Pacific Scientific 6415 Installation & Hardware Reference Manual Download Page 7

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4 Maintaining/Troubleshooting

4-1

4.1 Maintaining the 6415 Drive . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 Troubleshooting the 6415 Drive . . . . . . . . . . . . . . . . . . . 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 & Hardware Reference Manual

Summary of Contents for 6415

Page 1: ...l service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE INSPECTION Remotely inspect equipment before purchasing with our interactive website at www instraview com LOOKING FOR MORE INFORMATION Visit us on the web at www artisantg com for more information on ...

Page 2: ...M A 6 4 1 5 6 4 1 5 Oscillator Drive Installation Hardware Reference Manual 110 Fordham Road Wilmington MA 01887 978 988 9800 Fax 978 988 9940 Part MA6415 List Price 25 U S December 1998 Rev E ...

Page 3: ...ific Scientific Company It is 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 ...

Page 4: ...ic 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 th...

Page 5: ... 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 OPERA...

Page 6: ...J3 Motor Connections 2 9 2 5 2 J2 Power Connector 2 17 2 5 3 J4 Signal Interface Connector 2 19 3 Powering Up the 6415 Drive 3 1 3 1 Oscillator Board Settings 3 2 3 1 1 Potentiometer Settings 3 3 3 1 2 Jumper Settings 3 6 3 2 Drive Board Settings Switch S1 Jumper J6 3 15 3 2 1 Step Size 3 16 3 2 2 Digital Electronic Damping Control 3 17 3 2 3 Idle Current Reduction 3 18 3 2 4 Setting Motor Current...

Page 7: ...4 2 Troubleshooting the 6415 Drive 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 Hardware Reference Manual ...

Page 8: ...rincipal 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...

Page 9: ...ow 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 los...

Page 10: ...ing 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 s...

Page 11: ...igital 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 magnetic 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 ...

Page 12: ...iometer 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...

Page 13: ...ration 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 ...

Page 14: ...tor wafer polishing Constant speed applications 1 2 Other System Components Overview The other components that along with the drive comprise a complete motor control system are Single logic power supply 4 75 5 25 Vdc Single bus power supply 24 75 Vdc Motor Installation guidelines for these components are described in Chapter 2 Installing the 6415 Stepper Motor Drive 6415 Installation Hardware Refe...

Page 15: ...Hardware Reference Manual Rev E 8V External Pot Analog Input Run Stop Cmd Low Speed Cmd Direction Cmd Enable Cmd Step Pulse Out VCO Input Mon 5V Opto Supply Oscillator Drive Motor 13 5V Step Pulse Direction Enable Unregulated Power Supply 24Vdc to 75Vdc User s Control Electronics 6415 Oscillator Drive ...

Page 16: ...d power up instructions contained in Chapter 2 and Chapter 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 Hardware Reference Manual Rev ...

Page 17: ...nst the packing list A label located inside the chassis of the unit identifies the unit by model number serial number and date code Inspection procedure Inspect the unit for any physical damage that may have been 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...

Page 18: ...sonal 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 Do not make any connections to the internal circuitry The input and output signals are the only safe connection points Always remove power before ma...

Page 19: ...on Control Solutions Catalog or contact your local Pacific Scientific distributor for sizing and motor compatibility assistance Selecting bus power supply A single power supply is required to operate the 6415 unit Note In 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...

Page 20: ...pation 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...

Page 21: ...his 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 Panel mounting 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...

Page 22: ...n and Hardware Reference Manual Rev E B A B A 6415 CUSTOMER MTG 4 75 120 7mm OPTIONAL SIDE MTG CLEARANCE FOR M4 or 6 32 SCREW 2 75 69 9 mm 1 50 38 1 mm 5 00 127 0 mm 0 04 CUSTOMER MTG 0 75 19 1 mm 0 02 0 02 0 04 1 10 27 9 mm 4 30 109 2 mm 0 04 0 02 0 04 ACCEL RAMP RUN SPEED LOW SPEED DECEL RAMP LED 1 ...

Page 23: ... 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 J1 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 Ref...

