Danaher Motion Superior Electric SLO-SYN SS2000D3 User manual

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Installation Instructions for SLO-SYN ®
SS2000D3 AND SS2000D6 Packaged Drives
400030-024 Rev K

Record of Manual Revisions
ISSUE Date Description of Revision
K 09/12/2003 Updated corporate information
Copyright Information
Copyright 1992 -2003 Danaher Motion -All rights reserved.
Printed in the United States of America.
NOTICE:
Not for use or disclosure outside of Danaher Motion except under written agreement. All rights are
reserved. No part of this book shall be reproduced, stored in retrieval form, or transmitted by any
means, electronic, mechanical, photocopying, recording, or otherwise without the written permission
from the publisher. While every precaution has been taken in the preparation of the book, the
publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for
damages resulting from the use of the information contained herein.
This document is proprietary information of Danaher Motion that is furnished for customer use
ONLY. No other uses are authorized without written permission of Danaher Motion. Information in
this document is subject to change without notice and does not represent a commitment on the part
of Danaher Motion. Therefore, information contained in this manual may be updated from time-to-
time due to product improvements, etc., and may not conform in every respect to former issues.

Safety
Safety symbols used in this manual are:
Warning Alerts users to potential physical danger or harm. Failure to follow
warning notices could result in personal injury or death.
Caution Directs attention to general precautions, which if not followed, could result
in personal injury and/or equipment damage.
Note Highlights information critical to your understanding or use of the product.
Instructions
Only qualified personnel should install or perform servicing procedures on this
equipment. Do not operate the unit without the enclosures in place as voltage present in
this unit can cause serious or fatal injury.
Before performing any work on the unit, allow at least five minutes for the
capacitors to discharge fully.
Voltage is present on unprotected pins when unit is operational.
The "PWR ON" LED must be off for approximately 30 seconds before making or
breaking the motor connections.
Motors powered by these drives may develop extremely high torque. Disconnect
AC power to these drive before doing any mechanical work.
This unit is designed for 115 VAC input only (see Section 4.2,
Electrical Specifications).
Warranty And Limitation Of Liability
Danaher Motion (the "Company") warrants to the first end user purchaser (the "purchaser")
of equipment manufactured by the Company that such equipment, if new, unused and in
original unopened cartons at the time of purchase, is free from defects in material and
workmanship under normal use and service for a period of one year from date of shipment
from the Company's factory or a warehouse of the Company in the event that the
equipment is purchased from the Company or for a period of one year from the date of
shipment from the business establishment of an authorized distributor of the Company in
the event that the equipment is purchased from an authorized distributor.
THE COMPANY'S OBLIGATION UNDER THIS WARRANTY SHALL BE STRICTLY AND
EXCLUSIVELY LIMITED TO REPAIRING OR REPLACING, AT THE FACTORY OR A
SERVICE CENTER OF THE COMPANY, ANY SUCH EQUIPMENT OR PARTS
THEREOF WHICH AN AUTHORIZED REPRESENTATIVE OF THE COMPANY FINDS
TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP UNDER NORMAL USE AND
SERVICE WITHIN SUCH PERIOD OF ONE YEAR. THE COMPANY RESERVES THE
RIGHT TO SATISFY SUCH OBLIGATION IN FULL BY REFUNDING THE FULL
PURCHASE PRICE OF ANY SUCH DEFECTIVE EQUIPMENT. This warranty does not
apply to any equipment which has been tampered with or altered in any way, improperly
installed or has been subject to misuse, neglect or accident.

THE FOREGOING WARRANTY IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS
OR IMPLIED, INCLUDING, WITHOUT LIMITATION, ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, and of any other
obligations or liabilities on the part of the Company; and no person is authorized to assume
for the Company any other liability with respect to equipment manufactured by the
Company. The Company shall have no liability with respect to equipment not of its
manufacture. THE COMPANY SHALL HAVE NO LIABILITY WHATSOEVER IN ANY
EVENT FOR PAYMENT OF ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES,
INCLUDING, WITHOUT LIMITATION, DAMAGES FOR INJURY TO ANY PERSON OR
PROPERTY.
Written authorization to return any equipment or parts thereof must be obtained from the
Company. The Company shall not be responsible for any transportation charges.
IF FOR ANY REASON ANY OF THE FOREGOING PROVISIONS SHALL BE
INEFFECTIVE, THE COMPANY'S LIABILITY FOR DAMAGES ARISING OUT OF ITS
MANUFACTURE OR SALE OF EQUIPMENT, OR USE THEREOF, WHETHER SUCH
LIABILITY IS BASED ON WARRANTY, CONTRACT, NEGLIGENCE, STRICT LIABILITY
IN TORT OR OTHERWISE, SHALL NOT IN ANY EVENT EXCEED THE FULL
PURCHASE PRICE OF SUCH EQUIPMENT.
Any action against the Company based upon any liability or obligation arising hereunder or
under any law applicable to the sale of equipment, or the use thereof, must be commenced
within one year after the cause of such action arises.
The right to make engineering refinements on all products is reserved. Dimensions and
other details are subject to change.

