Pacific Scientific 5345 User manual

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5345/5445
Microstepping Indexer / Drive
Installation & Hardware Reference Manual
AUTOMATION TECHNOLOGY GROUP
MOTION TECHNOLOGY DIVISION
110 Fordham Road
Wilmington, MA 01887
[phone]
Fax [phone]
Part# 903-544501-04
List Price $25 U.S.
September, 1997
Rev F
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Table of Contents
.....................................................
1 Overview of the 5345/5445 Microstep Indexer/Drive 1-1
1.1 5345/5445 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 System Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
2 Installing the 5345/5445 Microstep Indexer/Drive 2-1
2.1 Unpacking and Inspecting the 5345/5445 . . . . . . . . . . . . . . . . . 2-1
2.2 Selecting a Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 5345/5445 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Mounting the 5345/5445 in Your Installation . . . . . . . . . . . . . . . 2-4
2.5 Connecting the Seven Input/Output Cables . . . . . . . . . . . . . . . . 2-8
2.5.1 J1 Motor Connection . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.5.2 J2 120\230 Vac Power Connection . . . . . . . . . . . . . . . . . 2-17
2.5.3 J3 Serial Port Connection . . . . . . . . . . . . . . . . . . . . . . 2-18
2.5.4 J4 and J5 Discrete Input/Output Connection . . . . . . . . . . . . 2-26
2.5.5 J6 Encoder/Step and Direction Input Connection . . . . . . . . . . 2-33
2.5.6 J7 Step and Direction Output Connection . . . . . . . . . . . . . . 2-37
2.6 Setting the Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.6.1 Setting Up Functions Using Switch S1 . . . . . . . . . . . . . . . 2-42
2.6.2 Setting Up Serial Addresses Using Switch S2 . . . . . . . . . . . 2-47
3 Powering Up the 5345/5445 Microstep Indexer Drive 3-1
3.1 Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.2.1 POWER LED Not On - 5345/5445 Does Not Power Up . . . . . . 3-5
3.2.2 DISABLE FAULT LED On - 5345/5445 Disable Fault . . . . . . 3-7
3.2.3 LEDs Do Not Respond - Communications Interface Fault . . . . . 3-8
5345/5445 Hardware and Installation Manual Rev F
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Appendix A - Specifications A-1
Appendix B - Order Number and Ordering Information B-1
Appendix C - Series/Parallel Connections C-1
Index
Rev F 5345/5445 Hardware and Installation Manual
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1 Overview of the 5345/5445
Microstep Indexer/Drive
In this Chapter This Chapter introduces the 5345/5445 Microstep Indexer/Drive.
Topics covered are:
 5345/5445 definition
 System diagram
 How to use this manual
1.1 5345/5445 Definition
Overview The Pacific Scientific5345/5445 Microstep Indexer/Drive
combines a high-performance, bipolar chopper drive with a
Pacific Scientific StepperBASICprogrammable indexer for
stepper motor motion control.
Drive features Output current - 5.0 Amps per phase in full step mode (2.5
Amps per phase for the 5345) and 3.5 Amps per phase in
microstep mode (1.75 Amps per phase for the 5345).
Bipolar chopper drive -controls motor current at 20 KHz
chopper frequency.
Internal power supplies -operates from either the 120 or 230
Vac input. The main motor supply consists of a full wave bridge
rectifier into a capacitive input filter.
Shunt regulator circuitry -protects the drive by removing
energy from the supply if the dc bus voltage exceeds 84 volts.
This feature protects the circuitry from excessive voltage that
may be generated under certain motor deceleration conditions.
Short circuit protection circuitry - latches the drive off and
lights the DISABLE LED if a short circuit occurs on the motor
outputs. After removing the short circuit, the DISABLE LED
will go off. Reset the 5345/5445 by cycling power.
Rev F 5345/5445 Installation and Hardware Manual 1 - 1
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Microstep power boost switch - increases the drive current in
microstep mode at speeds above 500 Full Steps/sec. The rms
microstep current level while microstepping is 70% of the full
step rated current, the current boost feature boosts current by a
factor of 1.4 and brings winding current back to rated levels.
Status indicators - LEDs for operation and troubleshooting
information.
