ADVANCED MICRO CONTROLS INC. Manual #: 940-0S013 al u an Built With DuraDrive™ Technology ro du ct s User M SD17063 Rev.
GENERAL INFORMATION Important User Information The products and application data described in this manual are useful in a wide variety of different applications. Therefore, the user and others responsible for applying these products described herein are responsible for determining the acceptability for each application. While efforts have been made to provide accurate information within this manual, AMCI assumes no responsibility for the application or the completeness of the information contained herein.
ABOUT THIS MANUAL Read this chapter to learn how to navigate through the manual and familiarize yourself with the conventions used in it. The last section of this chapter highlights the manual’s remaining chapters and their targeted audiences. Audience This manual explains the set-up, installation, and operation of AMCI’s SD17063 Rev. B stepper motor drive with DuraDrive Technology™.
ABOUT THIS MANUAL Revision Record This manual, 940-0S013, is the fourth revision of this manual. This revision clarifies some drawings, adds information on disabling Anti-resonance when using the drive’s self test, and adds information on converting from an SD8055 to the SD17063 Rev. B. It was first released March 8th, 2002. Revision History 940-0S012: 04/05/2001. Update for Rev. B drive. 940-0S011: 05/21/2000. Update for Rev. A drive 940-0S010: 06/02/1998. Initial Release.
CHAPTER 1 INTRODUCTION TO THE SD17063 The Rev. B drive makes a few minor improvements to the Rev. A drive and it retains the new features and switch setting that were not available on the older, non-revised SD17063 drives. Therefore, this manual can be used with the SD17063 Rev. A drives with the exceptions noted below. This manual cannot be used with the older, non-revised SD17063 drives. The easiest way to determine if you have a revised or non-revised drive is by the power connector. The new SD17063 Rev.
1 INTRODUCTION The SD17063 Rev. B With DuraDrive Technology AMCI’s SD17063 is an advanced, high-power microstepping drive for NEMA 17 through NEMA 42 frame size motors. The drives many features include: h DuraDrive Technology protects the drive from extremes in temperature, input voltage, and motor regenh h h h h h h h eration currents.
1 INTRODUCTION Other AMCI Stepper Products The following table lists some of our other stepper products, but the line is constantly growing so the list may be incomplete. For the latest information on all of our products, browse through our website www.amci.com. Model Number Product Type Description Full Step / Half Step drive with an 170 Vdc motor bus and output current up to 4.0Apk. The drive also has settings for Idle Current Reduction.
1 INTRODUCTION Other Products From AMCI AMCI has been serving the industrial automation sector since 1985, and we have a broad range of other products that are used in industrial applications. h DURACODERS: Absolute, Analog, or Incremental encoders that replace the fragile glass disk and sen- sitive optics of optical encoders with an industrial resolver. The size 25 DuraCoders are drop in replacements for similar sized optical encoders.
CHAPTER 2 SPECIFICATIONS Drive Type Two bipolar MOSFET H-bridges with 170V output bus. 20KHz PWM current control. Internal 25 watt regeneration resistor. Weight 4.3 lbs. (2.0 kg.) Inputs Electrical Characteristics for all Inputs: ....... Differential. 1500 Vac/dc opto-isolated. Can be wired as single ended inputs. Step ...... Motor steps on high going pulse. 200nS min. pulse width, 2 MHz maximum input frequency. Disable . Active high. Disables current to motor. Drive does not accept steps while disabled.
2 SPECIFICATIONS SD17063 Features Overview The following section gives brief descriptions of the SD17063 settings. They are presented so that you can familiarize yourself with the drive. More in-depth descriptions are given in the Chapter 3: SD17063 SWITCH SETTINGS, starting on page 17. Pulse Train Input Most indexers output their directional pulses in one of two formats, CW/CCW or Pulse and Direction. By default, the SD17063 uses the CW/CCW format, but can be configured for either.
