Applied Motion Products PDO 2035 User manual

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DIR
EN
COM
STEP
TACH+
TACH-
WPR
CCW
CW
123
12345
PDO 2035
Step Motor Driver
POWER
HALF
STEP
B–
B+
A–
A+
GND
N
L
HI LO
➜ BYPASS
INT ➜ ➜ EXT
➜ ➜
FULL
STEP
SPEED
DECEL
ACCEL
MOTOR
AC POWER
1000
500
250
125
CURRENT
(BASE = 125mA)
6.80"
.245"
4.00"
.273"
1.75"
.19"
6.00"
User's Manual
PDO 2035
Step Motor Driver
motors • drives • controls
Applied Motion Products, Inc.
404 Westridge Drive Watsonville, CA 95076
Tel [phone] [phone] Fax [phone]
Mechanical Outline
10/2/00 PDO2035.ai
Copyright 2000
DIR
EN
COM
STEP
TACH+
TACH-
WPR
CCW
CW
123
12345
PDO 2035
Step Motor Driver
POWER
HALF
STEP
B–
B+
A–
A+
GND
N
L
HI LO
➜ BYPASS
INT ➜ ➜ EXT
➜ ➜
FULL
STEP
SPEED
DECEL
ACCEL
MOTOR
AC POWER
1000
500
250
125
CURRENT
(BASE = 125mA)

Technical Specifications
-15--2-
Amplifiers
Oscillator
Power Supply
Inputs
Pulse Out
Physical
Connectors
Fuse
Dual, bipolar recirculating H-bridge, pulse width modulated
switching at 20 kHz. 0.125 - 2.0 amps/phase output current, switch
selectable in 0.125 A increments. 50 watts maximum output power.
Automatic idle current reduction, reduces current to 50% of setting
after one second. Min. motor inductance 1 mH.
HI range: 100 - 12000 steps/sec range, 100 Hz resolution
LO range: 10 - 1200 steps/sec, 10 Hz resolution
Speed adjustable by 15 turn potentiometer, or user supplied
external pot, or 0 - 5 volt analog signal. Linear acceleration and
deceleration, individually adjustable from 750 to 200,000
steps/sec/sec, with single turn potentiometers.
110 or 220 VAC input, switch selectable. 50 - 60 Hz. 75 W max.
DC voltage at nominal line voltage: 28 VDC full load, 40 VDC no
load.
Step: optically isolated, 5-24V, 730 ohm input impedance. Motor
steps on rising edge of step line. 10 µsec minimum low pulse. Step
input used as run/stop in oscillator mode. (closed = run, open =
stop.)
Direction and Enable: optically isolated, 5-24V, 2200 ohm input
impedance. 50 µsec minimum set up time for direction signal.
Optically isolated, uncommitted (open collector, open emitter)
photo transistor. 30V, 20 mA max.
Constructed on black anodized aluminum heat transfer plate.
Covered by heavy gauge ventilated steel housing. 1.75 x 4.0 x 6.8
inches overall. Power on LED. See drawing on back cover for
more information. Ambient temperature range: 0 - 70˚C.
Pluggable screw terminal blocks.
Motor: 4 position. Wire size: AWG 12-22
Signals (step, dir, enable): 4 position, AWG 16-28.
Signals (tach, external speed pot): 5 position, AWG 16-28.
AC Power: 3 position, AWG 12-22.
1A UL rated, fast acting, TR5 style. Available from Digikey (800-
DIGIKEY) as part number WK3048BK.
Do I Have the Right Manual?
In April, 1999 we began shipping PDO 2035 drives. Prior to that, we made a similar
drive called the PD2035. The PDO 2035, which is the subject of this manual, sports
the following improvements:
• Connections to the Enable input, the external speed input or the TACH output
used to require a "crimped on" connector, which our customers found to be
complicated and difficult. We now use pluggable, screw terminal connectors for
everything.
• The Step, Dir and Enable inputs now support 5-24V signal levels without adding
dropping resistors or setting the old "5V/24V switch." You can also use sourcing
(PNP) or sinking (NPN) input signals. The PD2035 only accepted sinking signals.
So Which Drive Do I Have?
Just look at the front panel: it either reads "PDO 2035" or "PD2035".
If you have a PD2035, call or fax the factory and request the
"PD2035 User's Manual". You can also download the
manual, in Adobe PDF format, from our website at
www.applied-motion.com.