Page 24: ..._OUT 8V_REF_OUT EXTERNAL_POT GNDA GNDA GNDA GNDA ANALOG_INPUT ANALOG_INPUT LOW_SPD LOW_SPD RUN RUN STOP STOP DIR DIR ENABLE ENABLE STEP_OUT STEP_OUT STEP_OUT STEP_OUT User s Control Electronics J4 1 2 3 4 5 6 7 8 9 NOT USED 5 4 3 2 1 1 2 3 J3 J2 DC DC Case GND Unregulated 24Vdc to 75Vdc 2 Phase Stepper Motor Phase A Phase A Phase B Phase B Case GND J1 6415 OSCILLATOR DRIVE ...

Page 25: ...hock hazard reduction Refer to section 2 2 for safety information that must be followed to reduce shock hazard 2 5 1 J3 Motor Connections Introduction 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 ...

Page 26: ...with the mating connectors already attached install as follows Note All wires are 16 AWG 2 10 6415 Installation and Hardware Reference Manual Rev E 1 5 J3 5 Pin PCD 6415 SPC XXX 6410 5 Pin MS Connector MOTOR JACKET MOTOR PHASES A B CASE GND A B 1 2 3 4 5 A B C D E BLK ORG RED YEL GRN ...

Page 27: ...tes to a PCD 5 pin screw cable connector The mating cable connector is type ELVP05100 Cable requirements The mating connector terminals will accept 16 to 28 AWG wire 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 per centimeter for the motor phase excitations and a fifth wire for t...

Page 28: ...te Make sure the screws on the PCD connector are tightened down firmly on the wiring Caution Do not solder the tips of the cables before insertion into the connector Solder can contract and cause a loose connection over time 2 12 6415 Installation and Hardware Reference Manual Rev E 5 4 3 2 1 To Drive To Motor A Black A Orange B Red B Yellow Motor Case Gnd Green 27 in 27 in 27 in 27 in 27 in 7 mm ...

Page 29: ...tions at the motor end 6415 Installation and Hardware Reference Manual Rev E 2 13 Installation TO J3 4 TO J3 4 TO J3 4 TO J3 5 TO J3 5 TO J3 5 TO J3 3 TO J3 3 TO J3 3 TO J3 2 TO J3 2 TO J3 2 TO J3 1 TO J3 1 TO J3 1 A A A A A A B B B B B B DRIVE EARTH GROUND DRIVE EARTH GROUND DRIVE EARTH GROUND FOUR LEAD MOTOR EIGHT LEAD MOTOR CONNECTED IN PARALLEL EIGHT LEAD MOTOR CONNECTED IN SERIES BLK BLK ORG ...

Page 30: ...d 8 lead motors with series windings 2 14 6415 Installation and Hardware Reference Manual Rev E TERMINAL TERMINAL TERMINAL CASE CASE CASE FOUR LEAD MOTOR EIGHT LEAD MOTOR CONNECTED IN PARALLEL EIGHT LEAD MOTOR CONNECTED IN SERIES DRIVE EARTH GROUND DRIVE EARTH GROUND DRIVE EARTH GROUND A A A A A A B B B B B B 1 3 2 4 TO J3 1 TO J3 1 TO J3 1 TO J3 2 TO J3 2 TO J3 2 TO J3 3 TO J3 3 TO J3 3 TO J3 4 T...

Page 31: ...windings 6415 Installation and Hardware Reference Manual Rev E 2 15 Installation MS CONNECTOR MS CONNECTOR MS CONNECTOR CASE CASE CASE DRIVE EARTH GROUND DRIVE EARTH GROUND DRIVE EARTH GROUND FOUR LEAD MOTOR EIGHT LEAD MOTOR CONNECTED IN PARALLEL EIGHT LEAD MOTOR CONNECTED IN SERIES A A A A A A B B B B B B A B C D E TO J3 1 TO J3 1 TO J3 1 TO J3 2 TO J3 2 TO J3 2 TO J3 4 TO J3 4 TO J3 4 TO J3 5 TO...