2 SPECIFICATIONS SD17063 Settings Overview (continued) Self Test This feature allows you to verify motor wiring and drive operation without an indexer. When the drive is set for self test, the drive rotates the motor counter-clockwise at 60 RPM with a resolution of 50,000 steps per turn. Indexer I/O Figure 2.1 shows the I/O connector on the SD17063. The inputs are typically connected to an indexer, but the Reset and Disable input are sometimes connected to push buttons.
2 SPECIFICATIONS Indexer I/O (continued) Reset Input When active, the Reset Input forces the drive into a reset state. Power is removed from the motor and the Fault Output is active while the drive is in its reset state. The drive will start to re-initialize itself when the input is released. Initialization will take up to 325 milliseconds. Power is restored to the motor and the Fault Output becomes inactive once the drive re-initializes correctly.
2 SPECIFICATIONS Indexer I/O Specifications (continued) Timing Specifications Electrical Specifications Disable and Reset Inputs Input Type Input Isolation Turn ON voltage and Current Maximum Input Current Opto-isolated 5 Vdc Differential 1500 Vdc 5 Vdc @ 4 mA 30 mAdc VDC 5 Volts 12 Volts 15 Volts 24 Volts Suggested Current Limiting Resistors RLIMIT None 2.0 KΩ 2.0 KΩ 3.9 KΩ Times listed are the amount of time needed from the release of the input until the SD17063 is ready to accept pulses.
2 SPECIFICATIONS Motor Output (continued) EARTH GND Connection The EARTH GND connection on the Motor Connector is for the shields of the motor’s cable. This point is internally attached to the chassis and grounding lug of the SD17063. Motor Insulation and Inductance Specifications Because of the high voltage bus generated by the SD17063 for the motor, be sure that the winding insulation for you motor is rated for 500 Vdc minimum.
2 SPECIFICATIONS Detectable Faults and Errors (continued) Major Faults The other seven faults are termed Major Faults and occur when there is a hardware fault with the drive or motor. When one of these faults occur, the Fault Output is activated, which means it doesn’t conduct current. Power is removed from the motor and the drive ignores pulses from the indexer. These eight faults are: h Disabled: The Disable Input is active, or motor current is ramping up after its release.
2 SPECIFICATIONS Stepper Motors AMCI offers a total of 21 different stepper motor configurations. Three different NEMA sizes are available, size 23, 34, and 42. The size 23 and 34 motors are available in one, two, and three stack configurations. All motors have single and dual shaft configurations, and the dual shaft models can have an incremental optical encoder factory installed. The part numbers are given below. Outline drawings for all of the motors are available on our website, www.amci.com.
CHAPTER 3 SD17063 SWITCH SETTINGS SD17063 Worksheet This worksheet is for documenting the settings of your SD17063. Feel free to print out extra copies of this sheet to use while you work. The worksheet shows all of the switch setting and provides space to document your motor size and hookup as well as indexer connections. You should highlight or check mark your default switch settings while going through this chapter.
3 CHOOSING YOUR SETTINGS Choosing Your Motor Most of your drive’s settings are determined by the motor you select. This chapter assumes that you’ve already selected the motor and you’re using this chapter to determine the appropriate drive settings. If you have not selected you motor, then refer to Appendix A: CHOOSING YOUR MOTOR, starting on page 45.
3 CHOOSING YOUR SETTINGS DIP Switch Settings (continued) Motor Settings Switch Blocks 1 & 2 O1 2 3 4 5 N SB2 CW / CCW Step & Direction SB3 O1 2 3 4 5 N SB4 Normal Inertial Load IDLE CURRENT REDUCTION Anti-Resonance Disabled RMS Current Peak Current Idle Current Reduced to 0% Anti-Resonance Enabled Idle Current Reduced to 50% Idle Current Not Reduced Low Inertial Load Idle Current Not Reduced Typical Pure Sine Output Reduced 1 –4% Third Harmonic or SELF TEST Reduced 2 OUTPUT WAVEFORM
3 CHOOSING YOUR SETTINGS DIP Switch Settings (continued) Pulse Train Input (SB1-1) You must define the format of the directional pulses from your indexer. Directional pulses generally have one of two formats; Step & Direction or CW/CCW. Some indexers can be programmed to output either. Figure 3.4 shows the differences between the two formats and the SD17063’s switch settings for each. The factory default setting is CW/CCW.