Mounting the Drive
You should mount the PDO 2035 on the heat transfer plate as shown below. Use #8
or #10 screws.
The amplifiers in the drive generate heat. Unless you are running at 1 amp or
below, you may need a heat sink. To operate the PDO 2035 continuously at maximum
power you must properly mount it on a heat sinking surface with a thermal constant
of no more than 4°C/watt. Often, the metal chassis or enclosure of your system will
work as an effective heat sink.
Features
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 there's anything we can do to improve our products or help you use them better,
please call or fax. We'd like to hear from you. Our phone number is (800) 525-
1609 or you can reach us by fax at (831) 761–6544.
-3--14-
Built in 30 volt DC power supply. Drive accepts AC input, 110/220 V, 50/60Hz
Drives sizes 14 through 23 step motors. Can also be used to drive size 34
motors at low speeds.
Pulse width modulation, recirculating switching amplifiers
Phase current from 0.125 to 2.0 amps (switch selectable, 16 settings)
Step, direction, amplifier enable inputs, tach output, all optically isolated
Full and half step (switch selectable)
Automatic 50% idle current reduction (defeatable by internal jumper)
Built in ramping pulse generator with adjustable speed, accel, decel
Two speed ranges: 10 - 1200 Hz and 100 - 12000 Hz
Pluggable, screw terminal connectors
Fully enclosed in ventilated steel housing with aluminum heat transfer plate
•
•
•
•
•
•
•
•
•
•
•
Optical
Isolators
step
external speed pot
direction
common
Step
Sequencer
Oscillator
current setting
full step/
half step
step
dir
accel
decel
speed adj
A+
A–
B+
B–
to
motor
Power
Supply
110/220
VAC
Amplifier
Block Diagram
!
Never use your drive in a space where there is no air flow
or where the ambient temperature exceeds 50˚C (120˚F)
Never block the vent holes.
Never put the drive where it can get wet.
Never allow metal particles near the drive.
2345
123
osc
options
1
enable
tach
out

-4-
You can also use an external analog voltage to set the speed. The voltage must be
between 0 and 5 VDC. Connect the voltage to the WPR pin and the voltage
return to CCW. For the LO speed range, the conversion is 240 steps/sec/volt. For
the HI speed range, the formula is 2400 steps/sec/volt.
If the analog voltage source generates it's own accel and decel ramps (such as a
servo controller) set the ACCEL and DECEL trimpots at the "no accel/decel" setting
so the oscillator does not interfere with the ramps.
-13-
cw
external
pot Signal +
Signal -
Using Remote Speed Control Potentiometer
The PDO 2035 step motor driver includes an analog signal input connector that can
be used to control the oscillator speed externally. Normally, an on board
potentiometer controls the speed. Whether you use the on-board or external pots,
the accel/decel ramping remains active.
You will need:
• a 1kΩ- 10kΩlinear potentiometer. A multiturn type is recommended.
• a shielded, three wire cable
To install the external pot:
• locate the 5 position front panel connector (marked tach+, tach-, etc)
• prepare a cable with your pot on one end and the connector on the other end:
➤the potentiometer wiper connects to the WPR terminal
➤the potentiometer CW terminal connects to the CW terminal
➤the third pot terminal connects to CCW
➤the cable shield connects to the third pot terminal
With this arrangement, speed will increase as you turn the external pot clockwise.
The on board trimpots will still control acceleration and deceleration times.
Set the EXT/INT switch to EXT to select the external potentiometer.
External Pot Connection Analog Signal Connection
DIR
EN
COM
STEP
TACH+
TACH-
WPR
CCW
CW
123
12345
PDO 2035
Step Motor Driver
POWER
HALF
STEP
B–
B+
A–
A+
GND
N
L
HI LO
➜ BYPASS
INT ➜ ➜ EXT
➜ ➜
FULL
STEP
SPEED
DECEL
ACCEL
MOTOR
AC POWER
1000
500
250
125
CURRENT
(BASE = 125mA)
motor connector
switches
(current setting
full/half step)
signal connector
(step, dir, enable)
mounting hole
mounting hole
switches
(osc set up)
trimpots
(speed, accel, decel)
signal connector
(ext speed, tach out)
AC Power connector
Getting Started
To use your Applied Motion Products motor control, you will need the following:
•an AC power cord
•5-24 volts DC to activate the optoisolation circuits
•a source of step pulses
•if your application calls for bidirectional rotation, you'll also need a direction
signal
•a compatible step motor (minimum inductance of 1 mH/phase)
•a small flat blade screwdriver (2.5 mm) for tightening the connectors and
adjusting the oscillator
•If your application calls for connection to 220 VAC, you will need a small Phillips
screwdriver in order to remove the drive cover.
Always disconnect AC power to the drive before removing the cover.
The sketch below shows where to find the important connection and adjustment
points. Please examine it now.
All mating connectors are included.
CW
WPR
CCW
WPR
CCW