Page 32: ...nnector and can be configured with either parallel or series windings 2 16 6415 Installation and Hardware Reference Manual Rev E CONNECTOR CONNECTOR PARALLELED WINDINGS SERIES WINDINGS CASE CASE MOTOR MOTOR DRIVE EARTH GROUND DRIVE EARTH GROUND TO J3 1 TO J3 1 TO J3 2 TO J3 2 TO J3 3 TO J3 3 TO J3 4 TO J3 4 TO J3 5 TO J3 5 6 2 5 1 8 4 7 3 A A A A B B B B 6 2 5 1 8 4 7 3 ...

Page 33: ...xample 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 ...

Page 34: ...per inch 1 to 1 5 turns per centimeter 2 18 6415 Installation and Hardware Reference Manual Rev E BUSS MDA 10 FUSE BUSS MDA 10 FUSE BUSS MDA 10 FUSE AC IN AC IN EARTH GROUND EARTH GROUND 3 FEET MAX 3 FEET MAX TWISTED TWISTED TWISTED J2 J3 J1 2 1 3 TO OTHER AXES SINGLE AXIS MULTIPLE AXES J2 J2 J3 J3 J1 J1 2 2 1 1 3 3 ...

Page 35: ...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 an...

Page 36: ...center tap of the external customer potentiometer The voltage at this point controls the VCO oscillator frequency GNDA J4 4 5 16 17 Drive module return This return is used in conjunction with the external customer potentiometer and step output interface and is not referenced directly to the user supply return ANALOG_IN J4 18 Differential amplify analog input with customer supplied 10Vdc to 10Vdc a...

Page 37: ...te when the RUN opto is driven momentarily In single run mode the run opto is controlled directly from the RUN input RUN_SPD J4 8 STOP J4 21 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 ...

Page 38: ...LE 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 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 enabling the driv...

Page 39: ...Hardware Reference Manual Rev E 2 23 Installation TLP 2601 DIR DIR 22 10 STOP STOP RUN RUN 20 8 21 9 23 11 TTL TTL TTL TTL USER S CONTROL ELECTRONICS 5 Vdc STEPPER DRIVE 6415 ENABLE ENABLE J4 2 21K 2 21K 2 21K 2 21K 1K 1K TLP 621 TLP 621 TLP 621 1K 1K 19 7 TTL LOW_SPD LOW_SPD 2 21K TLP 621 1K MOTION BEGINS WITHIN 50 s µ SETUP TIME RUN INPUT DIRECTION INPUT DIRECTION DATA 50 s MIN µ OVER THIS INTER...

Page 40: ...ctor outputs pull up resistors R2 should be added as shown A typical value of R2 is 2 7K Opto Supply to 6415 R1 12 Vdc 1 5 K 15 Vdc 2 2 K 30 Vdc 6 8 K 2 24 6415 Installation and Hardware Reference Manual Rev E R1 R1 R1 R1 R1 R2 R2 R2 R2 R2 TLP 2601 DIR DIR 22 10 STOP STOP RUN RUN 20 8 21 9 23 11 TTL TTL TTL TTL USER S CONTROL ELECTRONICS OPTO SUPPLY STEPPER DRIVE 6415 ENABLE ENABLE J4 2 21K 2 21K ...

Page 41: ...he J4 signal interface connector is 25 contact female D connector The mating cable connector is an ITT Cannon DB 255 with ITT Cannon DB110963 3 Hood 6415 Installation and Hardware Reference Manual Rev E 2 25 Installation ...

Page 42: ... 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 ...

Page 43: ...rol Mode 1 2 IN 3 4 IN 5 6 IN 1 2 IN 1 2 IN N A 1 2 IN 3 4 IN Internal RUN SPEED Potentiometer External Potentiometer External Analog Input External Analog Input scaled by internal RUN SPEED potentiometer LED1 RUN SPEED LOW SPEED ACCEL RAMP DECEL RAMP E3 1 1 6 E1 U13 E8 E7 E6 E5 E4 U16 U3 U14 U10 U12 U1 U2 U7 U8 U15 E2 U9 J4 1 14 25 Control Source DIR DIR Jumpers Analog In E6 OUT OUT IN IN IN OUT ...

Page 44: ...h 4 multi turn potentiometers LOW SPEED is typically set lower than 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 position The figure below shows the typical velocity pulse frequency ...

Page 45: ...ocity 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 twice the acceleration rate 3 4 6415 Installation and Hardware Reference Manual Rev ...

