PDO 5580 - Applied Motion
Contents
1. Applied Motion Products Inc 404 Westridge Drive Watsonville CA 95076 Tel 831 761 6555 800 525 1609 Fax 831 761 65442. 5580 has four modes of operation selected by three dip switches Self Test Mode is used for trouble shooting If you are unsure about the motor or signal connections to the drive or if the PDO 5580 isn t responding to your step pulses you can turn on the self test SELF TEST To activate the self test slide switch 6 toward the TEST label The drive will slowly rotate the motor 1 2 revolution forward then 1 2 rev backward The Self Test Mode pattern repeats until you slide the switch away from the TEST label The PDO 5580 always uses half step mode during the self test no matter how you set Osc BYPASS the steps rev switches The self test ignores the SELFTEST LJ STEP and DIRECTION inputs while operating The ENABLE input continues to function normally 9 6 Pulse amp Direction Mode Pulse amp Direction Mode the PDO 5580 receives step pulses from an indexer such as the Applied Jovsrick Motion Si 1 or Si 100 Steps revolution are set by switches 1 4 see pages 10 11 LS osc BYPASS C H o Joystick mode speed and direction are deter SELF TEST mined by an external analog voltage STEP and DIR inputs can be used for limit switches SPEED input selects speed range LO SPEED and HI SPEED pots adjust the 2 speed ranges Joystick Mode Oscillator mode speed can be controlled by on sovstick H board potentiometers and or by an external analog voltage STEP input starts and stops
3. amps phase Easy to configure with on board switches and potentiometers for all settings Automatic idle current reduction reduces motor and drive heating saves power Pluggable screw terminal connectors make wiring easy Oscillator Mode operates from internal pots external pots 0 5 V analog signal or analog joystick Two speed ranges can be selected on the fly by a digital signal with automatic ramping between speeds Inputs and outputs are optically isolated differential sourcing or sinking Speed amp Enable 5 24V Step amp Direction 5 12V Tach Out signal allows easy measurement of speed e Enable input allows motor current to be shut off on command Built in 80 volt power supply accepts 110 or 220 VAC power 50 60 Hz MOSFET pulse width modulation switching amplifiers 3 state Microstepping pulse amp direction mode with 16 step rev settings from 200 full step through 50 800 Overtemp and overcurrent short circuit and surge protection Built in self test for troubleshooting CEand compliant 2 Getting Started To use your Applied Motion Products motor control you will need V a power cable line cord acompatible step motor see page 21 asmall flat blade screwdriver for tightening the connectors an Applied Motion Products screwdriver suitable for this purpose is included with your drive For pulse amp direction mode source of s
4. and electri cal codes The AC cord you can install yourself but be careful AC power can be dangerous 220 Volts The PDO 5580 is set for 110 volt operation at the factory In order to use 220 volts you ll need to change a switch setting inside the case However you can do this from outside the case with your Applied Motion screwdriver Before you can change the 110 220 volt switch setting you must remove the motor connector and the AC power connector from the drive Set the drive on the widest side so that the heat sink fins are pointing upward Once you ve done that you ll see an opening in the case just above the three position and four position green connectors If you look into the slot you should see two black objects The one on the left is the fuse The black object to the right of the fuse is the 110 220 volt switch The sketches below and on page 5 show the two positions of the switch To change from 110V to 220V carefully insert your screwdriver into the slot and push the switch to the right ACPOWER MOTOR rre 0855 4010 deis sjonpojd Unplug these connectors 4 fuse switch in 110V position fuse Switch in 220V position Installing an AC Line Cord Remove a