User-defined
functions
Mid-range instability control - eliminates loss of torque and
possible motor stalling when operating at mid-range speeds. This
instability is a phenomenon of the electronic, magnetic, and
mechanical characteristics of a stepping motor system. When
enabled, mid-range instability control damps mid-range
oscillations by advancing or delaying the switching of the output
transistors relative to the incoming pulse train.
Step size - sets the amount of rotation per step. The five settings
range from full step to fractions of a full step (microsteps). The
microstep settings range from 1/2 to 1/125 microsteps per step for
up to 25,000 steps/revolution with a standard 1.8ostepper motor.
Idle current reduction (ICR) - reduces motor winding current
by 50% during motor dwell periods. ICR begins one second after
the last input step pulse occurs.
Indexer
features
The indexer circuitry provides programmable motion control and
allows flexible interfacing to the application.
Pacific Scientific StepperBASIC - programming language with
over 100 instructions, combines the ease of the programming
language BASIC with sophisticated motion control features.
Serial port RS-232 or RS-422/485 communications -interfacing
the user computer or terminal for programming and/or computer
control. RS-422/485 control allows multiple 5345/5445 units to
be controlled from a single computer or terminal.
1 - 2 5345/5445 Installation and Hardware Manual Rev F
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Indexer
features
(contd)
12 outputs - user programmable outputs to external devices. One
output is program-selectable to indicate motor moving.
16 inputs - user programmable inputs from external devices. Six
inputs can be pre-defined for limit, start, stop, and jog functions.
Encoder inputs - for position verification, or for electronic
gearing. Alternatively, these inputs can be redefined for external
step and direction control.
Step and direction outputs - outputs step and direction signals
for control of another drive.
Memory - indexer memory capacity is 12K bytes (battery-backed
RAM).
Typical
applications
Typical applications for the 5345/5445 microstep indexer/drive
include:
 X-Y tables and slides
 Packaging machinery
 Feed to length
 Labeling machines
1.2 System Diagram
The following diagram shows an installation of the drive in a
typical system. Your installation may vary from this
configuration. Typical components used with the 5345/5445
include:
 Motor
 Computer or terminal
 External switches
Selection and installation guidelines for these components are
described in Chapter 2, “Installing the 5345/5445 Microstep
Indexer/Drive.”
Rev F 5345/5445 Installation and Hardware Manual 1 - 3
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System
Diagram
Note: 230 Vac is for use with 5345-230 and 5445-230 ONLY.
1
2
3
J1
J6
J4
J3
5345/5445
INDEXER
DRIVE
J2
J7
J5
4
5
CH A
CH A
CH B
CH B
CASE GND
MOTOR
N/C
CH A (STEP)
CH A (STEP)
CH B (DIR)
CH B (DIR)
CH Z
CH Z
+5 VDC
+5 RTN
1
2
3
4
5
6
7
8
9
3
2
1
1
2
3
4
5
6
7
8
9
STEP OUT
STEP OUT
DIR OUT
DIR OUT
ENABLE
I/O RTN
+5 VDC
FAULT OUT
N/C
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
17
14
N/C
I/O RTN
OUTPUT 12
OUTPUT 11
OUTPUT 10
OUTPUT 9
OUTPUT 8
OUTPUT 7
I/O RTN
INPUT 16
INPUT 15
INPUT 14
INPUT 13
INPUT 12
INPUT 11
INPUT 10
INPUT 9
1N/C
2INPUT 1
3INPUT 2
4INPUT 3
5INPUT 4
6INPUT 5
7INPUT 6
8INPUT 7
9INPUT 8
I/O RTN
OUTPUT 1
OUTPUT 2
10
11
12
I/O RTN 17
OUTPUT 6 16
OUTPUT 5 15
OUTPUT 4 14
OUTPUT 3 13
1+5 VDC RTN
2
TXD 232
3
RXD 232
4
+5 VDC
6
TXD (+)
7TXD (-)
8RXD (+)
9
RXD (-)
5COMMON
120/230 VAC
50/60 HZ
POWER
1 - 4 5345/5445 Installation and Hardware Manual Rev F
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1.3 How to Use this Manual
This manual contains information and procedures to install, set
up, test with simple commands, and troubleshoot the 5345/5445.
Refer to the StepperBASIC Programming Manual for
programming instructions and reference.
