a loose connection over time 2 12 6415 Installation and Hardware Reference Manual Rev E Flying Lead The figure below shows the connections required between the Connection 6415 connector J3 and Pacific Scientific motors having flying leads Connections are shown for 4 lead motors 8 lead motors with paralleled windings and 8 lead mo
65. rectly from the run input only Internal or External speed source the analog speed command is derived from the internal run speed potentiometer external user s potentiometer external analog input and external analog input scaled by internal run speed potentiometer sources depending upon the on board E1 and E3 jumpers setting configurations Oscillator frequency range sets the voltage controlled oscillator VCO output full scale frequency range With E2 jumper installed the maximum full scale VCO output frequency is set to 250 KHz for Run Speed and 180 KHz for Low Speed controls When removed E2 jumper the maximum full scale output frequency is set to 500 KHz for run speed and 370 KHz for low speed controls This feature offers user s selectable speed resolution for the best system performance Min speed control sets the minimum speed which is the initial motor speed The minimum speed is set to 4 KHz and 2 KHz maximum E5 jumper removed for high and low frequency range respectively Steps below this frequency are inhibited to insure no movement at end of deceleration ramp This functionality can be disabled by installing the on board E5 jumper Note Motor stalling may occur if this feature is used with step sizes less than 1 4 step 6415 Installation amp Hardware Reference Manual Rev E 1 5 Using on board potentiometer Direction controls This optically isolated input controls the direction of motor rotation when all
66. ronic damping control set up 3 17 step size set up 3 16 Safety 2 2 E 4 Series connection 2 13 2 16 Shock hazard reduction 2 9 Short circuit protection circuitry 1 2 6415 Installation amp Hardware Reference Manual Rev E Signal interface J4 connector 2 25 high voltage 2 24 input output table 2 20 interface diagram 2 23 opto supply 2 24 requirements A 2 Specifications A 1 Step rate A 3 Step size set up 3 16 benefits 3 16 definition 3 16 Step size 1 4 A 2 Storage 2 1 System components 1 7 2 3 diagram 1 8 2 8 Temperature operating 2 4 A 6 storage 2 1 A 6 Testing 3 20 connections 3 20 procedure 3 20 signals 3 21 Troubleshooting 4 1 6415 Installation amp Hardware Reference Manual U V W Rev E UL recognition 1 3 Unpacking 2 1 User adjustments 1 4 using S1 1 4 using jumpers 1 5 using potentiometers 1 6 Velocity control mode 3 6 Ventilation 2 7 Voltage motor supply 1 1 2 17 A 1 C 1 Warranty 1 9 Weight 2 7 A 8
67. rten the deceleration time while monitoring the voltage If regeneration causes the supply voltage to exceed 75 Vdc peak a clamping circuit is required Note Be sure to consider the effect of high line voltage when evaluating this test 6415 Installation amp Hardware Reference Manual Rev E Clamping Circuit Ifa clamp is required a power zener diode can be used as shown in the figure The maximum zener clamp voltage must not exceed 75 volts Caution If a clamp is required the transformer secondary voltage must be re checked to insure that the minimum clamp voltage is not exceeded under high line and low load conditions when there is no regeneration Otherwise the zener might overheat and fail To determine the required diode power rating start with a 5W device and monitor the zener current with a current probe Power in watts is the average current in amps times the zener voltage Estimate the average current from the oscilloscope trace and compute the power Select a zener rated slightly higher than the measured power If the average power is too high to be conveniently dissipated in a zener diode the active voltage clamp circuit shown below can be used instead Power is dissipated in the 25Q 30W resistor if the Motor Power Supply voltage exceeds 75 volts Active clamp circuit Q 2 gt o E o O a Considerations MOTOR POWER SUPPLY A
68. s to conform to Pacific Scientific s specifications manual PACIFIC SCIENTIFIC DOES NOT SEPARATELY WARRANT THE RESULTS OF ANY SUCH CORRECTION OR WARRANT THAT ANY OR ALL FAILURES OR ERRORS WILL BE CORRECTED OR WARRANT THAT THE FUNCTIONS CONTAINED IN PACIFIC SCIENTIFIC S PROGRAMS WILL MEET CUSTOMER S REQUIREMENTS OR WILL OPERATE IN THE COMBINATIONS SELECTED BY CUSTOMER This warranty for Programs is contingent upon proper use of the Programs and shall not apply to defects or failure due to 1 accident neglect or misuse ii failure of Customer s equipment iii the use of software or hardware not provided by Pacific Scientific iv unusual stress caused by Customer s equipment or v any party other than Pacific Scientific who modifies adjusts repairs adds to deletes from or services the Programs This warranty for Programs is valid for a period of ninety 90 days from the date Pacific Scientific first delivers the Programs to Customer THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXCEPT AS TO TITLE WHETHER EXPRESSED OR IMPLIED INCLUDING WITHOUT LIMITATION ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR ANY PARTICULAR PURPOSE AND ARE IN LIEU OF ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF PACIFIC SCIENTIFIC PACIFIC SCIENTIFIC S MAXIMUM LIABILITY WITH RESPECT TO THESE WARRANTIES ARISING FROM ANY CAUSE WHATSOEVER INCLUDING WITHOUT LIMITATION BREACH OF CONTRACT NEGLIGENCE STRICT LIABILITY TORT WARRANTY
