Phd Fsc-01 User manual

Programmable Motion Controller

Internet Web Site: http://www.phdinc.com • E-Mail: [email protected]

PHD, Inc.

9009 Clubridge Drive

P.O. Box 9070, Fort Wayne, Indiana 46899 U.S.A.

Phone (219) 747-6151 • Fax (219) 747-6754

PHD Ltd. PHD GmbH

7 Eden Way, Pages Industrial Park Arnold-Sommerfeld-Ring 2

Leighton Buzzard, Bedfordshire LU7 8TP U.K. D-52499 Baesweiler GERMANY

Phone 01525 853488 • Fax 01525 378210 Phone 02401-805 230 • Fax 02401-805 232

100 7/99 4769

6441-335

L2/N

PC/MMI

POWER

OUT 3+

OUT 3-

IN1

IN2

IN3

IN4

OUT 1+

OUT 1-

OUT 2+

OUT 2-

+24 VDC

24V GND

+5 VDC

GND

STEP+

STEP-

DIR+

DIR-

IN/JOG COM

STOP

CWJOG/IN5

CCWJOG/IN6

LIMIT COM

CW LIMIT

CCW LIMIT

AC POWER

FSC-01

Motion Controller

-19-

Mechanical Outline - Optional PHD

Part Number 64725 MMI

-2-

4.90

4.90 1.38

0.13

3.875

CENTERED

3.875

CENTERED 123

➝

456

➝

789

YES NO

SPACE BKSP ENTER

2.988

1.975

0.425

0.963

0.960

Table of Contents

Features 3

Block Diagram 3

Getting Started 4

Connecting AC Power 5

Installing an AC Line Cord 6

Connecting the Step and Direction Outputs 7

Installing the PHD Programmer Software 8

Connecting to the PC 8

Front Panel Stop Button 9

Jogging 9

Limit Switches 9

Wiring a Limit Switch 10

Limit Sensors 10

Wiring Inputs 11

Wiring Outputs 13

Mircrostep Resolution 14

Mounting the FSC-01 15

Mounting the Optional PHD Part Number 64725 MMI 15

Flush Mounting 16

Surface Mounting 16

Mechanical Outline: FSC-01 17

Technical Specifications 18

Mechanical Outline - Optional PHD Part Number 64725 MMI 19

Technical Specifications

Block Diagram

Linear, transformer based for high reliability and low noise. 110 or 220 VAC

input, switch selectable. 50/60 Hz. 50 W max.

24 VDC ±5%, 100 mA max. Self resetting fuse.

5 VDC ±5%, 100 mA max, including MMI which draws 45 mA.

Self resetting fuse.

IN 1-4, CW JOG, CCW JOG, CW LIMIT, CCW LIMIT: Optically isolated, 5 -

24V. Can be configured to accept sourcing (PNP) or sinking (NPN) signals.

2200 ohms input impedance.

Optically isolated. 24V, 100 mA max. Can be individually configured to

provide sourcing (PNP) or sinking (NPN) signals.

15 software selectable resolutions. Steps per revolution with 1.8 motor: 200,

400, 2000, 5000, 10000, 12800, 18000, 20000, 21600, 25000, 25400,

25600, 36000, 50000, 50800.

12800 Hz.

Constructed with heavy gauge steel housing. 1.25 x 8 x 3.86 inches overall.

2 lbs. 0 - 70°C ambient temperature range.

Power/status LED. Mounting brackets included. See page 17 for detailed

drawing .

European style, pluggable screw terminal blocks, mating connectors included.

Signal Input/output: Three 8 position. AWG 16 - 28 wire.

AC Input: 3 position. AWG 12 - 24 wire.

PC/MMI: RJ11C, cable & connectors included.

Wickman TR-5 style, 0.25A fast acting.

Order from Digikey (1-800-DIGIKEY), P/N WK3035.

CE [Complies with EN 55011A, EN 50082-1 (1996), EN 50178 (1997)]

and TUV

Power Supply

Output

Voltages

Inputs

Outputs

Microstepping

Motion Update

Physical

Connectors

Fuses

Agency

Approvals

Features

• Powerful, flexible, easy to use indexer.