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2 Installing the 5345/5445
Microstep Indexer/Drive
In this Chapter This Chapter explains how to install the 5345/5445 Microstep
Indexer/Drive. Topics covered are:
 Unpacking and inspecting the 5345/5445
 Selecting a motor
 5345/5445 safety
 Mounting the 5345/5445 in your installation
 Connecting input/output cabling
 Selecting switch functions
2.1 Unpacking and Inspecting the 5345/5445
Unpacking
procedure
1. Remove the 5345/5445 from the shipping carton. Make sure
all packing materials are removed from the unit.
2. Check the items against the packing list. A label located on
the side 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 as soon as
possible after receipt of the unit.
Storing the unit Store the 5345/5445 in a clean, dry place. The storage
temperature must be between -55 degrees C and 70 degrees C.
To prevent damage during storage, replace the unit in the original
shipping carton.
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2.2 Selecting a Motor
Selecting a
motor
The 5345/5445 is designed for use with Pacific Scientific’s line
of hybrid stepper motors. The drive works with either the
standard line or the enhanced high performance line of stepper
motors. Use the system Torque/Speed curves for the 5345/5445
shown in the Pacific Scientific “Motion Control Solutions”
Catalog to select the right motor for your application.
To use a motor not included in the system selections, observe the
following rules:
 The motor winding current rating must be equal or greater
than the drive’s output current:
-5345 - 2.5 Amps RMS (3.55 Amps peak)
-5445 - 5.0 Amps RMS (7.1 Amps peak)
 The electrical and magnetic losses of the motor must not
exceed the motor power dissipation rating. This is of special
concern at high speed and with low inductance motors. The
motor case temperature should not exceed 100 degrees C.
If you need help in selecting a motor, contact your local Pacific
Scientific distributor for sizing and motor compatibility assistance.
2.2.1 Selecting System Components
Introduction Match your 5345/5445 unit to your other components.
Serial
communications
interfaces
The 5345/5445 requires a serial communication link in order to
develop StepperBASIC software (using PacCom). A serial
interface may be used under software control to interface the
5345/5445 with other user-supplied equipment such as:
 Operator displays
 Host computers
 Programmable controllers (PLC)
The 5345/5445 uses serial communication interfaces supported by
the RS-232 and RS-485 hardware specifications.
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Single- and
Multi-unit
control
For controlling a single 5345/5445, use RS-232 communications
and install cable as described in section 2.5.3.1 “J3 Serial Port -
RS-232 Connection.”
For controlling multiple 5345/5445s, use RS-422 or RS-485
communications, which permit a single PC to host from 1 to 31
5345/5445s (each requiring a unique switch selectable address).
For detailed information on setup refer to section 2.5.3.2 “Serial
Port - RS-422 or RS-485 Connection.”
Digital I/O Enable input - One dedicated input to enable the controller.
Connecting this input to I/O Return enables the 5345/5445.
Fault output - An open collector (NPN) dedicated output
showing controller fault status. This output turns off to indicate a
fault. Maximum current sinking capability is 50 milliamperes
and maximum off voltage is 24 volts.
General inputs - 16 inputs to support logic type interfaces. The
input circuitry is intended to be operated with open collector type
circuitry. These inputs can be polled under software control.
Seven of the 16 inputs can be pre-defined for specific functions:
LIMIT +/-, START/STOP, JOG +/- and mechanical HOME
SWITCH.
General outputs - 12 open collector discrete outputs under
software control. Each output can sink a maximum of 50
milliamperes. Maximum off voltage is 24 volts. One of the 12
outputs can be pre-defined for MOTOR MOVING status.
Encoder I/O - The external encoder I/O port permits interfacing
to quadrature type encoder signals for applications such as
electronic gearing. This input can also be configured by software
as a step and direction input.
Note: Factory default is for quadrature encoder inputs.
Step/Dir Out - The Step/Dir output permits controlling external
devices so they can follow step and direction from the 5345/5445.
This output signal is present as long as the 5345/5445 is enabled
and executing any motion profile.
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2.3 5345/5445 Safety
Your
responsibility
As the user or person applying this unit, you are responsible for
determining the suitability of this product for any application you
intend. In no event will Pacific Scientific Company be
responsible or liable for indirect or consequential damage
resulting from the use of this product.
WARNING
The circuits in the 5345/5445 are a potential source of severe
electrical shock. Follow the safety guidelines to avoid shock.
Safety
guidelines
To avoid possible personal injury whenever you are working with
the 5345/5445:
 Do not power up the unit without the cover on and the
chassis tied to earth ground.