Connecting the AC Line
110 Volts
220 Volts
The PDO 2035 is set for 110 volt operation at the factory. In order to use 220 volts,
you'll need to remove the cover and slide the switch to the "220V" setting.
First, disconnect all power from the system. Next, remove all four of the
green connector plugs from the front panel. Then, using your small Phillips screw
driver, remove the five screws that hold the cover on.
The cover will slide off easily once all of the screws are removed. You should see a
black switch near the "AC POWER" connector, right next to the big transformer.
Push the switch to the "220V" side.
Now put the cover back on and replace all five screws, tightening them carefully.
Never operate the drive with the cover off
-12- -5-
.125
AMPS/PHASE
Current Setting Table
2345
1000
500
250
125
1.125
AMPS/PHASE
.25
AMPS/PHASE 1.25 AMPS/PHASE
.375
AMPS/PHASE 1.375 AMPS/PHASE
.5
AMPS/PHASE 1.5 AMPS/PHASE
.625
AMPS/PHASE 1.625 AMPS/PHASE
.75
AMPS/PHASE 1.75 AMPS/PHASE
.875
AMPS/PHASE 1.875 AMPS/PHASE
1
AMPS/PHASE 2 AMPS/PHASE
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
!
The PDO 2035 is set for 110 volt operation at the factory. All you need to do is
install a power cord and plug it in. If you want to direct wire the PDO 2035 to AC
power, you must consult a qualified electrician and observe all building and
electrical codes.
You can install the AC cord yourself, but be careful: AC power can be dangerous.
k
c
a
l
b
e
t
i
h
w
n
e
e
r
g
To Earth Ground
To Neutral
To Line (Hot)
To Earth Ground
To Neutral
To Line (Hot)
g
r
e
e
n
bl
ac
k
o
r
b
r
o
w
n
w
h
i
t
e
o
r
b
l
u
e
"Old Style" AC Power Plug "New Style" AC Power Plug
Installing an AC Line Cord
Remove about 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 2035 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 for your connector style.

!
Always unplug the line cord from the wall before attaching it
to the PDO 2035
-11-
12345
1000
500
250
125
HALF
STEP
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 PDO 2035 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 DIP switches next to the motor connector. Four of the switches
have a value of current printed next to them, such as 500 and 1000. Each switch
controls the amount of current, in milliamperes (mA), that it's label indicates. There
is always a base current of 125 mA. To add to that, slide the appropriate switches
toward their labels. You may need your small screwdriver for this.
Example
Suppose you want to set the driver for 1.25 amps
per phase (1250 mA). You need the 125 mA base
current plus another 1000 and 125 mA.
1250 = 125 + 1000 +125
Slide the 125 and 1000 mA switches toward
the labels as shown in the figure.
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.
Four lead motors can only be connected
one way. Please follow the sketch at the
right.
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.
Winding diagrams for both connection
methods are shown below. NC means not
connected.
A+
A–
B+ B–
4
lead
motor
Red
Blue
Yellow White
4 Leads
A+
A–
NC
B+
B– NC
6
lead
motor
Red Black
Red/
Wht
Green
Grn/Wht
White A+
A–
NC
B+B– NC
6
lead
motor
Grn/Wht
White
Green
Red Red/
Wht
Black
6 Leads Series Connected 6 Leads Center Tap Connected
-6-
!
DIR
PDO 2035
5 position
connector
PDO 2035
4 position
connector
CW
CCW
WPR
COM
STEP
Using the Oscillator with Switches & PLCs.
If you plan to use the PDO 2035 in oscillator mode, you may need a source of
voltage to activate the optoisolation circuits. This is true if you are using
mechanical switches or relays. It may also be the case if you are using a PLC with
optically isolated outputs, since they behave like switches.
run switch
(closed=run)
direction switch
•Connect the black or brown wire to the PDO 2035 "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 "N" terminal.
•Finally, and most importantly, connect the green wire to the GND terminal. That
connects the PDO 2035 metal enclosure and DC power supply ground to earth
ground.