CHOOSING YOUR SETTINGS 3 DIP Switch Settings (continued) Current Loop Gain (SB1-4 & SB1-5) Current loop gain refers to the gain of the closed loop amplifier that controls the current through the motor. Its default setting of TYPICAL is designed to work with motors whose inductance value is above 2.5 mH. You should use the default setting for all AMCI motors except for the SM42 when it is parallel connected to the SD17063. Non-AMCI motors that are series connected should also use the default setting.
3 CHOOSING YOUR SETTINGS DIP Switch Settings (continued) Output Waveform (SB2-4 & SB2-5) Physical inaccuracies in the motor, such as tolerances in windings and laminations, tend to add a third harmonic to the dynamic torque curves of a stepper motor. This additional dynamic torque is not evident when full-stepping the motor. However, this harmonic torque can have a pronounced effect when half-stepping or microstepping the motor by affecting resolution and smooth motor operation.
3 CHOOSING YOUR SETTINGS DIP Switch Settings (continued) Step Resolution (SB3-1,2,3,4) The SD17063 offers sixteen step resolutions. Based on a 1.8° per step motor, figure 3.5 lists the available step resolutions along with the amount of rotation per indexer pulse. Step Resolution Switch Block 3: Switches 1 – 4 O1 2 3 4 5 N SB1 The resolution that you should choose is dependent on your application and equipment.
3 CHOOSING YOUR SETTINGS DIP Switch Settings (continued) Motor Current (SB3-5 & SB4-1,2,3,4,5) Your motor current setting is based on the amount of torque you need. Torque curves for our motors are available in Appendix A: CHOOSING YOUR MOTOR, starting on page 45. Table 3.1 gives the maximum current ratings for all of our stepper motors. In the cases of the SM34-650D and SM42-1250D, the maximum current of 6.3 amps is the limit of the SD17063, not the motor.
3 CHOOSING YOUR SETTINGS DIP Switch Settings (continued) Motor Current (SB3-5 & SB4-1,2,3,4,5) MOTOR CURRENT (Pg 2 of 3) Switch Block 3: Switch 5 & Switch Block 4: Switches 1 – 5 O1 2 3 4 5 N SB1 O1 2 3 4 5 N SB2 O1 2 3 4 5 N SB3 O1 2 3 4 5 N SB4 1.3 Amps 2.3 Amps 3.3 Amps 1.4 Amps 2.4 Amps 3.4 Amps 1.5 Amps 2.5 Amps 3.5 Amps 1.6 Amps 2.6 Amps 3.6 Amps 1.7 Amps 2.7 Amps 3.7 Amps 1.8 Amps 2.8 Amps 3.8 Amps 1.9 Amps 2.9 Amps 3.9 Amps 2.0 Amps 3.0 Amps 4.0 Amps 2.1 Amps 3.
3 CHOOSING YOUR SETTINGS DIP Switch Settings (continued) Motor Current (SB3-5 & SB4-1,2,3,4,5) MOTOR CURRENT (Pg 3 of 3) Switch Block 3: Switch 5 & Switch Block 4: Switches 1 – 5 O1 2 3 4 5 N SB1 O1 2 3 4 5 N SB2 O1 2 3 4 5 N SB3 O1 2 3 4 5 N SB4 4.3 Amps 5.0 Amps 5.7 Amps 4.4 Amps 5.1 Amps 5.8 Amps 4.5 Amps 5.2 Amps 5.9 Amps 4.6 Amps 5.3 Amps 6.0 Amps 4.7 Amps 5.4 Amps 6.1 Amps 4.8 Amps 5.5 Amps 6.2 Amps 4.9 Amps 5.6 Amps 6.