69. tage circuit is designed to protect the drive from minor transients Voltages in excess of 100 Vdc will damage the drive and void the warranty IMPORTANT NOTE Important information about the power supply is outlined in Section 2 5 2 and Appendix C Read these sections carefully before applying power to the drive 6415 Installation and Hardware Reference Manual Rev E 2 3 fe Ng 7 ELE 2 4 Mounting the 6415 Unit Cooling plate For optimal thermal performance and minimum panel usage mounting mount the 6415 bookcase style to a cooling plate typically an Aluminum plate or heatsink with enough thickness and surface area to maintain the 6415 s chassis below 60 C using two M4 or 6 32 screws inserted through the mounting slots on the back of the unit Use a thermal pad or grease if surface is irregular The maximum temperature of the 6415 s back plate must be held below 60 C The graph of 6415 power dissipation vs current setting shown below may be used to design the cooling plate or direct measurements can be taken during normal operations and adjustments made to plate area or airflow over the plate if necessary Make sure that any difference between the ambient temperature during the measurement and worst case ambient temperature is accounted for The 6415 can also be mounted with its side against the cooling plate using 4 M4 or 6 32 screws if mounting depth is of greater concern than panel area The same thermal c
70. tion contained in this appendix supplements the material in the MA6415 This appendix supplied with all 6415 series drives provides detailed information on installation This appendix must be closely followed if EMC compliance is to be maintained It covers details such as mechanical mounting safety earth connections and motor wiring The 6415 s input voltage is provided by a user supplied dc power supply System harmonics and conducted emissions are dependent on the system chosen Therefore the machine builder is responsible to properly filter the installation thereby preventing unwanted conducted line noise EN 61800 3 also puts the responsibility of filtering on the machine builder For additional information please see the Assessment of Compatability section in EN 61800 3 6415 Installation and Hardware Reference Manual Rev E E 1 im ES 7 i LL oO CE Declaration of Conformity This is to certify that Pacific Scientific Motion Technology Division 110 Fordham Road Wilmington MA 01887 USA Declares that the product s Designation STEPPER DRIVE Type 6410 6415 6420 comply with the following relevant regulations CE Guideline 89 336 EEC EMC Directive Applied harmonized standards EN 61800 3 1996 Manufacturer s Contact Peter Deneault Compliance Engineer Issued By Pacific Scientific Motion Technology Division President William T F
71. to order Contact Pacific Scientific to order these parts Call 815 226 3100 from 8am to 6pm Eastern Standard Time Write Pacific Scientific 4301 Kishwaukee Street Rockford IL 61105 Fax 815 226 3048 B 2 6415 Installation amp Hardware Reference Manual Rev E Appendix C Power Supply Considerations C 1 Bridge Capacitor Power Supply The figure below shows the full wave bridge capacitor input configuration most commonly used to power one or more 6415 drive modules A single transformer provides isolation and transforms the AC input voltage to a level that when rectified provides the desired DC bus voltage Fusing should be between the rectifier and individual bus capacitors This allows fuse size to be based upon the current requirements of a single module to provides the greatest protection The capacitors must be connected to the 6415 DC and DC inputs using twisted pairs no longer than three feet in length as shown to control winding inductive effects A regen clamp to absorb power transferred from the motor to the 6415 s is sometimes required This Q 2 gt o E o z O a Considerations section provides selection guidelines for the power supply components Block diagram 2 I NGA BLEEDER TRANSFORMER Dh FUSE RESISTOR TWISTED 4 BUS iis K MDA 75 VOLT VAC K T MAX K 4 e d l RECTIFIER REGEN can Nune 3FEETMA