Using the Oscillator
The PDO2035 is equipped with an internal pulse
generator that you can use to control the motor. To
select the oscillator mode of operation (run/stop mode)
move switch 2 away from the
BYPASS label, as shown
at the right.
The oscillator is activated by driving the STEP input low. The frequency of step
pulses will increase linearly, accelerating the motor until it reaches a preset slew
speed. The motor will remain at this speed until the
STEP input is driven high. The
step pulse frequency then decreases linearly, decelerating the motor and load to
rest. The PDO2035 lets you choose from two oscillator speed ranges: 10 - 1200
steps/second (LO) and 100 - 12000 steps/sec (HI). Set the speed range with the
"LO/HI" switch.
3362
20,000
steps/sec2
10,000
steps/sec2
5000 steps/sec2
2500 steps/sec2
1200 steps/sec
2
600
steps/sec
2
300
steps/sec
2
150
steps/sec
2
(no ramp)
To adjust the speed, locate the trimpot labeled SPEED . By turning the brass screw
you can raise or lower the speed within the range you have selected. Turning the
screw clockwise makes the motor run faster.
The acceleration and deceleration rates can also be adjusted using the trimpots
labeled
ACCEL and DECEL . The range of accel and decel rates is illustrated below.
Turning the screw clockwise makes the motor accelerate or decelerate faster.
123
HI
LO
➜
BYPASS
INT ➜ ➜ EXT
➜ ➜
123
HI
LO
➜
BYPASS
INT ➜ ➜ EXT
➜ ➜
123
HI
LO
➜
BYPASS
INT ➜ ➜ EXT
➜ ➜
10 - 1200 steps/sec 100 - 12000 steps/sec
A+
A–
B+ B–
8
lead
motor
8 Leads Series 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 over heating. The wiring diagrams for eight
lead motors are shown below.
8 Leads Parallel Connected
A+
A–
B+ B–
8
lead
motor
Orange
Org/Wht
Blk/Wht
Black
Red Red/
Wht Yel/
Wht Yellow
Orange
Org/
Wht
Blk/Wht
Black
Red
Red/Wht
Yel/
Wht
Yel
low
Step A+ A- B+ B-
0+–+–
1–++–
2–+–+
3+– –+
4+–+–
DIR=1
cw DIR=0
ccw
Step 3 is the Power Up State
Step Table
(full stepping)
-7--10-
200,000
steps/sec2
100,000
steps/sec2
50,000 steps/sec2
25,000 steps/sec2
12000 steps/sec
2
6000
steps/sec
2
3000
steps/sec
2
1500
steps/sec
2
(no ramp)
LO range accel/decel settings
Shown at 2500 steps/sec2HI range accel/decel settings Shown at 25,000 steps/sec2
3362
(speed range)
(internal oscillator)
(potentiometer)

COM
DIR
Inside PDO 2035
2200
EN
2200
730
STEP
PDO2035 1000 Ohm
Resistor
1/4 watt scope probe
Selecting Between Full and Half Step
-8- -9-
STEPtells the driver when to move the motor one step. The drive steps on the
rising edge of the pulse. If the pulse is negative (low) the minimum width is 10
microseconds.
DIRECTION signals which way the motor should turn. See the step table on page 7
for details. The
DIRECTION signal should be changed at least 50 microseconds
before a step pulse is sent. If you change the state of the direction input
and send a step pulse at the same instant the motor may take a step in
the wrong direction.
ENABLEallows 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. If you have no need to disable the amplifiers, you don't
need to connect anything to the
ENABLE input.
Using the TACH Output
12345
1000
500
250
125
HALF
STEP
output
signal
5 usec
Locate the bank of DIP switches on the front panel. Switch
number 1 is labeled
HALF STEP . Sliding the switch
toward the
HALF STEP label sets the driver for that mode
of operation. The opposite position is full step. When set
to full step, the driver always uses "two phases on" mode
to provide maximum motor torque.
The PDO2035 has a pulse output to tell you how fast the oscillator is going. It
produces one pulse per motor step. You can connect this to a counter to provide
position information, or to a tachometer to provide speed data, or both. The pulse
output is optically isolated for noise immunity, which makes it more flexible and
more reliable, but also harder to hookup.
The TACH output is rated for 5 - 24VDC operation, up to 20 mA.
Connecting the Pulse Output
to a Frequency Counter
or Oscilloscope Connecting the Pulse Output
to a PLC
TACH+
CW
CCW
TACH– PDO2035
TACH+
TACH–
COMMON
INPUT
PLC
24 VDC
Power Supply
+–
Connecting Logic
The PDO2035 drive contains optical isolation circuitry to prevent the electrical noise
(inherent in switching amplifiers) from interfering with your circuits. Optical
isolation is accomplished by powering the motor driver from a different supply than
your circuits. There is no electrical connection between the two: signal
communication is achieved by infrared light. When your circuit turns on or turns off
an infrared LED (built into the PDO2035) signals a logic state to the photo-
transistors that are wired to the brains of the drive.
A schematic diagram of the input circuit is shown on the right.
You must supply 5-24 volts DC to activate
the LEDs on the input side of the
optoisolators. The maximum current draw
is 30 mA.
If your controlling logic is 24V, it must be
capable of sinking at least 30 mA to control
each drive input. If you are using 5 volt
logic (TTL level) then each signal must sink
5 mA.
If your STEP, DIR and ENABLE signals are
sinking (NPN) then connect COM to your power supply +. If your signals are
sourcing (PNP) then connect COM to power supply -.