5. on Microstepping drives like the PDO 5580 precisely control the amount of current in each phase at each step position as a means of electronically subdividing the steps even further The PDO 5580 offers a choice of full and half step as well as 14 other step resolutions The highest setting divides each full step into 254 microsteps providing 50 800 steps per revolution when using a 1 8 motor In addition to providing precise positioning and smooth motion microstep drives can be used for motion conversion between different units The 25 400 step rev setting is provided as a means of converting motion from metric to english There are 25 4 mm in an inch Other settings provide step angles that are decimal degrees 36 000 steps rev makes the motor take 0 01 steps Some settings are used with lead screws When the drive is set to 2000 steps rev and used with a5 pitch lead screw you get 0001 inches step 10 c S 3 Q 9 MICROSTEP RESOLUTI ON N STEPS REV 1 100 m 123 000 MICROSTEP RESOLUTION 200 STEPS REV FULL 1234 008 MICROSTEP RESOLUTION 21600 STEPS REV 1 arc min MICROSTEP RESOLUTION 400 STEPS REV HALF 123 4 MICROSTEP RESOLUTION 25000 1 125 STEPS REV MICROSTEP RESOLUTION 1000 STEPS REV 1 5 1234 nn MICROSTEP RESOLUTION 2540
6. 0 1 127 STEPS REV 1 MICROSTEP RESOLUTION 2000 STEPS REV 1 10 1234 MICROSTEP RESOLUTION 25600 1 128 STEPS REV 1234 0050 MICROSTEP RESOLUTION 5000 STEPS REV 1 25 1234 MICROSTEP RESOLUTION 36000 01 STEPS REV 1234 du MICROSTEP RESOLUTION 10000 STEPS REV 1 50 1294 0855 MICROSTEP RESOLUTION 50000 STEPS REV 1 250 123 4 0590 MICROSTEP RESOLUTION 12800 STEPS REV 1 64 1 1 1 MICROSTEP RESOLUTION 50800 STEPS REV 1 254 1234 MICROSTEP RESOLUTION 18000 02 STEPS REV 11 Joystick Mode In this mode speed and direction are determined by the voltage applied to the WPR wiper terminal 2 5 volts is stopped no speed Increasing the WPR voltage toward 5 volts results in forward motion speed increases with voltage Decreasing the WPR voltage from 2 5 toward 0 results in reverse motion with speed increasing as voltage decreases In joystick mode the PDO 5580 operates at 12800 steps rev The maximum speed is determined by two things the state of the SPEED input and the HI SPEED and LO SPEED trimpots When the SPEED input is ON the speed range of the joystick can be adjusted with the LO SPEED pot up to 5 rev sec 300 rpm When the SPEED input is OFF or open the joystick speed range is adjusted with the HI SPEED pot up to 25 rev sec 1500 rpm Turning the pots clockwise i
7. The low speed can be set from 0 to 5 rev sec 0 300 rpm by adjusting the LO SPEED pot Turning the pot clockwise increases the speed The high speed setting is used when the SPEED input is off or open If switch 215 toward the words EXT SPEED then the high speed is proportional to the voltage applied to the WPR terminal and is trimmed by the HI SPEED pot You can connect an external 1K 5K pot to the WPR CW and CCW terminals or you can apply 0 to 5 volt analog signal to the WPR terminal ground your analog signal to the CCW pin The high speed range is 0 25 rev sec 0 1500 rpm You can reduce the range by turning down the HI SPEED pot For example if you want the motor to go 750 rpm when the external pot is on maximum turn the HI SPEED pot down about half way When switch 2 is away from the EXT SPEED label the high speed is set by the HI SPEED pot and the WPR input does nothing Never apply more than 5 volts DC or less than 0 volts to the WPR pin In joystick and oscillator modes the accel decel rate is set by the ACCEL pot The range is 1 to 250 rev sec sec Turning the pot clockwise makes the motor start and stop faster but if you set it too high the motor may run out of torque and stall In nearly all cases the accel decel rate you set is respected by the PDO 5580 For example if you switch the SPEED input while the motor is moving the drive will change speeds smoothly If you are operating in EXT SPEED mode and
8. User s Manual PDO 5580 Step Motor Driver 20 SPEED 25 on SPEED step_ LH TACH o E LH TACH ES FAULT OO wen FAULT QO temp Joystick EXT SPEED CURRENT o 28 1 6 2 0 HIGH SPEED a 25 LOW SPEED gm ACCEL cu SELF TEST MOTOR B 90V pk B SMS A 5580 Step Motor Driver Applied Motion Products 6 QE D IINS Applied Motion Products motors drives controls Introduction Thank you for selecting an Applied Motion Products motor control We hope our dedication to performance quality and economy will make your motion control project successful If theres anything we can do to improve our products or help you use them better please call or fax Wed like to hear from you Our phone number is 800 525 1609 or you can reach us by fax at 831 761 6544 Features Digital oscillator provides smooth accel decel ramps and precise speed control Powerful microstepping amplifier provides high torque and smooth quiet motion Accepts a wide range of motors NEMA sizes 14 42 0 5 to 5 5