Page 46: ...0 STEP SIZE 1 25 Accel pot fully CW Tau 0 4sec Accel Rate B steps sec volts Speed controls Time 0 Accel Rate A 2 Accel Rate B Note tauA and tauB 0 4sec 2 52 5 04 157248 314496 8 6 4 2 0 500 000 375 000 250 000 125 000 STEP SIZE 1 25 Decel pot fully CW time 1 4sec steps sec volts Speed controls Time 0 tB 1 2 t A Decel Rate A Decel Rate B tA 1 4sec ...

Page 47: ...tentiometer 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 3 6 6415 Installation and Hardware Reference Manual Rev E 8V 1 2 3 4 E3 1 3 5 4 2 6 E1 8V LOW_SPD Control RUN Control STOP Control 332 6 04V 20 118mV CW LOW SPEED POT R43 1 K RUN SPEED POT R7 CW 10 150 10 K 7 99V 118mV DECEL POT R17 CW 25K ACCEL POT ...

Page 48: ...V LOW_SPD Control RUN Control STOP Control 332 6 04V 20 118mV CW LOW SPEED POT R43 1 K DECEL POT R17 CW 25K ACCEL POT R14 CW 1M STEP OUT Motion Profile Generator and VCO Speed Cmd and RUN STOP Controls Note means other connection is not shown USER S POT J4 6415 J4 15 J4 3 J4 16 8V_REF_OUT GND EXTERNAL_POT 10K ...

Page 49: ... LOW SPEED POT R43 1 K RUN SPEED POT R7 CW 10 150 10 K 7 99V 118mV DECEL POT R17 CW 25K ACCEL POT R14 CW 1M STEP OUT Motion Profile Generator and VCO Speed Cmd and RUN STOP Controls Note means other connection is not shown 0 CW CCW Speed Speed Cmd 16 2K 10K 10K 10K 10K 16 2K 0 01uF 0 01uF Gain 0 81 Tau 50usec ANALOG INPUT ANALOG INPUT J4 6415 J4 6 J4 18 USER S Signal Source ...

Page 50: ...32 6 04V 20 118mV CW LOW SPEED POT R43 1 K RUN SPEED POT R7 CW 10 150 10 K 7 99V 118mV DECEL POT R17 CW 25K ACCEL POT R14 CW 1M STEP OUT Motion Profile Generator and VCO Speed Cmd and RUN STOP Controls Note means other connection is not shown 0 CW CCW Speed Speed Cmd 16 2K 10K 10K 10K 10K 16 2K 0 01uF 0 01uF Gain 0 81 Tau 50usec ANALOG INPUT ANALOG INPUT J4 6415 J4 6 J4 18 USER S Signal Source ...

Page 51: ...requency Range IN Low Frequency 250 Khz maximum VCO output pulses OUT High Frequency 500 Khz maximum VCO output pulses Coarse Resolution E2 Removed Fine Resolution E2 Installed 3 10 6415 Installation and Hardware Reference Manual Rev E Speed Resolution 62 5Khz V 0 8V 0 500Khz 2V 4V 6V 375Khz 250Khz 125Khz Speed Resolution 31 25Khz V 0 8V 0 250Khz 2V 4V 6V 62 5Khz 125Khz 187 5Khz ...

Page 52: ... 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 Single Input E4 jumper removed If the E4 jumper is removed the RUN STOP mode of the drive is controlled directly from the RUN input When the RUN opto is driven the o...

Page 53: ...y 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 Source Jumper E6 Jumper E7 Jumper E8 DIR Opto Analog In Rotation DIR DIR ...

Page 54: ...e driven to enable the drive Minimum opto current opto on 3 ma Maximum opto current opto on 4 5 ma Oscillator Enabled LED LED is lit when drive is enabled A fault is indicated if the drive is commanded enabled but the LED is not lit 6415 Installation and Hardware Reference Manual Rev E 3 13 Powering Up USER S CONTROL ELECTRONICS 5Vdc OPTO SUPPLY J4 6415 ENABLE ENABLE 2 21K 1K TLP 621 ENABLE DISABL...