COM
DIR
Inside PDO 2035
2200
EN
2200
730
STEP
PDO2035 1000 Ohm
Resistor
1/4 watt scope probe
Selecting Between Full and Half Step
-8- -9-
STEPtells the driver when to move the motor one step. The drive steps on the
rising edge of the pulse. If the pulse is negative (low) the minimum width is 10
microseconds.
DIRECTION signals which way the motor should turn. See the step table on page 7
for details. The
DIRECTION signal should be changed at least 50 microseconds
before a step pulse is sent. If you change the state of the direction input
and send a step pulse at the same instant the motor may take a step in
the wrong direction.
ENABLEallows 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. If you have no need to disable the amplifiers, you don't
need to connect anything to the
ENABLE input.
Using the TACH Output
12345
1000
500
250
125
HALF
STEP
output
signal
5 usec
Locate the bank of DIP switches on the front panel. Switch
number 1 is labeled
HALF STEP . Sliding the switch
toward the
HALF STEP label sets the driver for that mode
of operation. The opposite position is full step. When set
to full step, the driver always uses "two phases on" mode
to provide maximum motor torque.
The PDO2035 has a pulse output to tell you how fast the oscillator is going. It
produces one pulse per motor step. You can connect this to a counter to provide
position information, or to a tachometer to provide speed data, or both. The pulse
output is optically isolated for noise immunity, which makes it more flexible and
more reliable, but also harder to hookup.
The TACH output is rated for 5 - 24VDC operation, up to 20 mA.
Connecting the Pulse Output
to a Frequency Counter
or Oscilloscope Connecting the Pulse Output
to a PLC
TACH+
CW
CCW
TACH– PDO2035
TACH+
TACH–
COMMON
INPUT
PLC
24 VDC
Power Supply
+–
Connecting Logic
The PDO2035 drive contains optical isolation circuitry to prevent the electrical noise
(inherent in switching amplifiers) from interfering with your circuits. Optical
isolation is accomplished by powering the motor driver from a different supply than
your circuits. There is no electrical connection between the two: signal
communication is achieved by infrared light. When your circuit turns on or turns off
an infrared LED (built into the PDO2035) signals a logic state to the photo-
transistors that are wired to the brains of the drive.
A schematic diagram of the input circuit is shown on the right.
You must supply 5-24 volts DC to activate
the LEDs on the input side of the
optoisolators. The maximum current draw
is 30 mA.
If your controlling logic is 24V, it must be
capable of sinking at least 30 mA to control
each drive input. If you are using 5 volt
logic (TTL level) then each signal must sink
5 mA.
If your STEP, DIR and ENABLE signals are
sinking (NPN) then connect COM to your power supply +. If your signals are
sourcing (PNP) then connect COM to power supply -.

Using the Oscillator
The PDO2035 is equipped with an internal pulse
generator that you can use to control the motor. To
select the oscillator mode of operation (run/stop mode)
move switch 2 away from the
BYPASS label, as shown
at the right.
The oscillator is activated by driving the STEP input low. The frequency of step
pulses will increase linearly, accelerating the motor until it reaches a preset slew
speed. The motor will remain at this speed until the
STEP input is driven high. The
step pulse frequency then decreases linearly, decelerating the motor and load to
rest. The PDO2035 lets you choose from two oscillator speed ranges: 10 - 1200
steps/second (LO) and 100 - 12000 steps/sec (HI). Set the speed range with the
"LO/HI" switch.
3362
20,000
steps/sec2
10,000
steps/sec2
5000 steps/sec2
2500 steps/sec2
1200 steps/sec
2
600
steps/sec
2
300
steps/sec
2
150
steps/sec
2
(no ramp)
To adjust the speed, locate the trimpot labeled SPEED . By turning the brass screw
you can raise or lower the speed within the range you have selected. Turning the
screw clockwise makes the motor run faster.
The acceleration and deceleration rates can also be adjusted using the trimpots
labeled
ACCEL and DECEL . The range of accel and decel rates is illustrated below.
Turning the screw clockwise makes the motor accelerate or decelerate faster.
123
HI
LO
➜
BYPASS
INT ➜ ➜ EXT
➜ ➜
123
HI
LO
➜
BYPASS
INT ➜ ➜ EXT
➜ ➜
123
HI
LO
➜
BYPASS
INT ➜ ➜ EXT
➜ ➜
10 - 1200 steps/sec 100 - 12000 steps/sec
A+
A–
B+ B–
8
lead
motor
8 Leads Series 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 over heating. The wiring diagrams for eight
lead motors are shown below.
8 Leads Parallel Connected
A+
A–
B+ B–
8
lead
motor
Orange
Org/Wht
Blk/Wht
Black
Red Red/
Wht Yel/
Wht Yellow
Orange
Org/
Wht
Blk/Wht
Black
Red
Red/Wht
Yel/
Wht
Yel
low
Step A+ A- B+ B-
0+–+–
1–++–
2–+–+
3+– –+
4+–+–
DIR=1
cw DIR=0
ccw
Step 3 is the Power Up State
Step Table
(full stepping)
-7--10-
200,000
steps/sec2
100,000
steps/sec2
50,000 steps/sec2
25,000 steps/sec2
12000 steps/sec
2
6000
steps/sec
2
3000
steps/sec
2
1500
steps/sec
2
(no ramp)
LO range accel/decel settings
Shown at 2500 steps/sec2HI range accel/decel settings Shown at 25,000 steps/sec2
3362
(speed range)
(internal oscillator)
(potentiometer)