9. bout 5 mm 3 16 inches of insulation from each of the three wires of your line cord That s right three wires For safety always use a three wire power cord on anything with a metal case Depending on where you got your power cord it may have black white and green wires or brown blue green The AC power plug that was shipped with your PDO 5580 might be one of two types The old style is shown below on the left The new style shown on the right comes with an insulating rubber boot Make sure you follow the proper sketch your connector style To Earth Ground 2 To Neutral gt To Line Hot Old Style New Style AC Power Plug AC Power Plug unplug the line cord fromthe nall before attaching it to the PDO 55800 Connect the black or brown wire to the 5580 L terminal of the AC power connector That is the line or hot connection Connect the white or blue wire to neutral That s the terminal Finally and most importantly connect the green wire to the GND terminal That connects the PDO 5580 metal enclosure and DC power supply ground to earth ground 5 Connecting the Motor Never connect the motor to the driver when the AC power is on Secure any unused motor leads Never disconnect the motor while the AC power is on Never connect motor leads to ground or to a power supply You must now decide how to connect your motor to the drive Red 4 lead Four
10. ction switch a 0 5V speed signal WPR gt signal return CCW cee Wiring for Speed Control by 0 5 Volt Analog Signal with Dir Control 15 0 5V speed signal signal return 0855 Odd p ER Wiring for Speed Control by 0 5 Volt Analog Signal Unidirectional speed rev sec 9 o 0 1 2 3 4 5 Speed vs Input Voltage EXT SPEED mode HI SPEED pot at maximum Connecting Digital Inputs and Limit Switches The PDO 5580 contains optical isolation circuitry to prevent the electrical noise inherent in switching amplifiers from interfering with your circuits This arrangement also allows a wide range of input voltages to be used and gives you the option of using sinking or sourcing inputs A schematic diagram of the input circuit is shown on the next page You must supply 5 12 volts DC to supply current to the LEDs on the input side of the optoisolators 24 VDC is acceptable for the SPEED and ENABLE inputs You can operate the STEP and DIR inputs at 24V if you add a 1000 ohm resistor to each input Most CMOS and open collector TTL devices are directly compatible with this drive as are typical PLC and proximity sensor outputs 16 PDO5580 Input Circuit Sinking Circuits NPN If your output devices prefer to sink current then connect the terminals to your positive power supply and the teminals to your signals i e STEP DIR etc If you are using a TTL circ
11. eeds 50 120 F Never block the fins of the heat sink or the vent holes Never put the drive where it can get wet Never allow metal particles near the drive 21 Technical Specifications Amplifiers Dual MOSFET H bridge 3 state pulse width modulated switching at 20 kHz 0 5 5 5 amps phase output current switch selectable in 0 2 increments Overcurrent and overtemperature protection Automatic idle current reduction defeatable reduces current to 5096 of setting after one second Minimum motor inductance is 0 8 mH Power Supply Linear toroidal transformer based for high reliability and low noise 110 or 220 VAC input switch selectable 50 60 Hz DC voltage at nominal line voltage 75 VDC full load 90 VDC no load Speed Enable optically isolated differential 5 24V logic 2200 ohms internal resistor Step Direction optically isolated differential 5 12V logic 680 ohms internal resistance 24V with external 1000 ohm resistors Wiper 0 5 VDC analog signal Max recommended pot joystick impedance 1K 5K ohms Joystick dead zone 80 mV Potentiometer analog signal dead zone 40 mV In pulse amp direction mode motor steps on falling edge of step input 0 25 usec minimum pulse 2 MHz max step rate 1 usec minimum set up time 50 minimum hold time for direction signal Tach amp Fault Optically isolated uncommitted open collector open emitter photo transistors 30V 20 mA max Tach output
