Intelligent Motion Systems IM805, Operating Instructions Manual

Page 1: ...5 HIGH PERFORMANCE MICROSTEPPING DRIVE STANDARD DRIVER CONNECTOR OPTIONS COOLING SOLUTIONS ACCESSORIES OPERATING INSTRUCTIONS 370 N MAIN ST PO BOX 457 MARLBOROUGH CT 06447 PH 860 295 6102 FAX 860 295...

Page 2: ...rights of others Intelligent Motion Systems and are trademarks of Intelligent Motion Systems Inc Intelligent Motion Systems Inc s general policy does not recommend the use of its products in life sup...

Page 3: ...Section Overview 19 Selecting a Power Supply 19 Selecting an Opto Supply 21 Recommended Wiring 22 AC Line Filtering 23 Motor Requirements 24 Section Overview 24 Selecting a Motor 24 Motor Wiring 29 Co...

Page 4: ...ndix Overview 55 IM805 34P1 56 IM805 8P2 61 IM805 34P1 8P2 62 IM805 PLG 63 Cooling Solutions 65 H 4X Heat Sink Kit 65 Thermal Non Isolating Pad TN 48 65 Accessories 66 Appendix Overview 66 U3 CLP Side...

Page 5: ...Interface 45 Figure 7 7 Open Collector Interface 46 Figure 7 8 TTL Interface 46 Figure 7 9 LYNX Interface 47 Figure 7 10 The Fault Output Connected to an LED 48 Figure 7 11 The Full Step Output Conne...

Page 6: ...signment and Description 12 Table 3 1 IM805 Mounting Screw Washer Requirements 14 Table 5 1 Motor Power Supply Requirements 20 Table 5 2 5 VDC Power Supply Requirements 21 Table 7 1 Current Adjust Res...

Page 7: ...set the driver This feature allows the user to rapidly move long distances yet precisely position the motor at the end of travel without the expense of high performance controllers With the developmen...

Page 8: ...the standard IM805 driver which come with 8 position screw terminals as a connection medium The different connector input options and accessories are covered in detail in the appendices T h e B o o k...

Page 9: ...the maximum input voltage of the IM805 WARNING A current adjustment resistor is always necessary to keep the Driver and or Motor in a safe operating range DO NOT operate the IM805 Driver without a cu...

Page 10: ...tion pin de scription power environmental and thermal requirements of the IM805 It is broken down as follows n Mechanical Specifications n Electrical Specifications n Thermal Specifications n Pin Assi...

Page 11: ...tructions Revision R032306 E l e c t r i c a l S p e c i f i c a t i o n s Test Condition TA 25 C V 75VDC Table 2 1 IM805 Electrical Specifications Includes motor back EMF Lower currents may be used f...

Page 12: ...i o n Figure 2 2 IM805 Pin Configuration NOTE This pin configuration diagram and table represent the pinout of any 8 position connector used for P1 If you purchased the IM805 34P1 option 34 Position H...

Page 13: ...he IM805 components are sensitive to ElectroStatic Discharge ESD All handling should be done at an ESD protected workstation WARNING Hazardous voltage levels may be present if using an open frame powe...

Page 14: ...Descriptions S t a t u s I n d i c a t o r s Green Power On Red Fault Figure 2 3 Status Indicator LED The IM805 features a two color LED mounted to the left of connector P2 for status indication When...

Page 15: ...diameter greater than 0 230 inches 5 8 mm an insulating washer MUST be used to maintain proper electrical isolation between the mounting screw and the IM805 s components The washer must have a minimum...

Page 16: ...ay result in damage to the driver circuitry Use ONLY the hardware recommended by this document to mount the IM805 to your panel or heat sink plate The following insulating washers listed by vendor and...

Page 17: ...or such appli cations In order to subdivide motor steps into microsteps while maintaining positional accuracy precise current control is required The IM805 ac complishes this by the use of a unique Du...