Danaher Motion Superior Electric Table of Contents
SS2000 D3 AND D6 i
Table of Contents
SECTION 1: INTRODUCTION ...................................................................... 1
1.1 USING THIS MANUAL ................................................................................ 1
1.2 PRODUCT FEATURES................................................................................. 1
SECTION 2: EXPRESS START UP............................................................... 2
SECTION 3: INSTALLATION GUIDELINES.............................................. 3
3.1 GENERAL WIRING GUIDELINES ......................................................... 3
3.2 MOUNTING ............................................................................................... 4
3.3 CONNECTOR LOCATIONS AND PIN ASSIGNMENTS.................................. 6
3.3.1 MOTOR CONNECTIONS ....................................................................... 7
3.3.2 POWER INPUT..................................................................................... 8
SECTION 4: SPECIFICATIONS .................................................................... 9
4.1 MECHANICAL ........................................................................................... 9
4.2 ELECTRICAL............................................................................................. 9
4.3 ENVIRONMENTAL ..................................................................................... 9
4.4 MOTOR COMPATIBILITY ....................................................................... 10
4.5 CURRENT SETTINGS............................................................................... 11
4.6 STEP RESOLUTION ................................................................................. 11
4.7 SIGNAL SPECIFICATIONS ....................................................................... 12
4.7.1 CONNECTOR PIN ASSIGNMENTS....................................................... 12
4.7.2 SIGNAL DESCRIPTIONS..................................................................... 12
4.7.3 LEVEL REQUIREMENTS .................................................................... 13
4.7.4 TIMING REQUIREMENTS .................................................................. 13
4.8 INDICATOR LIGHTS................................................................................ 14
4.9 TEST........................................................................................................ 14

Table of Contents Danaher Motion
ii SS2000 D3 AND D6
SECTION 5: TORQUE VERSUS SPEED CHARACTERISTICS .............15
5.1 MOTOR PERFORMANCE .........................................................................15
5.2 TYPICAL TORQUE VERSUS SPEED CURVES........................................... 16
SECTION 6: SYSTEM CHECKING............................................................23
APPENDIX A: TROUBLESHOOTING...........................................................25
A.1 ELECTRICAL INTERFERENCE PROBLEMS.............................................25
A.2 CUSTOMER SUPPORT.............................................................................26

Danaher Motion Superior Electric Section 1: Introduction
SS2000 D3 AND D6 1
SECTION 1: INTRODUCTION
1.1 USING THIS MANUAL
It is important that you understand how this SLO-SYN®2000 unit is installed
and operated before you attempt to use it. Read this manual completely before
proceeding with the installation of this unit.
This manual is an installation and operating guide to the SLO-SYN 2000 Drive.
Section 1 gives an overview of the Drive and its features. Section 2 de
scribes the
steps necessary to place the drive into operation. General wiring guidelines as
well as the physical mounting of the unit and connections to the drive portion
are covered in Section 3.
Complete specifications, listed in Section 4, provide electrical, mechanical and
performance specifications. The procedure for setting the motor current level is
also covered in this section.
Torque versus speed characteristics with all appropriate SLO-SYN Stepper
Motors are given in Section 5. Section 6, System Checking, gives procedures to
follow if the SLO-SYN 2000 drive fails to operate properly.
Appendix A provides procedures for troubleshooting electrical interference
problems.
1.2 PRODUCT FEATURES
SLO-SYN 2000 drives are bipolar, speed adjustable, two-phase chopper drives
which use power MOSFET and IGBT devices. They can be set to operate a
stepper motor in full or half steps or in 1/5, 1/10, 1/16, 1/36, 1/50, 1/100, 1/125
or 1/250 microsteps. The maximum running speed is 10,000 full steps per
second. To reduce the chances of electrical noise problems, the control signals
are optically isolated from the drive circuit.
U.L. Recognized under Component Program, File #E146240
Switch selectable current levels of .05 through 6 amperes depending on unit selected.
Latched short circuit protection (phase-to-phase and phase-to-ground)
Unlatched undervoltage and transient overvoltage protection
Inputs are optically isolated
Boost/Reduce Current and Windings Off capabilities
Drive Ready output
Built-in AC line filter plus MOV
Self-test function
Boost Current
Reduce Current