!
Always unplug the line cord from the wall before attaching it
to the PDO 2035
-11-
12345
1000
500
250
125
HALF
STEP
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 PDO 2035 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 DIP switches next to the motor connector. Four of the switches
have a value of current printed next to them, such as 500 and 1000. Each switch
controls the amount of current, in milliamperes (mA), that it's label indicates. There
is always a base current of 125 mA. To add to that, slide the appropriate switches
toward their labels. You may need your small screwdriver for this.
Example
Suppose you want to set the driver for 1.25 amps
per phase (1250 mA). You need the 125 mA base
current plus another 1000 and 125 mA.
1250 = 125 + 1000 +125
Slide the 125 and 1000 mA switches toward
the labels as shown in the figure.
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.
Four lead motors can only be connected
one way. Please follow the sketch at the
right.
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.
Winding diagrams for both connection
methods are shown below. NC means not
connected.
A+
A–
B+ B–
4
lead
motor
Red
Blue
Yellow White
4 Leads
A+
A–
NC
B+
B– NC
6
lead
motor
Red Black
Red/
Wht
Green
Grn/Wht
White A+
A–
NC
B+B– NC
6
lead
motor
Grn/Wht
White
Green
Red Red/
Wht
Black
6 Leads Series Connected 6 Leads Center Tap Connected
-6-
!
DIR
PDO 2035
5 position
connector
PDO 2035
4 position
connector
CW
CCW
WPR
COM
STEP
Using the Oscillator with Switches & PLCs.
If you plan to use the PDO 2035 in oscillator mode, you may need a source of
voltage to activate the optoisolation circuits. This is true if you are using
mechanical switches or relays. It may also be the case if you are using a PLC with
optically isolated outputs, since they behave like switches.
run switch
(closed=run)
direction switch
•Connect the black or brown wire to the PDO 2035 "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 "N" terminal.
•Finally, and most importantly, connect the green wire to the GND terminal. That
connects the PDO 2035 metal enclosure and DC power supply ground to earth
ground.

Connecting the AC Line
110 Volts
220 Volts
The PDO 2035 is set for 110 volt operation at the factory. In order to use 220 volts,
you'll need to remove the cover and slide the switch to the "220V" setting.
First, disconnect all power from the system. Next, remove all four of the
green connector plugs from the front panel. Then, using your small Phillips screw
driver, remove the five screws that hold the cover on.
The cover will slide off easily once all of the screws are removed. You should see a
black switch near the "AC POWER" connector, right next to the big transformer.
Push the switch to the "220V" side.
Now put the cover back on and replace all five screws, tightening them carefully.
Never operate the drive with the cover off
-12- -5-
.125
AMPS/PHASE
Current Setting Table
2345
1000
500
250
125
1.125
AMPS/PHASE
.25
AMPS/PHASE 1.25 AMPS/PHASE
.375
AMPS/PHASE 1.375 AMPS/PHASE
.5
AMPS/PHASE 1.5 AMPS/PHASE
.625
AMPS/PHASE 1.625 AMPS/PHASE
.75
AMPS/PHASE 1.75 AMPS/PHASE
.875
AMPS/PHASE 1.875 AMPS/PHASE
1
AMPS/PHASE 2 AMPS/PHASE
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
2345
1000
500
250
125
!
The PDO 2035 is set for 110 volt operation at the factory. All you need to do is
install a power cord and plug it in. If you want to direct wire the PDO 2035 to AC
power, you must consult a qualified electrician and observe all building and
electrical codes.
You can install the AC cord yourself, but be careful: AC power can be dangerous.
k
c
a
l
b
e
t
i
h
w
n
e
e
r
g
To Earth Ground
To Neutral
To Line (Hot)
To Earth Ground
To Neutral
To Line (Hot)
g
r
e
e
n
bl
ac
k
o
r
b
r
o
w
n
w
h
i
t
e
o
r
b
l
u
e
"Old Style" AC Power Plug "New Style" AC Power Plug
Installing an AC Line Cord
Remove about 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 2035 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 for your connector style.