 Do not operate the unit without the motor case tied to earth
ground.
 Always remove power before making or removing
connections from the unit.
 Before removing the cover of the unit, shut off power and
allow the unit to sit for 5 minutes to discharge the bus
capacitors.
 Be careful of the motor terminals when disconnected from
the motor. With the motor disconnected and power applied
to the drive, the motor terminals have high voltage present.
 Do not use the enable input as a safety shutdown. Always
remove power to the drive for a safety shutdown.
2.4 Mounting the 5345/5445 in Your Installation
Cabinet
selection
Select a standard 8-inch (205 mm) deep or greater NEMA
(National Electrical Manufacturers Association) enclosure
appropriate for industrial applications.
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CAUTION
The internal cabinet temperature should not exceed 50oC (60oC
with derating). If the cabinet is ventilated by filtered or
conditioned air make sure to prevent the accumulation of dust
and dirt on the unit’s electronic components. The air should
also be free of corrosive or electrically conductive contaminants.
Mounting
dimensions
Prepare the cabinet for the 5345/5445 using the dimensions in
inches or millimeters as shown in the following figures.
(in inches)
6.00
0.30
MATING CONNECTOR CLEARANCE
1.70 MIN FOR J3
1.00 MIN FOR ALL OTHER CONNECTORS
0.75
12.42
MTG
10.14
J2
J1
J6
J4
J3
J7
J5
5345/5445
INDEXER/DRIVE
0.44
1.01
1.24
3.26
0.40
1/4" - 20
GROUND STUD
.14
.28
11.48
1.48
1.45
0.280 DIA.
0.625 DIA.
0.10
0.45 REF
7.02
6.25
1.63
0.50
Rev F 5345/5445 Installation and Hardware Manual 2 - 5
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Mounting
dimensions
(in millimeters)
152.4
7.62
MATING CONNECTOR CLEARANCE
43.18 MIN FOR J3
25.40 MIN FOR ALL OTHER CONNECTORS
19.05
315.47
MTG
10.14
J2
J1
J6
J4
J3
J7
J5
5345/5445
INDEXER/DRIVE
11.17
31.5
82.80
10.16
1/4" - 20
GROUND STUD
3.56
7.11
291.59
1.48
36.83
7.11 DIA.
15.87 DIA.
2.54
11.43 REF
178.31
158.75
41.4
12.7
25.65
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Mounting
guidelines
Select a cabinet position that meets these guidelines:
 Flat, solid surface capable of supporting the approximate
9.75 pound (4.423 kilogram) weight of the unit.
 Free of excessive vibration or shock.
 Minimum unobstructed space of two inches (50 mm) at the
fan input on the unit bottom and the exhaust on the unit top.
 Operating temperature of:
5445 - 0 to 50 degrees C at full rated current
5345 - 0 to 60 degrees C at full rated current
0 to 60 degrees C with idle current reduction enabled
(microstep mode).
Mounting
procedure
Bolt the unit to the cabinet using the three slots (refer to the
dimensions figure) using a 1/4 - 20 or #10 (M6 metric equivalent)
bolt.
Power
dissipation for
cabinet
The 5345/5445 dissipates power causing cabinet heating. Power
dissipation is determined by a number of factors, such as output
current, motor winding impedance, input step rates, and idle
current reduction. The 5345 is factory preset for 2.5 amps/phase
current and idle current reduction enabled. The 5445 is factory
preset for 5 amps/phase current and idle current reduction enabled.
For an estimate of the power dissipation for use in calculating
cabinet cooling requirements, use the values shown:
For an RMS current of
(amps): Use a value of (watts):
5.0 50
2.5 20
Rev F 5345/5445 Installation and Hardware Manual 2 - 7
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2.5 Connecting the Seven Input/Output Cables
Introduction The seven input/output connectors are:
 J1-Motor
 J2-120 or 230 Vac power
 J3-RS-232/RS-485 serial port
 J4-Discrete inputs and outputs
 J5-Discrete inputs and outputs
 J6-Encoder/Step and direction inputs
 J7-Step and direction outputs, fault output, and enable input
Note: These inputs and outputs are shown on the next page.
Wiring is
application
specific
Wiring sizes, wiring practices, and grounding/shielding
techniques described in the following section represent common
wiring practices and should prove satisfactory in the majority of
applications.