Section 2: Express Start Up Danaher Motion
2SS2000 D3 AND D6
SECTION 2: EXPRESS START UP
The following instructions define the minimum steps necessary to make your
Drive operational.
Always disconnect the AC power to the unit and be certain the "PWR
ON" LED is OFF before connecting or disconnecting the motor leads.
FAILURE TO DO THIS RESULTS IN A SHOCK HAZARD.
Always operate the Motor and the Drive GROUNDED. Be sure to twist
together the wires for each motor phase. Six twists per foot is a good
guideline.
1. Check to see that the motor used is compatible with the drive. Refer to Section
4.4 for a list of compatible motors.
2. Set the correct current level for the motor being used per the instructions in
Section 4.5.
3. Select the appropriate step resolution and set the front panel switches as
described in Section 4.6.
4. Wire the motor per the "Motor Connections" description in Section 3.3.
5. Connect the power source to the AC input terminal strip. The terminal labeled
"L1" is line or hot, "N" is neutral or common and ""is ground.
If the motor operates erratically, refer to Section 5, "Torque Versus Speed
Characteristics". Clockwise and counter-clockwise directions are properly
oriented when viewing the motor from the end opposite the mounting
flange.

Danaher Motion Superior Electric Section 3: Installation Guidelines
SS2000 D3 AND D6 3
Section 3: Installation Guidelines
3.1 GENERAL WIRING GUIDELINES
SLO-SYN 2000 drives use modern solid-state electronics to provide the features
needed for advanced motion control applications. In some cases, these
applications produce electromagnetic interference (EMI, or electrical "noise")
that cause inappropriate operation of the digital logic used in the drive, or in any
other computer-type equipment in the user's system.
In general, any equipment that causes arcs or sparks or that switches voltage or
current at high frequencies can cause interference. In addition, AC utility lines
are often "polluted" with electrical noise from sources outside a user's control
(such as equipment in the factory next door). Some of the more common causes
of electrical interference are:
Power from the utility AC line
Relays, contactors and solenoids
Light dimmers
Arc welders
Motors and motor starters
Induction heaters
Radio controls or transmitters
Switch-mode power supplies
Computer-based equipment
High frequency lighting equipment
DC servo and stepper motors and drives
Use the following wiring practices to reduce noise interference.
Solid grounding of the system is essential. Be sure that there is a solid connection to
the AC system earth ground. Bond the drive case to the system enclosure. Use a
single-point grounding system for all related components of a system (a "hub and
spokes" arrangement). Keep the ground connection short and direct.
Keep signal and power wiring well separated. If possible, use separate conduit or
ducts for each. If the wires must cross, they should do so at right angles to minimize
coupling.
Power wiring includes AC wiring, motor wiring, etc. and signal wiring
includes inputs and outputs (I/O), serial com
munications (RS232 lines),
etc.
Use shielded, twisted-pair cables for Indexer I/O lines. BE SURE TO GROUND
SHIELDS ONLY AT ONE END, THE INDEXER/DRIVE END FOR OUTPUTS
AND THE SWITCH OR SENSOR END FOR INPUTS.

Section 3: Installation Guidelines Danaher Motion
4SS2000 D3 AND D6
Suppress all relays to prevent noise generation. Typical suppressors are capacitors
or MOVs. (See manufacturers’ literature for complete information). Whenever
possible, use solid-state relays instead of mechanical contact types to minimize noise
generation.
If you are experiencing problems with drive operation that might be related to EMI, refer
to Appendix A for Troubleshooting pointers.
Figure 3.1 Recommended Wiring Practices
3.2 MOUNTING
The SLO-SYN Drive is mounted by fastening its mounting brackets to a flat surface as
shown in Figures 3.2 and 3.3.
Figure 3.2 D3 Mounting Diagram

Danaher Motion Superior Electric Section 3: Installation Guidelines
SS2000 D3 AND D6 5
Figure 3.3 D6 Mounting Diagram
The unit should be mounted upright (with the cooling fins vertical) , or
proper cooling will not occur. Air flow should not be obstructed. Case
temperature should not exceed +70° C (+158° F). Forced air cooling
may be required to maintain temperature within the stated limits.
When selecting a mounting location, it is important to leave at least two inches
(51mm) of space around the top, bottom and sides of the unit to allow proper
airflow for cooling.
It is also important to keep the drive away from obvious noise sources. If
possible, locate the drive in its own metal enclosure to shield it and its wiring
from electrical noise sources. If this cannot be done, keep the drive at least three
feet from any noise sources.