CHAPTER 4 GENERAL INSTALLATION GUIDELINES This chapter gives general information on installing electronic controls in an industrial environment including the importance of proper wiring, grounding, and surge suppression. If you are responsible for installing the SD17063, make sure you are familiar with these practices and follow them when installing the unit. This chapter is presented as a tool in the hopes of avoiding common installation problems.
4 GENERAL INSTALLATION GUIDELINES Grounding Proper grounding is the single most important consideration for a safe installation. Proper grounding also ensures that unwanted electrical currents, such as those induced by electromagnetic noise, will be quickly shunted to ground instead of flowing throughout the machine. h All ground connections must be permanent and continuous to GROUND BUS provide a low-impedance path to earth ground for induced noise currents.
4 GENERAL INSTALLATION GUIDELINES Wiring (continued) h Motor Wiring (High Power AC & DC) 1) Motor Wiring must be kept separate from the indexer cabling and other low power I/O wiring in order to lessen the possibility of coupling transient noise into the low power cabling. 2) If a conduit containing the indexer cabling or other low power wiring must cross conduit that contains motor wiring, they must cross at right angles.
4 GENERAL INSTALLATION GUIDELINES Surge (EMI) Suppression (continued) Surge Suppression: DC Outputs All inductive DC loads require a commutating, or “fly-back” diode across the load. Inductive DC loads include relays, solenoids, and DC motors. Unlike resistors, diodes have a polarity and only conduct current in one direction. Therefore, care must be taken when installing diodes.
CHAPTER 5 INSTALLING THE SD17063 REV B. Installing the SD17063 Installing the SD17063 is broken down into six steps. Step 1: Step 2: Step 3: Step 4: Step 5: Step 6: Installing the Drive Connecting the Indexer Installing the Stepper Motor Connecting the Motor Grounding and Powering the System Testing the System If the SD17063 is new to you, consider running the drive’s Self Test on a bench to familiarize yourself with the drive before installing it.
Grounding Lug 3.00" (76.2) (32.51) 1.280" L N GND 8.60" 8.02" 5.53" (140.5) 0.70" (17.8) max. Total clearance of 3.0" (76.2) needed for Connector installation and removal. 0.400" (38.10) 1.500" (10.16) (203.7) (3.86) typ. (218.3) (4.78) 0.188" 0.152" Stepper Drive SD17063 95 – 132 VAC 50/60 Hz AC POWER INTERLOCK A CTAP A A EARTH GND B B B CTAP INTERLOCK POWER MOTOR FAULT OVER TEMP STEP DIR/CCW + DIR/CCW STEP/CW + STEP/CW DISABLE + DISABLE FAULT + FAULT RESET + RESET 0.
5 INSTALLING THE SD17063 Step 1: Installing the Drive (continued) Clearance Dimensions In order to assure proper convectional airflow around the SD17063, you must follow the clearance guidelines given in figure 5.2. If you don’t have this amount of area around the drive, you may need to install a small fan below it to force air up through the drive. 2.
5 INSTALLING THE SD17063 Step 2: Connecting the Indexer 1) All of the Indexer I/O connections are low power, low voltage signals. All cabling must be done with twisted pair wires with an overall shield. Belden 9729 instrumentation cable is one example of an acceptable cable. 2) Cable from the indexer can be installed in conduit along with other low power cabling such as communication cables and low power ac/dc I/O lines.
5 INSTALLING THE SD17063 Step 2: Connecting the Indexer (continued) A-B MicroLogix 1500 Many customers have started to use the Allen-Bradley MicroLogix 1500 as an indexer. The MicroLogix 1500 has a Pulse Train Output (PTO) Instruction that can be used to generate directional pulses to the SD17063. This instruction controls one output that generates the STEP pulses while your ladder logic controls an output that selects the DIRECTION. Outputs on the MicroLogix 1500 must be 24 Vdc.