CAUTION
Non-standard applications, local electrical codes, special
operating conditions, and system configuration wiring needs
take precedence over the information included here. Therefore,
you may need to wire the drive differently than described here.
Noise pickup
reduction
Use shielded and twisted cabling for the signal and power cables.
This precaution reduces electrical noise.
Shock hazard
reduction
Refer to section 2.3 for safety information that must be followed
to reduce shock hazard.
2 - 8 5345/5445 Installation and Hardware Manual Rev F
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Connection
diagram
Note: 230 Vac is for use with 5345-230 and 5445-230 ONLY.
1
2
3
J1
J6
J4
J3
5345/5445
INDEXER
DRIVE
J2
J7
J5
4
5
CH A
CH A
CH B
CH B
CASE GND
MOTOR
N/C
CH A (STEP)
CH A (STEP)
CH B (DIR)
CH B (DIR)
CH Z
CH Z
+5 VDC
+5 RTN
1
2
3
4
5
6
7
8
9
3
2
1
1
2
3
4
5
6
7
8
9
STEP OUT
STEP OUT
DIR OUT
DIR OUT
ENABLE
I/O RTN
+5 VDC
FAULT OUT
N/C
1
2
3
4
5
6
7
8
9
10
11
12
13
15
16
17
14
N/C
I/O RTN
OUTPUT 12
OUTPUT 11
OUTPUT 10
OUTPUT 9
OUTPUT 8
OUTPUT 7
I/O RTN
INPUT 16
INPUT 15
INPUT 14
INPUT 13
INPUT 12
INPUT 11
INPUT 10
INPUT 9
1N/C
2INPUT 1
3INPUT 2
4INPUT 3
5INPUT 4
6INPUT 5
7INPUT 6
8INPUT 7
9INPUT 8
I/O RTN
OUTPUT 1
OUTPUT 2
10
11
12
I/O RTN 17
OUTPUT 6 16
OUTPUT 5 15
OUTPUT 4 14
OUTPUT 3 13
1+5 VDC RTN
2
TXD 232
3
RXD 232
4
+5 VDC
6
TXD (+)
7TXD (-)
8RXD (+)
9
RXD (-)
5COMMON
120/230 VAC
50/60 HZ
POWER
Rev F 5345/5445 Installation and Hardware Manual 2 - 9
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In this section
To install
connector: Refer to Section:
J1 2.5.1
J2 2.5.2
J3 2.5.3
J4 and J5 2.5.4
J6 2.5.6
J7 2.5.7
2.5.1 J1 Motor Connection
Introduction The J1 motor cable connects the drive to the motor windings.
Motor cables are available from Pacific Scientific, or you can
make your own.
Note: Refer to Appendix C, “Series/Parallel Connections” for
additional information.
Mating
connector
The J1 motor connector is for a PCD 5-pin screw mating
connector. The mating connector, supplied with the unit, is type
ELFH05110.
Making your
own cable
If you need to build the cable, refer to the appropriate subsection
as follows:
To build the cable for
motor type: Refer to Section:
4-lead 2.5.1.1
8-lead series 2.5.1.2
8-lead parallel 2.5.1.3
Pacific
Scientific cable
If the motor cable is purchased from Pacific Scientific, install as
follows. The Pacific Scientific order number is SPC-xxx , where
“xxx” is the length in one-foot increments up to 50 feet. For
example, SPC-050 is a cable 50 feet long.
2 - 10 5345/5445 Installation and Hardware Manual Rev F
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Pacific
Scientific
cabling
installation
If you are using Pacific Scientific motor cable with the mating
connectors already attached, install as follows:
Pacific
Scientific
cable diagram
Procedure 1. Remove power from the 5345/5445.
WARNING
Always remove power before making or removing connections
to the unit. The motor terminals have high voltage present
when the 5345/5445 is On.
2. Plug the mating connector firmly into the 5345/5445.
3. Plug the other mating connector into the motor and screw
down the retaining collar.
4. Reconnect power to the 5345/5445.
5
1
JACKET
5 PIN MS CONNECTOR
MS3116F14-5S
5 PIN PHOENIX
A1
2
3
4
5
A
B
GND
B
MOTOR
PHASES
SPC - XXX
J1
BLK A
B
C
D
E
ORG
RED
YEL
GRN
SHIELD
Rev F 5345/5445 Installation and Hardware Manual 2 - 11
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