12. is 100 pulses per motor revolution 50 duty cycle square wave Microstepping Oscillator joystick modes 1 64 step 12 800 s r with 1 8 motor Pulse amp Direction mode 16 switch selectable resolutions 200 400 1000 2000 5000 10000 12800 18000 20000 21600 25000 25400 25600 36000 50000 50800 steps rev Self test 1 2 step 22 Technical Specifications continued Recommended Maurey Instrument Corp Chicago IL 773 581 4555 Joystick JS31462S5T3 2 axis or SAJ2515 F 502 1 axis Speed Ranges LO speed range 0 5 rev sec Physical Connectors CE Mark speed range 0 25 rev sec Accel decel range 1 to 250 rev sec sec Constructed with black anodized aluminum heat sink and heavy gauge steel housing 3 x 5 3 x 8 inches overall 7 8 Ibs Ambient temperature range 0 70 C Power temp and motor short circuit LEDs Mounting brackets and switch cover included See back cover for detailed drawing European style pluggable screw terminal blocks Motor 4 position Wire size AWG 12 28 Signal Input output 8 position AWG 16 28 AC Input 3 position Wire size AWG 12 28 Complies with EN55011A EN50082 1 1996 EN50178 1997 23 Mechanical Outline 8 28 00 FEFE 2392282 N 4030 deis 0855 E HHBBHEHH
13. lead motors can only be connected motor one way Pleasefollow the sketch at the right az Blue Yellow White B B 4 Leads Six lead motors can be connected in series or center tap In series mode motors produce more torque at low speeds but cannot run as fast as in the center tap configuration In series operation the motor should be operated at 30 less than the rated current to prevent overheating Wiring diagrams for both connection methods are shown below Note NC means not connected to anything A Grn Wht A Grn Wht c Mhi te White hr nd motor motor Green Green Red Red M NC B 6 Leads Series Connected 6 Leads Center Tap Connected Eight lead motors can also be connected in two ways series and parallel As with six lead motors series operation gives you more torque at low speeds and less torque at high speeds In series operation the motor should be operated at 30 less than the rated current to prevent overheating The wiring diagrams for eight lead motors are shown below Orange A Orange BIk Wht Org Wht 8 8 lead lead BIK Wht Org motor motor d A Black Black Yel Red low Red Red Yellow Wht Wht p Yel Red Wht p_ B B wht 8 Leads Series Connected 8 Leads Parallel Connected Step Table full stepping DIR 0 ccw Step 0 is the Power Up State E Modes of Operation The
14. make a sudden change in the voltage to the WPR terminal the drive accelerates or deceler ates to the new speed smoothly according to the accel pot setting The only time the drive makes an instant change is when the SPEED input is on and the STEP input goes off That is done so that you can stop instantly and exactly from alow speed 14 STEP run stop switch SPEED 51 2 closed run Y STEP g ae direction switch l 9 SPEED speed switch speed SPEED Typical Wiring for Oscillator Mode Using External Speed Control Pot Speed Control from a 0 to 5 Volt Analog Signal In oscillator mode the PDO 5580 can rotate the motor at a speed proportional to an analog voltage The voltage must be applied to the WPR terminal The direction of rotation is controlled by the digital DIR input and the motor can be stopped either by setting the analog input voltage to 0 or by turning the digital STEP signal off To use the PDO 5580 in this mode set switch 1 away from the JOYSTICK label and set switch 2 toward the EXT SPEED label The SPEED pot sets the maximum speed the motor speed when the analog signal is at 5 volt DC The range is 0 25 rev sec Wiring diagrams and a plot of speed vs voltage are shown below and on the next page run stop switch 79 closed run 1 dire