5 INSTALLING THE SD17063 Step 2: Connecting the Indexer (continued) Disable Input Wiring (continued) The Fault Output is active, (it will not conduct current), when the Disable Input is active and the fault output remains active during the current ramp up time. Therefore, you can use the Fault Output to signal when the drive is ready to accept pulses instead of timing out the 275 milliseconds. (The active state of the Fault Output is off. Therefore, a loss of power appears as a fault condition.
INSTALLING THE SD17063 5 Step 3: Installing the Stepper Motor Outline Drawings Outline drawings for all of our motors can be found on our website, www.amci.com, in the Document Download section. They’re available in two formats, AutoCad DWG and high resolution JPG. JPG files can be viewed in most web browsers. If you do not have internet access contact AMCI and we will fax the information to you. Mounting the Motor All AMCI motor have flanges on the front of the motor for mounting.
5 INSTALLING THE SD17063 Step 4: Connecting the Motor Motor Connector The motor connector is shown in figure 5.6. The two Interlock terminals are a safety feature. When these two terminals are not connected, the drive will not power the motor outputs, and the drive turns on the Motor Fault LED and the Fault Output. For normal operation, these two terminals must be connected together with a short wire. The two center tap pins, A CTAP and B CATP, are there for wiring convenience only.
5 INSTALLING THE SD17063 Step 4: Connecting the Motor (continued) Four Lead Motors As shown in figure 5.7, a four lead motor can be connected to the SD17063 in only one way. Many four lead motors, including AMCI’s SM42 motors, have eight wires inside the motor. These wires are connected in series or parallel in the motor, and four leads are brought out to the drive.
5 INSTALLING THE SD17063 Step 4: Connecting the Motor (continued) Eight Lead Motor As shown in figure 5.9, an eight lead motor can be connected to the SD17063 in two ways. A Series Connected motor may offer more torque than a Parallel Connected motor at low speeds, but a parallel connected motor will always offer higher torque at high speeds. The operating temperature of a parallel connected motor is always higher than a series connected motor.
5 INSTALLING THE SD17063 Step 5: Grounding and Powering the System The chassis must be connected to earth ground. Failure to properly ground the chassis leaves the potential for severe electrical hazard and/or problems with normal operation. Properly grounding the SD17063 is accomplished by using the grounding lug. Run a minimum #8 gauge, stranded wire from the drive’s grounding lug to your system ground bus. The wire should be as short as possible.
5 INSTALLING THE SD17063 Step 6: Testing the System At this point, the physical installation should be complete. Testing the system includes an initial test to verify wiring, and short procedures to set Current Loop Gain, Output Waveform, and Anti-Resonance settings. Initial Test You may what to uncouple the motor from its load while running the initial test. 1) Verify that the rubber boots are in place on the motor and power connectors of the SD17063. 2) Apply 120 Vac power to the drive.
INSTALLING THE SD17063 5 Step 6: Testing the System (continued) Determining Current Loop Gain (continued) 4) Apply power to the SD17063. You should hear at least one sound from the motor in the 3 to 5 KHz range that subjectively sounds like AM radio hiss. This is normal. You may also hear a much higher pitched sound in the 10 KHz range. If you do, set the Current Loop Gain setting to REDUCED 1. (SB1-4 = 0 and SB1-5 = 1.) This should eliminate the higher pitched sound.
5 INSTALLING THE SD17063 Notes 44 ADVANCED MICRO CONTROLS INC.
APPENDIX A CHOOSING YOUR MOTOR Sizing Your Motor Your motor choice is based on the output torque you need, the mounting space you have, and your budgetary constraints. Torque curves for all of AMCI’s motors are available on the following pages. There are a few things to remember when choosing your motor based on torque curves. 1) The torque curves in this manual are for the SD17063.