Page 18: ...hase B position reference This digitally encoded 9 bit sine and 9 bit cosine signal is directly fed into a digital to analog converter The step clock SCLK and direction DIR inputs are buffered using S...

Page 19: ...s up through the bridge and back to the supply in the OFF phase of the cycle This method of controlling current allows for much better response but reduces efficiency and increases current ripple espe...

Page 20: ...r of microsteps in between A controller that utilizes this output can greatly reduce its position tracking overhead thus substantially increasing its throughput Interface guidelines and a sample appli...

Page 21: ...time between steps to reach current The point where the rate of commutation does not allow the driver to reach full current is referred to as voltage mode Ideally you want to be in current mode which...

Page 22: ...ne voltage are also a point of concern These fluctuations may cause the unregulated linear supply to be above or below the antici pated or acceptable voltage A regulated supply maintains a stable outp...

Page 23: ...below are the power supplies recommended for use with the IM805 I P 8 0 4 I P 8 0 4 2 4 0 U n r e g u l a t e d L i n e a r S u p p l y Range Input 120 VAC Version 102 132 VAC 240 VAC Version 204 264...

Page 24: ...than 4 amps n Do not Daisy Chain power wiring to system components R u l e s o f S h i e l d i n g n The shield must be tied to zero signal reference potential In order for shielding to be effective i...

Page 25: ...ARNING Turn off the AC power side to power down the DC power supply WARNING For battery operated systems connect a transient suppressor across the power switch to prevent arcs and high voltage spikes...

Page 26: ...eyond the scope of this document they are details that you must know in order to select a motor that is appropriate for your application These details will affect everything from the power supply volt...

Page 27: ...le Duty cycles that exceed 50 can cause unstable chopping This character istic is directly related to the motor s winding inductance In order to avoid this situation it is necessary to choose a motor...

Page 28: ...een by the driver will be as specified Using the following equation we will show an example of sizing a motor for a IM805 used with an unregulated power supply with a minimum voltage V of 18 VDC 2 X 1...

Page 29: ...oz in M 2218 2 4 to 1303 oz in M 3447 6 3 64 N cm to 920 N cm These CE rated motors are ideal for applications where higher torque is required For more detailed information on these motors please see...

Page 30: ...IOS motor can replace gearboxes in applications where gearboxes are used for inertia damping between the motor and the load The induced backlash from the gearbox is eliminated providing improved bi di...

Page 31: ...Mo tor cabling exceeding 1 in length should be shielded twisted pairs to reduce the transmission of EMI Electromagnetic Interference which can lead to rough motor operation and poor system performance...

Page 32: ...rade at higher speeds Use the per phase or unipolar current rating as the peak output current or multiply the bipolar current rating by 1 4 to determine the peak output current P a r a l l e l C o n n...

Page 33: ...of 8 lead motor the torque output will be more stable at higher speeds This configuration is also referred to as half copper In setting the driver output current multiply the speci fied per phase or u...

Page 34: ...rs are the least flexible but easiest to wire Speed and torque will depend on winding inductance In setting the driver output current multiply the specified phase current by 1 4 to determine the peak...

Page 35: ...run as pairs When leaving the driver module motor cables should not run paral lel with other wires Phases should be wired using twisted pairs If motor cabling in excess of one foot is required motor c...

Page 36: ...Screw Tightening Torque 4 5 lb in 0 5 N m WARNING Do not exceed the recommended tightening torque for the screw terminals WARNING Do not connect or disconnect any wiring when power is applied M o t o...

Page 37: ...or values The IM805 also has an automatic current reduction feature which allows the user to reduce the current in the motor windings to the level required to maintain holding torque thus allowing for...

Page 38: ...rent setting that would be used with different motor lead configurations 4 L e a d M o t o r s Multiply the specified phase current by 1 4 to determine the peak output current 6 L e a d M o t o r s 1...