Page 55: ...llation and Hardware Reference Manual Rev E VCO 4 64K MMBT2907 ALT1 J4 6415 Step Pulse Out Step Output 8V_REF_OUT J4 12 J4 2 J4 13 J4 24 J4 25 TLP 2601 TLP 2601 TLP 2601 TLP 2601 6410 Stepper Drive 1 Step Input J1 1 J1 6 J1 1 J1 1 J1 1 J1 6 J1 6 J1 6 6410 Stepper Drive 2 Step Input 6410 Stepper Drive 3 Step Input 6410 Stepper Drive 4 Step Input 2 21K 2 21K 2 21K 2 21K 464 464 464 464 ...

Page 56: ...NABLE ENABLE SENSE JUMPER IDLE T JUMPER SELECT IDLE CURRENT REDUCTION TIME SEE TABLE BELOW DEC JUMPER SEE SW1 TABLE BELOW IN SELECT DECIMAL STEP SIZES OUT SELECT BINARY STEP SIZES STEP BW JUMPER REMOVED AT FACTORY JUMPERS 3 4 7 8 INSTALLED AT FACTORY OPEN IDLE T JUMPER SW1 POSITION 5 IDLE CURRENT REDUCTION IN IN OUT OUT CLOSED OPEN CLOSED OPEN DISABLED 0 1 SEC DELAY 0 05 SEC DELAY 1 0 SEC DELAY PC...

Page 57: ...e 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 smoother low speed operation ability to operate in low speed resona...

Page 58: ... 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 if your application is affected by loss of torque at mid range speeds If pulse placement techniques are being use...

Page 59: ... 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 t...

Page 60: ...enable opto This allows the 6415 to be used with no connection to the enable input With the J6 5 6 jumper installed the enable input must be driven current in opto for the 6415 power stage to be enabled 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 posi...

Page 61: ...hipping 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 electronic damping enabled Idle current reduction enabled 5 A rms moto...

Page 62: ... 3 1 Note J1 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...

Page 63: ...m 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 Getting help If you need further assistance with your installation please c...

Page 64: ...e 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 Output overcurrent line to line or line to neutral short Bus overvoltage Low voltage su...

Page 65: ... 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 24 Volts and 75 Vdc If possible check with a...

Page 66: ... 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 lit drive is disabled 1 Turn the bus power off 2 Disconnect the motor winding from the drive 3 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 Re...

Page 67: ...esent check for open circuit in motor phase winding by measuring resistance 3 One motor phase not wired correctly at stepping motor Check stepping motor wiring 4 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...

Page 68: ...le 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...

Page 69: ...urrent Setting 5 A 5A 0 25A 4 375 4 375 0 2A 3 75 3 75 0 2 A 3 125 3 125 0 15 A 2 5 2 5 0 15 A 1 875 1 875 0 125 1 25 1 25 0 125 0 625 0 625 0 1 A Drive circuit Two phase bipolar chopper current regulated Chopper frequency 20 KHz nominal 6415 Installation and Hardware Reference Manual Rev E A 1 Specifications ...

Page 70: ... 51200 Signal input requirements See circuit diagram Section 2 5 3 Optically Isolated Inputs Input Min Input Current Opto ON Max Input Current Max Reverse 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...

Page 71: ...0 ma Max Max Reverse voltage 50 Vdc 25 C Ambient 50 ma Max Max Reverse voltage 50 Vdc 50 C Ambient Maximum step rate 500 KHz Run Direction timing requirements The figure below show the required timing relationship between the RUN and DIRECTION inputs 6415 Installation and Hardware Reference Manual Rev E A 3 Specifications MOTION BEGINS WITHIN 50 s µ SETUP TIME RUN INPUT DIRECTION INPUT DIRECTION D...

Page 72: ...n 500 µsec At frequencies greater than 500 full steps sec delay is less than 270 of the input pulse period 2 With digital electronic damping circuit disabled delay is less than 10 µsec at all step frequencies RUN SPEED Control Analog Input Analog Input Range 10 Vdc Also controllable with internal or external potentiometers Analog Input Impedance 20 KΩ differential amp High Frequency Range RUN SPEE...