A CHOOSING YOUR MOTOR Determining Your Motor Current Setting (continued) Because of this, its difficult to calculate the exact amount of high speed torque a motor will give you when you reduce its current setting. Its often easier to determine your optimum current setting by testing your machine at various current settings and then deciding which setting gives you the best performance.
A CHOOSING YOUR MOTOR Unipolar Ratings (continued) In order to avoid confusion, AMCI publishes the bipolar series and bipolar current ratings on all of our motors. For your convenience, Table 2.5, Stepper Motor Specifications on page 16 lists the maximum series and parallel currents for our motors. ––Torque (oz-in) –– - - - Power (W) - - - As a conversion example, assume a size 34, two stack motor has a unipolar current rating of 3.7 amps and you will be wiring the motor to the SD17063 in parallel.
A CHOOSING YOUR MOTOR Notes 48 ADVANCED MICRO CONTROLS INC.
APPENDIX B UPGRADING TO THE SD17063 REV. B This appendix gives information on upgrading from an AMCI SD8055 or older revision SD17063 to the SD17063 rev. B. This information is valuable if you are replacing one of these units or are upgrading the design of your system. Information on setting the switches of an SD17063 rev. B to mimic the older units is given as well as information on wiring and operation changes.
B UPGRADING Replacing a SD8055 (continued) Indexer Connector Wiring Changes h ± Step and ± Direction: Can be brought over directly to the SD17063. h ± Enable Input: Can be brought over to the SD17063’s ± Disable Input. Any current limiting resistors used because the input voltage exceeds 5 Vdc must be replaced. 12 to 15 Vdc systems that used a 1KΩ resistor with the SD8055 must replace them with 2 KΩ resistors. 24 Vdc systems need to replace the 2 KΩ resistor with a 3.9 KΩ resistor.
UPGRADING B Replacing a SD8055 (continued) Grounding Lug Connection A grounding wire from the SD17063’s grounding lug to your system’s ground bus must be installed. See figure 5.10, Power and Grounding Connections on page 41 for more information.
B UPGRADING Replacing an Older SD17063 The older SD17063 stepper drive has also been phased out and replaced by the SD17063 rev. B. The older SD17036 is still supported by AMCI but it is no longer sold as a new unit. The SD17063 rev. B has several additional features but the two drives are basically the same. The new Current Loop Gain feature, and improvements to the Idle Current and Anti-Resonance features, are the primary enhancements to the SD17063 rev. B drive.
APPENDIX C TROUBLESHOOTING Self Test Mode The Self Test can be used to familiarize yourself with the drive or test the SD17063 and motor hookup without an indexer. To run the Self Test on a bench, use the following instructions: 1) Indexer connections are not necessary. If you have a 5 to 24 Vdc power supply, you can wire switches to the ±Disable and ±Reset inputs. See figure 5.4, Single Ended Input Connections, on page 35.
C TROUBLESHOOTING Troubleshooting Tables The following tables list problem symptoms and possible solutions. The tables break the problem symptoms into categories to make it easier to search for your specific problem. Cross-references into the manual are sometimes given that leads to additional information. Indicator LED’s Symptom Solution A Velocity Step Violation has occurred. The frequency of the direcpulses from the indexer exceeded 2 MHz.
C TROUBLESHOOTING Troubleshooting Tables (continued) Motor Problems Symptom Solution 1) If any of the Indicator LED’s are on, other than the POWER LED, refer to the Indicator LED’s table on the preceding page. 2) If the motor rotates when commanded but has no holding torque, then your Idle Current Reduction switches are set to the To 0% setting which removes motor current when the drive is idle for more The motor has no holding torque. than one second. See figure 3.
ADVANCED MICRO CONTROLS INC. 20 GEAR DRIVE, TERRYVILLE, CT 06786 T: (860) 585-1254 F: (860) 584-1973 www.amci.