15. ncreases the speed In joystick mode limit switches can be connected to the PDO 5580 to prevent motion outside of defined limits The forward limit should be connected to the STEP input and the reverse limit should be connected to the DIR input When the forward limit is ON the motor will not move forward that is when the joystick voltage is between 2 5 and 5 volts When the reverse limit is ON the motor will not move when the joystick is in the 0 to 2 5 volt range If you don t need limits you can leave the STEP and DIR inputs unconnected 089 Odd joystick speed rev sec 0 1 2 3 4 5 Speed vs Input Voltage Joystick Mode SPEED input off open HI SPEED pot at maximum Oscillator Mode In oscillator mode the PDO 5580 uses the direction set by the DIR input Off or open gives clockwise motion if the motor is wired according to pages 6 and 7 Motor speed and the function of the STEP input can be determined from the follow ing table In oscillator mode the PDO 5580 operates at 12800 steps rev speed set when STEP when STEP by goes ON goes OFF a ei accel to speed instant stop accel to speed instant stop vemm LO SPEED OFF open accel to speed to stop WPR input iovsti trimmed by OFF open _ 108 accel to speed to stop on ont HI SPEED 13 There are two speed ranges in oscillator mode Oneis the low speed range which is activated when the SPEED input is on
16. o the ENABLE input 17 Setting Phase Current Before you turn on the power supply the first time you need to set the driver for the proper motor phase current The rated current is usually printed on the motor label The current you set on the PDO 5580 is the peak current not RMS The 5580 drive current is easy to set If you wish you can learn a simple formula for setting current and never need the manual again Or you can skip to the table on the next page find the current setting you want and set the DIP switches according to the picture Current Setting Formula Locate the bank of eight switches Five of the switches have a value of current printed next to them such as 0 2 and 1 6 Each switch controls the amount of current in amperes A that it s label indicates There is always a base current of 0 5 A To add to that slide the appropriate switches toward their labels You may need your small screwdriver for this Sample 0 2 Suppose you want to set the driver for 2 9 amps 0 4 Oo per phase You need the 0 5 A base CURRENT current plus another 2 0 and 0 4 A 0 5 0 8 Ho 2 9 TOTAL 0 5 2 0 0 4 1 6 CEN Slide the 2 0 and 0 4 A switches toward the labels 2 0 as shown in the figure Idle Current Reduction Your drive is equipped with a feature that automatically reduces the motor current by 50 anytime the motor is not moving This reduces drive heating by about 50 and lo
17. r Check the motor leads for shorts between phases or to ground Using the Fault Output The PD5580 hes a fault output to tel another device such a PLC if the drive has Overhests or encounters a short circuit hes occured amp the noor outputs The fault output is optically isolated for noise intrunity This nekes it rore flexible and nore rdiabe but also requires 5 12 or 22 VDC power source to hook it up To connect totypicd PLC followthe sketch The photo transistor tums on doses when there is 20 Recommended Motors The following tables lists motors and current settings that are recommended for the PDO 5580 drive Winding Torque Max Power Current Setting Number Connection oz in Watts Amps phase 5023 122 paalia 75 60 20 Mounting the Drive You can mount your drive on the wide or the narrow side of the case Either way you ll need to get the brackets and screws out of the accessory bag and bolt them onto the PDO 5580 If you re mounting on the narrow side you ll first have to remove one of the screws from the heat sink then put it back with the bracket in place as shown in the figure 2 Bracket Bracket position for wide side mounting position Place brackets on for narrow top and bottom of side drive EZ bottom of drive This screw is already in the drive Never use your drive in a space where there is no air flow N or where the ambient temperature exc
18. tep pulses usually an indexer is used For oscillator mode an instrument for measuring motor speed tachometer freq counter or o scope For joystick mode v An analog joystick The sketch below shows where to find the important connection and adjustment points Please examine it now All mating connectors are included Dm Eu connector SPEED 5 DIRECTION En rn STEP EN O E ENABLE connector wer a EH FAULT SPEED ccw rr TACH OUT power Owr LEDs EXTERNAL POT POWER JOYSTICK 0 5V ie a OVER TEMP FAULT ANALOG SPEED AES MOTOR SHORT in switches wee 8 MOTOR CURRENT wwe e 1822 eem IDLE CURRENT 4 ex gr 95 EXT INT otentiometers JOYSTICK MODE ACCEL DECEL RATE LOW SPEED itch joven ia OSC MODE M id SELF TEST mE a MOTOR Step Motor Driver JI Applied Motion Products __ connector Ln AC POWER DAS L Lr Connecting the AC Line 110 Volts The PDO 5580 is set for 110 volt operation at the factory All you need to do is install a power cord and plug itin If you want to direct wire the PDO 5580 to AC power you must consult a qualified electrician and observe all building