Page 39: ...motor windings in series use the per phase or unipolar current rating as the peak output current or multiply the bipo lar current rating by 1 4 to determine the peak output current PARALLEL CONNECTION...

Page 40: ...iver P2 2 P2 3 Driver Output Current 002 X Resistor Value W Current Adjust Resistor 1 8 W 1 W Figure 7 2 illustrates the connection of this resistor Table 7 1 lists the resistor values for the driver...

Page 41: ...moves the drive may be disabled by pulling the enable disable input P1 5 to ground by means of a sinking output on your controller or PLC or by placing a shunt between pins 1 and 2 of connector P2 No...

Page 42: ...motor 800 Fullsteps Rev set to 16 microsteps step will have a resolution of 12 800 steps rev These settings may be switched on the fly There is no need to reset or disable the drive in order to chang...

Page 43: ...41 IM805 Operating Instructions Revision R032306 Table 7 2 Microstep Resolution Switch Settings e e...

Page 44: ...ut is internally pulled up to the level of the optocoupler supply and may be connected to sinking outputs on a controller such as the IMS LYNX or a PLC These inputs are 1 Step Clock P1 2 2 Direction P...

Page 45: ...higher voltage supply a current limiting resistor must be placed in series with the input or damage will occur to the IM805 s input circuitry rendering the drive inoperable Table 7 3 Recommended Inpu...

Page 46: ...e R e s e t P 1 6 The reset input will disable the outputs and reset the driver to its initial state Phase A OFF Phase B full ON when pulled LOW by a switch or sinking output Use of this input may als...

Page 47: ...3 TTL Interface We will also show IM805 inputs connected to the IMS LYNX modular mo tion controller which is a powerful machine control soulution S w i t c h I n t e r f a c e A switch connected betwe...

Page 48: ...or is required if an opto supply voltage greater than 5 VDC is used Figure 7 7 Open Collector Interface T T L I n t e r f a c e Figure 7 8 shows a TTL device connected to the enable input This inter f...

Page 49: ...pler supply voltage to two IM805 drivers The LYNX isolated I O may also be used to control the enable and reset inputs the MSEL inputs IM805 34P1 and receive feed back from the fault and fullstep outp...

Page 50: ...tion When the fault output becomes active it disables the driver outputs and latches in this condition It can only be cleared by toggling the reset input LOW or by powering OFF then powering ON the dr...

Page 51: ...op control merely a method of monitoring position and repeatability It represents full steps commanded by the driver not actual full steps moved by the motor The application example shown in figure 7...

Page 52: ...5 Operating Instructions Revision R032306 M i n i m u m C o n n e c t i o n s The following figure illustrates the minimum connection requirements for the IM805 Figure 7 12 IM805 Minimum Required Conn...

Page 53: ...lem As part of this process you may have to disconnect the individual components that make up your system and verify that they operate inde pendently It is important to document each step in the trou...

Page 54: ...ult P o s s i b l e P r o b l e m Current adjust resistor is incorrect value or not in place Motor phase winding shorted Power input or output driver electrically overstressed S y m p t o m Erratic mo...

Page 55: ...t too high Power supply voltage too low S y m p t o m Excessive motor and driver heating P o s s i b l e P r o b l e m Inadequate heat sinking cooling Current reduction not being utilized Current set...

Page 56: ...unavailable ensure that the product is enclosed in approved antistatic packing material Write the RMA number on the box The normal repair lead time is 10 business days Should you need your product re...

Page 57: ...rol method are discussed later in this appendix I M 8 0 5 8 P 2 This connector option uses 8 0 045 square pins at the P2 connector location The P1 connector location uses 8 0 025 square pins This conn...

Page 58: ...llow for remote control of the output resolution 2 Step Direction outputs follow the step direction inputs allow ing for multiple drives to be cascaded 0 100 2 54 0 100 2 54 8X 0 025 0 64 Sq Post Tin...