Page 73: ...bility Over Temp Range 1 of full scale typical ACCEL RAMP exponential accel pot fully CW 0 4 sec single time constant accel pot fully CCW 0 4 msec single time constant DECEL RAMP linear decel pot fully CW 1 4 sec decel pot fully CCW 6 0 msec 6415 Installation and Hardware Reference Manual Rev E A 5 Specifications ...

Page 74: ...perating Temperature Full rated current 0 to 50 C ambient air with or without cover provided chassis properly mounted so as not to exceed 60 C Storage Temperature 55o C to 70o C Maximum chassis temperature 60 C 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 m...

Page 75: ... 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 dissipation vs output current Figure 1 6415 Installation and Hardware Reference Manual Rev E A 7 Specifications 0 625 1 25 1 875 2 5 3 125 3 75 4 375 5 0 AMPS RMS 5 10 15 20 25 30 WATTS ...

Page 76: ... Supply PCD ELVH0310 connector Mating connector PCD ELVP03100 Signal 25 contact female D connector Mating connector ITT Cannon DB 255 with ITT Cannon DB110963 3 Hood Motor PCD ELVH0510 connector Mating connector PCD ELVP05100 A 8 6415 Installation and Hardware Reference Manual Rev E ...

Page 77: ...stallation and Hardware Manual MA6415 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 Installa...

Page 78: ...ic 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 Hardware Reference Manual Rev E ...

Page 79: ...urrent 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 section provides selection guidelines for the power supply comp...

Page 80: ...ent increases and winding failure Secondary voltage rating 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 excludi...

Page 81: ...ary voltage will increase Signal Transformer gives the following load regulation data for its line of rectifier transformers 1 VA Rating Load Regulation 1 100 10 100 350 8 500 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 disab...

Page 82: ...t 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 se...

Page 83: ...upply 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 IFSM 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 rat...

Page 84: ...e current rating 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 Example Suppose a 6415 is operating at 70 volts and is set for 5 A rms motor current Assuming a ...

Page 85: ...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 The mechanical energy of a spinning inertia is given by E 3 87 10 5 J S2 where E kinetic energy joules J inertia in oz in sec2 S speed in rpm Final voltage If this energy is converted to electrical energy in the form...

Page 86: ...sure 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 digi...

Page 87: ...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 25Ω ...

Page 88: ...ween 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 regener...

Page 89: ...acitor and regenerated power dump circuit are required The recommended fusing is also shown 6415 Installation Hardware Reference Manual Rev E C 11 Power Supply Considerations REGULATED POWER SUPPLY EARTH SAFETY GROUND 3 FEET MAX REGEN ZENER TWISTED BLEEDER RESISTOR 75 VOLT MAX 5 1K 2W 470UF BUS MDA10 FUSE 3 3 2 2 1 1 6420 J2 J2 6420 ...

Page 90: ...llowing examples give a flavor of just a few of the myriad applications for the 6415 D 1 Standalone Operation 6415 Installation Hardware Reference Manual Rev E D 1 Application Examples Power Supply Motor 6 4 1 5 Motor 6 4 1 0 User s Control Electronics ...

Page 91: ...ctor 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 D 2 6415 Installation Hardware Reference Manual Rev E Conveyer Belt Product to be Dispensed Paddlewheel Ejector Shipping Container 6415 Drive a...

Page 92: ...o plastic web is in position for cutting and sealing into bags 6415 Installation Hardware Reference Manual Rev E D 3 Application Examples Stepper Motor Thermal cutter sealer Pinch rolls Photoelectric Separate Run Stop position sensor Feed spool Plastic bags Pacific Scientific Model 6415 Oscillator Micro Stepping Drive Module ...

Page 93: ...rive Module to catch and stack fast moving shingles and then place them in a bundle forming chamber D 4 6415 Installation Hardware Reference Manual Rev E Pacific Scientific Model 6415 Oscillator Micro Stepping Drive Module shingles Right angle gearboxes Stepper Motor Bundle Start wheels ...

Page 94: ...nformation 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 fil...