19. the motor DIR osc Ho input controls direction of rotation SPEED input selects the speed range SELF TEST B Oscillator Mode 8 Setting up For Pulse amp Direction Mode You must Connect an indexer controller to the Step and Direction inputs Set the steps rev Turn off the SELF TEST switch and turn on the OSC BYPASS switch Differential Logic If your controller has STEP STEP DIR and DIR outputs which many indexers do the connections are simple Just connect STEP to STEP STEP to STEP and so forth as shown below Indexer or Controller PDO 5580 with E Drive Differential optional signal Sinking Logic If your controller has STEP DIR and 5V outputs like the Applied Motion Products 51 1 indexer connect STEP and DIR to 5V Connect STEP to STEP Connect DIR to DIR Indexer or Controller PDO 5580 with Drive Sinking Outputs 222 optional signal Sourcing Logic If your controller has STEP DIR and GND ground or common outputs connect STEP and DIR to GND Connect to STEP Connect DIR to DIR Indexer or Controller with optional signal Microstepping Most step motor drives offer a choice between full step and half step resolutions In full step mode both motor phases are used all the time Half stepping divides each step into two smaller steps by alternating between both phases on and one phase
20. uit to drive the PDO 5580 connect the terminals to your 5 volt bus No ground connection is needed If you are using a PLC or proximity sensor you ll need a power supply Sourcing circuits PNP If your output devices can only source current some PLC outputs are this way connect the terminals to the ground of the DC power supply that powers your output circuits Then connect your signals to the teminals STEP DIR etc Note We refer to an input as being ON when current is flowing through the input A signal is OFF when no current is flowing An input is OFF when COM and the input terminal are at the same voltage or when the input is left unconnected open Tach Output The Tach Out signal is provided for measuring the motor speed It generates 100 pulses per revolution so if you connect a frequency counter the speed reads out in revs second with two decimal places Do not connect the Tach output to more than 24VDC The current into the Tach terminal must not exceed 20 mA Enable Input ENABLE allows the user to turn off the current to the motor by setting this signal to logic 0 The logic circuitry continues to operate so the drive remembers the step position even when the amplifiers are disabled However the motor may move slightly when the current is removed depending on the exact motor and load characteristics f you have no need to disable the amplifiers you don t need to connect anything t
21. wers motor heating by 75 This feature can be disabled if desired so that full current is maintained at all times This is useful when a high holding torque is required To minimize motor and drive heating we highly recommend that you use the idle current reduction feature unless your application strictly forbids it Idle current reduction is enabled by sliding switch 3 toward the 50 IDLE label as shown in the sketch below Sliding the switch away from the 50 IDLE label disables the reduction feature 50 IDLE 50 IDLE Idle Current Reduction Idle Current Reduction Enabled Disabled 18 Current Setting Table 19 Fault Protection The PDO 5580 provides protection against notor short circuits and excessive drive terpeaure If the TEMP light 15 on the PDO 5580 hes detected a thean problemand shut down theanpiifias Thefirst thing you should do is to unplug the drive fromthe power source Nex touch the hee sink with your fingers If itis very hot thedrivehes probably overhested Usually this mens you need more flowaround the drive If the SHORT light is on the PDO 5580 hes detected a short circuit and hes shut donn the 5 Unplug thedrive fromthe power source Check the motor Wiring cerefully Make sure that the connections to the drive are secure end that any unused motor leecs insulated fromthe drive and power supply and fromeach othe
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