Section 3: Installation Guidelines Danaher Motion
6SS2000 D3 AND D6
3.3 CONNECTOR LOCATIONS AND PIN ASSIGNMENTS
Figure 3.4 shows the connector locations for the SLO-SYN 2000 drive.
Figure 3.4 Connector Locations

Danaher Motion Superior Electric Section 3: Installation Guidelines
SS2000 D3 AND D6 7
3.3.1 Motor Connections
All motor connections are made via the 5-pin connector. Pin assignments for
this connector are:
Motor Connection
Pin Assignment Leads Terminals
1M1 (Phase A) Red #1
2M3 (Phase A) White/Red #3
3M4 (Phase B) Black #4
4M5 (Phase B) White/Blk #5
5Shield Shield -
Motor phase A is M1 and M3 and motor phase B is M4 and M5. The
motor frame must be grounded.
Cabling from the drive to the motor should be done with a shielded, twisted pair
cable. As a guideline, the wires for each motor phase should be twisted about six
times per foot.
Danaher Motion offers the following motor cable configurations. These cables
have unterminated leads on both ends.
Length Part Number
10 ft (3 m) 216022-031
25 ft (7.6 m) 216022-032
50 ft (15.2 m) 216022-033
75 ft (22.8 m) 216022-034
Figure 3.5 shows the possible motor wiring configurations.

Section 3: Installation Guidelines Danaher Motion
8SS2000 D3 AND D6
5
4
1
3
5
4
1
3
GREEN
6-LEAD MOTORS
F
5
4
1
3
WHITE/BLACK
WHITE/RED
RED
8-LEAD MOTORS, SERIES CONNECTIONS
5
4
1
3
WHITE/RED
RED
8-LEAD MOTORS, PARALLEL CONNECTIONS
WHITE N.C.
2
N.C. BLACK
BLACK
WHITE
ORANGE
E
GREEN
WHITE/GREEN
WHITE/GREEN
6
2
7
8
WHITE/BLACK
BLACK
WHITE
ORANGE
6
2
7
8
GREEN
WHITE/GREEN
RED
WHITE/RED
4-LEAD MOTORS
WHITE/BLACK
BLACK
GREEN
PHASE B
GROUND
PHASE A
WHITE/RED
RED
PHASE A
PHASE B
N.C.
D
D
D
E
E
6
C
C
F
F
B
B
B
G
G
G
H
H
H
A
A
PHASE A
N.C.
PHASE B
PHASE B
PHASE A
Figure 3.5 Motor Wiring Configurations
3.3.2 Power Input
The AC input power is connected to a 3-screw terminal strip. The terminals are:
Lead Color,
North American
Terminal Standard
"L1 for Line or "Hot" Black
"N" for Common or Neutral White
""for Ground Green

Danaher Motion Superior Electric Section 4: Specifications
SS2000 D3 AND D6 9
SECTION 4: SPECIFICATIONS
4.1 MECHANICAL
SS2000D3
Size
(Inches) 2.5W x 5.6 (5.8*)D x 9.6 (10.8*)H
(mm) 63W x 142 (147*)D x 244 (274*)H
Weight 3.2 pounds (1.45 kg)
* Includes mounting hardware
SS2000D6
Size
(Inches) 3.8W x 5.6 (5.85*)D x 9.5* (10.75*)H
(mm) 97 W x 142 (149*) D x 241 (273*) H
Weight 6.5 pounds (2.95 kg)
* Includes mounting hardware
4.2 ELECTRICAL
AC Input Range 90 to 132 VAC, 50/60 Hz
AC Current D3 –5 amperes
D6 –7 amperes
Fuse Rating** 250 volts, 8 amperes
Fuse Type** Littelfuse part number 314008 or Bussman part number
ABC-8
Drive Power Dissipation
(Worse Case)D3 –35 watts
D6 –50 watts
** If this fuse blows, the power supply is prevented from energizing any of its
outputs, hence, the unit will not operate. Usually, this fuse only blows if an
internal failure occurs.
4.3 ENVIRONMENTAL
Temperature
Operating +32° F to +122° F
(0° C to +50° C) free air ambient, Natural Convection
Storage -40° F to +167° F
(-40° C to +75° C)
Humidity 95% max. non-condensing
Altitude 10,000 feet (3048 m) max.
Pollution Degree Level 2