-4-
You can also use an external analog voltage to set the speed. The voltage must be
between 0 and 5 VDC. Connect the voltage to the WPR pin and the voltage
return to CCW. For the LO speed range, the conversion is 240 steps/sec/volt. For
the HI speed range, the formula is 2400 steps/sec/volt.
If the analog voltage source generates it's own accel and decel ramps (such as a
servo controller) set the ACCEL and DECEL trimpots at the "no accel/decel" setting
so the oscillator does not interfere with the ramps.
-13-
cw
external
pot Signal +
Signal -
Using Remote Speed Control Potentiometer
The PDO 2035 step motor driver includes an analog signal input connector that can
be used to control the oscillator speed externally. Normally, an on board
potentiometer controls the speed. Whether you use the on-board or external pots,
the accel/decel ramping remains active.
You will need:
• a 1kΩ- 10kΩlinear potentiometer. A multiturn type is recommended.
• a shielded, three wire cable
To install the external pot:
• locate the 5 position front panel connector (marked tach+, tach-, etc)
• prepare a cable with your pot on one end and the connector on the other end:
➤the potentiometer wiper connects to the WPR terminal
➤the potentiometer CW terminal connects to the CW terminal
➤the third pot terminal connects to CCW
➤the cable shield connects to the third pot terminal
With this arrangement, speed will increase as you turn the external pot clockwise.
The on board trimpots will still control acceleration and deceleration times.
Set the EXT/INT switch to EXT to select the external potentiometer.
External Pot Connection Analog Signal Connection
DIR
EN
COM
STEP
TACH+
TACH-
WPR
CCW
CW
123
12345
PDO 2035
Step Motor Driver
POWER
HALF
STEP
B–
B+
A–
A+
GND
N
L
HI LO
➜ BYPASS
INT ➜ ➜ EXT
➜ ➜
FULL
STEP
SPEED
DECEL
ACCEL
MOTOR
AC POWER
1000
500
250
125
CURRENT
(BASE = 125mA)
motor connector
switches
(current setting
full/half step)
signal connector
(step, dir, enable)
mounting hole
mounting hole
switches
(osc set up)
trimpots
(speed, accel, decel)
signal connector
(ext speed, tach out)
AC Power connector
Getting Started
To use your Applied Motion Products motor control, you will need the following:
•an AC power cord
•5-24 volts DC to activate the optoisolation circuits
•a source of step pulses
•if your application calls for bidirectional rotation, you'll also need a direction
signal
•a compatible step motor (minimum inductance of 1 mH/phase)
•a small flat blade screwdriver (2.5 mm) for tightening the connectors and
adjusting the oscillator
•If your application calls for connection to 220 VAC, you will need a small Phillips
screwdriver in order to remove the drive cover.
Always disconnect AC power to the drive before removing the cover.
The sketch below shows where to find the important connection and adjustment
points. Please examine it now.
All mating connectors are included.
CW
WPR
CCW
WPR
CCW

Mounting the Drive
You should mount the PDO 2035 on the heat transfer plate as shown below. Use #8
or #10 screws.
The amplifiers in the drive generate heat. Unless you are running at 1 amp or
below, you may need a heat sink. To operate the PDO 2035 continuously at maximum
power you must properly mount it on a heat sinking surface with a thermal constant
of no more than 4°C/watt. Often, the metal chassis or enclosure of your system will
work as an effective heat sink.
Features
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 there's anything we can do to improve our products or help you use them better,
please call or fax. We'd like to hear from you. Our phone number is (800) 525-
1609 or you can reach us by fax at (831) 761–6544.
-3--14-
Built in 30 volt DC power supply. Drive accepts AC input, 110/220 V, 50/60Hz
Drives sizes 14 through 23 step motors. Can also be used to drive size 34
motors at low speeds.
Pulse width modulation, recirculating switching amplifiers
Phase current from 0.125 to 2.0 amps (switch selectable, 16 settings)
Step, direction, amplifier enable inputs, tach output, all optically isolated
Full and half step (switch selectable)
Automatic 50% idle current reduction (defeatable by internal jumper)
Built in ramping pulse generator with adjustable speed, accel, decel
Two speed ranges: 10 - 1200 Hz and 100 - 12000 Hz
Pluggable, screw terminal connectors
Fully enclosed in ventilated steel housing with aluminum heat transfer plate
•
•
•
•
•
•
•
•
•
•
•
Optical
Isolators
step
external speed pot
direction
common
Step
Sequencer
Oscillator
current setting
full step/
half step
step
dir
accel
decel
speed adj
A+
A–
B+
B–
to
motor
Power
Supply
110/220
VAC
Amplifier
Block Diagram
!
Never use your drive in a space where there is no air flow
or where the ambient temperature exceeds 50˚C (120˚F)
Never block the vent holes.
Never put the drive where it can get wet.
Never allow metal particles near the drive.
2345
123
osc
options
1
enable
tach
out