Page 95: ...standards EN 61800 3 1996 Manufacturer s Contact Peter Deneault Compliance Engineer Issued By Pacific Scientific Motion Technology Division President William T Fejes Place Date Wilmington MA USA 10 29 98 Legally binding Signature E 2 6415 Installation and Hardware Reference Manual Rev E CE Declaration of Conformity Pacific Scientific Motion Technology Division 110 Fordham Road Wilmington MA 01887 ...

Page 96: ...e Manual Rev E E 3 CE Installation Guide 1 5 4 3 2 1 3 2 To Earth Ground rail To Mains All mounting surfaces are free of paint 24 75 VDC Power Supply Metal Plate Motor Motor Cable SPC 020 6410 All other cables are in accordance with Chapter 2 of this manual All D Sub connectors have metallic hoods Wire to Earth Ground Rail AWG 3 0 or larger N32 HCHJ LNK NS 00 I O Box 6420 ...

Page 97: ...tric codes local accident prevention rules and EN 61800 3 All covers shall be closed during operation Braided cable shields should be connected to protective earth ground Drive mounting 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 loca...

Page 98: ...a ground connection is 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 clamping the shield It is important that the clamp chosen be conductive and provide a full 360 de...

Page 99: ...on 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 Application Note 106 Reducing Motor Drive Line Noise Application Note 107 Reducing Motor Drive Radiated Emissions E 6 6415 Installation and Hardware Reference Manual Rev E ...

Page 100: ...EF_OUT 8V_REF_OUT EXTERNAL_POT GNDA GNDA GNDA GNDA ANALOG_INPUT ANALOG_INPUT LOW_SPD LOW_SPD RUN RUN STOP STOP DIR DIR ENABLE ENABLE STEP_OUT STEP_OUT STEP_OUT STEP_OUT User s Control Electronics J4 1 2 3 4 5 6 7 8 9 NOT USED 1 2 3 J2 DC DC Case GND Unregulated 24Vdc to 75Vdc J1 6415 OSCILLATOR DRIVE J3 Phase A Phase A Phase B Phase B Case Gnd 1 2 3 4 5 2 Phase Stepper Motor B E A C D CHASSIS ...

Page 101: ...l Rev E B A B A 6415 CUSTOMER MTG 4 75 120 7mm OPTIONAL SIDE MTG CLEARANCE FOR M4 or 6 32 SCREW 2 75 69 9 mm 1 50 38 1 mm 5 00 127 0 mm 0 04 CUSTOMER MTG 0 75 19 1 mm 0 02 0 02 0 04 1 10 27 9 mm 4 30 109 2 mm 0 04 0 02 0 04 ACCEL RAMP RUN SPEED LOW SPEED DECEL RAMP LED 1 ...

Page 102: ...ncy A 1 Clamping circuit C 9 Cleaning unit 4 1 Components system 1 7 2 3 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 D Damage 2 1 Date code 2 1 Declaration of Conformity E 2 Defective unit 4 5 Definition general drive 1 1 Dimensi...

Page 103: ...nal capacitor 2 17 External step pulse 3 14 F Frequency range 3 10 Fuse selection C 7 G Getting help 3 22 Grounding E 5 H Heatsink mounting 2 5 Help getting 3 22 Holding torque and idle current reduction 4 3 Humidity A 6 I 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 h...

Page 104: ...L Line transformer selection C 2 M 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 N Noise pickup reduction 2 9 O Optically isolated...

Page 105: ...derations C 1 Motor 2 17 C 1 Power up 3 1 Problems Solutions 4 2 R 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 S S1 switch location 3 15 setting 3 15 idle current reduction setup 3 18 digital electronic damping control set up 3 17 step size set up 3 16 Safety 2 2 E 4 Series connect...

Page 106: ... 1 System components 1 7 2 3 diagram 1 8 2 8 T 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 U UL recognition 1 3 Unpacking 2 1 User adjustments 1 4 using S1 1 4 using jumpers 1 5 using potentiometers 1 6 V Velocity control mode 3 6 Ventilation 2 7 Voltage motor supply 1 1 2 17 A 1 C 1 W Warranty 1 9 Weight 2 7 A 8 6415 ...

Page 107: ...l service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE INSPECTION Remotely inspect equipment before purchasing with our interactive website at www instraview com LOOKING FOR MORE INFORMATION Visit us on the web at www artisantg com for more information on ...

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