Section 4: Specifications Danaher Motion
10 SS2000 D3 AND D6
4.4 MOTOR COMPATIBILITY
Motor Types Superior Electric KM and M Series
Frame Sizes D3: KML060 —KML091
M061 —M092
D6: KML060 —KML093
M061 —MH112
Do Not use larger frame size motor than those listed, or the drive may
be damaged.
Number of
Connections 4, 6, 8
Minimum Inductance 8 millihenrys
Maximum Inductance 64 millihenrys
Maximum Resistance 2 ohms at 6 amp. setting
Maximum resistance is total of motor plus cable.
MOTORS FOR USE WITH THE SS2000D3/D6 DRIVE
Motor
Current
(amperes) D3 D6
KML060-F02 1.5 XX
KML061-F03 1.5 XX
KML062-F03 1.5 XX
KML063-F04 2XX
KML091-F05 3XX
KML091-F07 3XX
KML092-F07 4X
KML093-F08 4X
KML093-F10 6X
M061-FF206 1XX
M062-FF206 1.5 XX
M063-FF206 1.5 XX
M091-FF206 3XX
M092-FF206 4X
M093-FF206 4X
M111-FF206 5X
M112-FF206 6X
MH112-FF206 6X
Duty cycle limiting or external motor cooling may be required to keep
the shell temperature below its rating.

Danaher Motion Superior Electric Section 4: Specifications
SS2000 D3 AND D6 11
4.5 CURRENT SETTINGS
The proper current setting for each motor is shown on the individual torque vs.
speed curves. Use this current level to obtain the torque shown. The access hole
for the switches which set the motor current level is located on the front of the
unit (see Figure 4.1). Select the desired operating current by setting the
appropriate switch to the "ON" position. Only one switch should be ON. If two
or more switches are ON, the one that selects the highest current level is the
active switch. The switch settings are:
Position
D3 Current
(amperes)
D6 Current
(amperes)
80.5 1.0
70.75 1.5
61.0 2.0
51.25 2.5
41.5 3.0
32.0 4.0
22.5 5.0
13.0 6.0
4.6 STEP RESOLUTION
The number of pulses per revolution is selected using the rotary switch on the
front panel. The arrow on the switch knob can point to any of ten positions. The
following chart shows the number of pulses per revolution selected by each
switch position.
Switch
Position
Pulses Per
Revolution
1200
2400
31,000
42,000
53,200
67,200
710,000
820,000
925,000
050,000

Section 4: Specifications Danaher Motion
12 SS2000 D3 AND D6
Figure 4.1 Switches For Setting Current Level and Step Resolution
4.7 SIGNAL SPECIFICATIONS
4.7.1 Connector Pin Assignments
All connections are made via the 8-pin connector, part number 220878-008.
Pin Assignment
1OPTO
2PULSE
3DIR
4AWO
5RDCE
6BOOST
7RESET
8READY
4.7.2 Signal Descriptions
OPTO Opto-Isolator Supply
User supplied power for the opto-isolators.
PULSEPulse Input
A low to high transition on this pin advances the motor one step. The step size
is determined by the Step Resolution switch setting.
DIR Direction Input
When this signal is high, motor rotation is clockwise. Motor rotation is counter-
clockwise when this signal is low.
Clockwise and counter-clockwise directions are properly oriented when
viewing the motor from the end opposite the mounting flange.

Danaher Motion Superior Electric Section 4: Specifications
SS2000 D3 AND D6 13
AWO All Windings Off Input
When this signal is low, AC and DC current to the motor will be zero. There is
no holding torque when the AWO signal is low.
RDCE Reduce Current Input
The motor current is 50% of the selected value when this signal is low.
Holding
torque is also reduced when this signal is low.
BOOST Boost Current Input
When this signal is low, the motor current is 150% of the selected level up to a
maximum of 6 amperes.
RESET Reset Input
The translator goes to the "power up" state when this signal goes low.
READY Ready Output
This pin is the emitter of an opto-isolator that activates when the drive is ready
to run a motor.
4.7.3 Level Requirements
OPTO
Voltage.................... 4.5 to 6.0 VDC
Current .................... 20 mA per signal used
READY
Voltage.................... 4.5 to 6.0 VDC (depends on OPTO)
Current .................... 0.5 mA source
Other Signals
Voltage
Low................... 0.8 VDC
0.0 VDC
High.................. OPTO
OPTO -1 volt
Current
Low................... 20 mA
High.................. 0.2 mA
4.7.4 Timing Requirements
PULSE
Max. Frequency....... 1 megahertz
Max. Rise and
Fall Times................ 1 microsecond
Min. Pulse
Width....................... 0.4 microseconds
Other Signals
Response Time....... 50 microseconds