Technical Specifications
-15--2-
Amplifiers
Oscillator
Power Supply
Inputs
Pulse Out
Physical
Connectors
Fuse
Dual, bipolar recirculating H-bridge, pulse width modulated
switching at 20 kHz. 0.125 - 2.0 amps/phase output current, switch
selectable in 0.125 A increments. 50 watts maximum output power.
Automatic idle current reduction, reduces current to 50% of setting
after one second. Min. motor inductance 1 mH.
HI range: 100 - 12000 steps/sec range, 100 Hz resolution
LO range: 10 - 1200 steps/sec, 10 Hz resolution
Speed adjustable by 15 turn potentiometer, or user supplied
external pot, or 0 - 5 volt analog signal. Linear acceleration and
deceleration, individually adjustable from 750 to 200,000
steps/sec/sec, with single turn potentiometers.
110 or 220 VAC input, switch selectable. 50 - 60 Hz. 75 W max.
DC voltage at nominal line voltage: 28 VDC full load, 40 VDC no
load.
Step: optically isolated, 5-24V, 730 ohm input impedance. Motor
steps on rising edge of step line. 10 µsec minimum low pulse. Step
input used as run/stop in oscillator mode. (closed = run, open =
stop.)
Direction and Enable: optically isolated, 5-24V, 2200 ohm input
impedance. 50 µsec minimum set up time for direction signal.
Optically isolated, uncommitted (open collector, open emitter)
photo transistor. 30V, 20 mA max.
Constructed on black anodized aluminum heat transfer plate.
Covered by heavy gauge ventilated steel housing. 1.75 x 4.0 x 6.8
inches overall. Power on LED. See drawing on back cover for
more information. Ambient temperature range: 0 - 70˚C.
Pluggable screw terminal blocks.
Motor: 4 position. Wire size: AWG 12-22
Signals (step, dir, enable): 4 position, AWG 16-28.
Signals (tach, external speed pot): 5 position, AWG 16-28.
AC Power: 3 position, AWG 12-22.
1A UL rated, fast acting, TR5 style. Available from Digikey (800-
DIGIKEY) as part number WK3048BK.
Do I Have the Right Manual?
In April, 1999 we began shipping PDO 2035 drives. Prior to that, we made a similar
drive called the PD2035. The PDO 2035, which is the subject of this manual, sports
the following improvements:
• Connections to the Enable input, the external speed input or the TACH output
used to require a "crimped on" connector, which our customers found to be
complicated and difficult. We now use pluggable, screw terminal connectors for
everything.
• The Step, Dir and Enable inputs now support 5-24V signal levels without adding
dropping resistors or setting the old "5V/24V switch." You can also use sourcing
(PNP) or sinking (NPN) input signals. The PD2035 only accepted sinking signals.
So Which Drive Do I Have?
Just look at the front panel: it either reads "PDO 2035" or "PD2035".
If you have a PD2035, call or fax the factory and request the
"PD2035 User's Manual". You can also download the
manual, in Adobe PDF format, from our website at
www.applied-motion.com.

DIR
EN
COM
STEP
TACH+
TACH-
WPR
CCW
CW
123
12345
PDO 2035
Step Motor Driver
POWER
HALF
STEP
B–
B+
A–
A+
GND
N
L
HI LO
➜ BYPASS
INT ➜ ➜ EXT
➜ ➜
FULL
STEP
SPEED
DECEL
ACCEL
MOTOR
AC POWER
1000
500
250
125
CURRENT
(BASE = 125mA)
6.80"
.245"
4.00"
.273"
1.75"
.19"
6.00"
User's Manual
PDO 2035
Step Motor Driver
motors • drives • controls
Applied Motion Products, Inc.
404 Westridge Drive Watsonville, CA 95076
Tel [phone] [phone] Fax [phone]
Mechanical Outline
10/2/00 PDO2035.ai
Copyright 2000
DIR
EN
COM
STEP
TACH+
TACH-
WPR
CCW
CW
123
12345
PDO 2035
Step Motor Driver
POWER
HALF
STEP
B–
B+
A–
A+
GND
N
L
HI LO
➜ BYPASS
INT ➜ ➜ EXT
➜ ➜
FULL
STEP
SPEED
DECEL
ACCEL
MOTOR
AC POWER
1000
500
250
125
CURRENT
(BASE = 125mA)

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