Page 59: ...57 IM805 Operating Instructions Revision R032306 Table A 1 IM805 34P1 Connector P1Pin Assignment and Description...

Page 60: ...inputs are non isolated and are active when in a logic LOW state if left open or floating the input is considered to be OFF They are pulled up to 5 VDC via 1 5 k resistors These inputs may to be inte...

Page 61: ...1 1 1 0 0 0 1 0 1 0 0 1 1 1 1 1 1 1 1 1 1 xxxxxxx 1 18 34 17 Microsteps per Full Step MSEL 0 MSEL 1 MSEL 2 MSEL 3 Microsteps per Full Step MSEL 0 MSEL 1 MSEL 2 MSEL 3 2 0 0 0 0 1 0 0 0 0 1 0 0 1 1 0 0...

Page 62: ...ice and the drives connected to the step direction outputs to follow the primary Figure A 4 illustrates a possible connection application of these outputs These outputs used in this configuration woul...

Page 63: ...rap the IM805 directly into a system interface or use a receptacle to make the connections Figures A 5 and A 6 show the pin dimensions 0 720 18 29 0 820 20 83 0 200 5 08 8X 0 025 0 64 Sq Post Tin Plat...

Page 64: ...es the features and potential uses of the IM805 34P1 and the IM805 8P2 The connector pins used for connector P2 are identical to those used on the IM805 8P2 This option may be wire wrapped or plugged...

Page 65: ...d details please see Appendix D Accessories BB 34 4P I M 8 0 5 P L G The IM805 PLG replaces both connectors P1 and P2 with an Altech 8 position pluggable interface The removeable plug in screw termina...

Page 66: ...64 IM805 Operating Instructions Revision R032306 Figure A 10 IM805 PLG Pin Location and Orientation 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 Connector P2 Connector P1...

Page 67: ...n s 6 00 152 4 5 50 139 7 3 15 80 1 3 51 89 5 6 X32 Threaded 4 PLACES 0 85 21 6 Figure B 1 H 4X Heat Sink Dimensions in Inches mm T h e r m a l N o n I s o l a t i n g P a d T N 4 8 The TN 48 thermal...

Page 68: ...for the IM805 IM483 series of Microstepping drivers and driver indexers and the ISP200 and ISP300 series power supplies to decrease overall panel space and allow for more flexible mounting patterns Th...

Page 69: ...They are not interchangeable They can however be attached to either vertical plate of the aluminum channel case WARNING The maximum plate temperature for all the units that may be used with these cli...

Page 70: ...P n Wire Size 16 22 AWG n Strip Length 0 200 5mm n Screw Torque 3 0 lb in 0 33 N m Mechanical specifications are illustrated in Figure C 4 I n s t a l l a t i o n To install the BB 34 4P first remove...

Page 71: ...Direction Output Pin 22 MSEL 0 Pin 23 MSEL 1 Pin 25 Ground Pin 27 N C Pin 29 N C Pin 31 N C Pin 33 MSEL 2 Pin 24 On Full Step Output Pin 26 N C Pin 28 N C Pin 30 N C Pin 32 N C Pin 34 N C No Connectio...

Page 72: ...l set for the IM805 PLG connection configuration Be cause the PLG is configured to eliminate the possibility of plugging the driver in backwards the kit includes two unique terminal blocks one each fo...

Page 73: ...mply with all of the terms set forth in this Limited Warranty This Limited Warranty is the sole warranty offered by IMS with respect to the Product IMS does not assume any other liability in connectio...

Page 74: ...3 Stage 139 14 1 G1C8 3 Stage 149 90 1 G1C9 3 Stage 168 85 1 G1D1 3 Stage 181 25 1 G1D2 3 Stage 195 27 1 G1D3 3 Stage 236 10 1 G1D4 3 Stage 307 55 1 G1D5 Planetary Gearbox Parameters other MDrive17Plu...