72. tors with series windings Wire nuts may be used for the winding connections at the motor end CASE D gt B 10133 TOJ34 YEL DRIVE EARTHIO 135 GROUND FOUR LEAD MOTOR D gt ware TEMERE 10 34 p 1l DRIVE EARTHrO J 3 5 GROUND EIGHT LEAD MOTOR CONNECTED IN PARALLEL CASE DRIVE EARTH GROUND EIGHT LEAD MOTOR CONNECTED IN SERIES 6415 Installation and Hardware Reference Manual Rev E 2 13 fe Ng T 7 Terminal board The figure below shows the connections required between the connections 6415 connector J3 and Pacific Scientific stepper motors having a terminal board in the rear end bell Connections are shown for 4 lead motors 8 lead motors with paralleled windings and 8 lead motors with series windings TERMINAL A TOJ3 1 1 3 CASE B 2 B 4 DRIVE EARTHIO L233 GROUND FOUR LEAD MOTOR TERMINAL TO J 3 1 A CASE B B DRIVE EARTH GROUND EIGHT LEAD MOTOR CONNECTED IN PARALLEL TERMINAL i TOJ3 2 CASE A TO 3 3 g 10 34 DRIVE EARTH 19 125 GROUND EIGHT LEAD MOTOR CONNECTED IN SERIES 6415 Installation and Hardware Reference Manual Rev E MS connectors The figure below shows the connections required between the connection 6415 J3 connector and Pacific Scientific stepper motors having MS connectors Connections are shown for 4 lead motors 8 lead motors with paralleled windings and 8 lead motors with series
73. uld have a 120 Hz ripple current rating of at least 5 amps rms and a working voltage of at least 1 3 70 91 volts The bus capacitor should be connected to the 6415 using a twisted pair no longer than 3 feet in length 6415 Installation amp Hardware Reference Manual Rev E C 1 4 Fuse Selection The BUS MDA1O0 slow blow fuse or equivalent is recommended when the 6415 is set for 5 Amps Fuses from the same family but with proportionally lower current rating can be used with lower current settings C 1 5 Regeneration Considerations The motor power supply voltage can be pumped up when the motor and load are decelerated by the drive In effect the motor becomes a generator converting mechanical energy stored in the spinning motor and load inertia into electrical energy If the mechanical energy is less than the losses in the drive and motor the supply voltage does not increase If the mechanical energy is greater than these losses the supply voltage will increase be pumped up Q 2 gt o E o O a Considerations The mechanical energy of a spinning inertia is given by E 3 87 10 J 8 where E kinetic energy joules J inertia in oz in sec S speed in rpm Final voltage If this energy is converted to electrical energy in the form of charge on the bus capacitor s the voltage will be vers C where V 1s the final voltage after energy transferred to capacitor s V 1s
74. wice the acceleration rate 4 6415 Installation and Hardware Reference Manual Rev E Accel Ramp Pot Speed controls steps sec volts Accel Rate A 2 Accel Rate B 375 000 l mu 314496 250 000 STEP SIZE 1 25 Accel pot fully CW Tauz 0 4sec 157248 125 000 Note tau and tau 0 4sec 0 Time o 2 D c gt O A Decel Ramp Pot Speed controls steps sec volts 500 000 8 o PE Decel Rate A Decel Rate B 375000 6 TEN A X STEP SIZE 1 25 250 000 4 l N Decel pot fully CW Ae time 1 4sec 125000 2 ON TR AXE 0 Time gt t 1 21 t 1 4sec 6415 Installation and Hardware Reference Manual Rev E 3 1 2 Jumper Settings The Oscillator is configured with several jumpers as follows Speed Command The analog speed command is derived from one of the following Settings sources depending upon the E1 and E3 jumper configuration E1 E3 Velocity Control Mode 1 2 IN 1 2 IN Internal RUN SPEED Potentiometer 3 4 IN N A External Potentiometer 5 6 IN 1 2 IN External Analog Input 1 2 IN 3 4 IN External Analog Input scaled by internal RUN SPEED potentiometer Internal RUN SPEED Pot 8V ACCEL 1 2 p POT R14 c 3594 Sw B 1M E3 a k CW a 8 O9 1 O a 7 99V 10K Cw pe SR E Motion Profile 3o o4 atin Toe Generator and STEP OUT RUN SPEED
75. y machinery e Index feed of material e Labeling machines e Clutch brake replacement e Smart conveyor systems e Semiconductor wafer polishing e Constant speed applications 1 2 Other System Components Overview The other components that along with the drive comprise a complete motor control system are e Single logic power supply 4 75 5 25 Vdc e Single bus power supply 24 75 Vdc e Motor Installation guidelines for these components are described in Chapter 2 Installing the 6415 Stepper Motor Drive 6415 Installation amp Hardware Reference Manual Rev E D o gt oO System Block The following diagram shows the drive in a typical system Diagram Unregulated Power Supply 24Vdc to 75Vdc m User s Control Electronics 8V Step Pulse External Pot H Drive Direction Analog Input LL i Enable Run Stop Cmd E Low Speed Cmd y Oscillator Direction Cmd y Enable Cmd y Step Pulse Out P _ VCO Input Mon yt 5V Opto Supply 6415 Oscillator Drive 1 8 6415 Installation amp Hardware Reference Manual Rev E 1 3 How to Use this Manual D o gt Oo This manual contains information and procedures to install setup and troubleshoot the 6415 stepper motor drive The most effective way to use this manual is to follow the installation and power up instructions contained in Chapter 2 and Ch

MA6415 6 4 1 5 Oscillator/Drive

Contents

Download Pdf Manuals

Related Search

Related Contents