• Microsoft Windows™-based software for easy set up and programming.

• Reliable, efficient, low noise linear power supplies provide 5V and 24V to the

user, 100mA each.

• Connects by a simple cable to your PC for programming (cable included).

• Eight inputs for interacting with the user and other equipment.

• Three programmable outputs for coordinating external equipment.

• High speed, differential step & direction outputs interface easily to popular step

motor and servo motor drives.

• Pulse rates to 2.5 MHz for high speeds at high resolutions.

• Accepts 110 or 220 volt AC power (factory preset for 110 volts).

• Sturdy 1.25 x 8 x 3.86 inch metal case with integral heat sink. Mounting

brackets included.

• Pluggable screw terminal connectors for I/O and AC power (all mating

connectors included).

• Bi-color (red/green) LED indicates power and indexer status.

• Optional man machine interface (MMI) allows operator to enter distances,

speeds, loop counts, and more.

110 or

220 VAC fuse

INPUT1

INPUT2

INPUT3

INPUT4

CW JOG/IN5

CCW JOG/IN6

to PC/MMI

CW LIMIT

CCW LIMIT

OUT1

OUT2

OUT3

5VDC, 100mA

24VDC, 100mA

STEP+

STEP-

RS232 Optical

Isolation

PHD

Microstepping

Indexer

Sequencer

eeprom

Optical

Isolation

Internal

Power

Supply

DIR+

DIR-

-18- -3-

FSC-01

Motion Controller

POWER

PC/MMI

L2/N

AC POWER

STOP

STEP+

STEP–

DIR+

DIR–

GND

+5 VDC

24V GND

+24 VDC

OUT3+

OUT3–

IN/JOG COM

IN1

OUT2–

OUT2+

OUT1–

OUT1+

CCWJOG/IN6

LIMIT COM

CW LIMIT

CCW LIMIT

CWJOG/IN5

IN4

IN3

IN2

I/O connector

+24V out, 100mA

+5V out, 100mA

step & dir out to driver

I/O connector

output 1,2,3

input 1

I/O connector

input 2,3,4

cw jog

ccw jog

cw limit

ccw limit

STOP button

mounting

bracket

LED

green = power on/status ok

flashing red = error

AC power

connector

RS232 connector

PC or MMI

Mechanical Outline: FSC-01

1.25

7.17

0.20

.625

7.625

8.00

3.86

0.06

FSC-01

Motion Controller

POWER

PC/MMI

L2/N

AC POWER

STOP

STEP+

STEP–

DIR+

DIR–

GND

+5 VDC

24V GND

+24 VDC

OUT3+

OUT3–

IN/JOG COM

IN1

OUT2–

OUT2+

OUT1–

OUT1+

CCWJOG/IN6

LIMIT COM

CW LIMIT

CCW LIMIT

CWJOG/IN5

IN4

IN3

IN2

-4- -17-

Getting Started

To use your FSC-01 motor control, you will need the following:

✔a power cable (line cord)

✔a compatible pulse & direction servo drive (PHD part number FSA-01)

✔a small flat blade screwdriver for tightening the connectors - a screwdriver suitable for this

purpose is included with your drive.

✔a personal computer running Windows 3.1, 95, 98 or NT with a 9 pin serial

port (486 or better with 8 MB ram recommended)

✔the PHD Programmer software that came with your FSC-01

✔the programming cable that came with your FSC-01

✔PHD Programmer Manual (part #6441-333)

✔PHD Quickstart Manual (part #6441-334)

The sketch below shows where to find the important connection and adjustment points. Please

examine it now.

All mating connectors are included.

When you remove the MMI from the shipping carton, you will notice that it has two parts. The

first is a fairly thin section that contains the keypad, display, and some circuit boards. The other

part is thicker and contains the telephone jack and a cable that

connects to the thin part.

When you flush mount the MMI in a

panel, only the thin section will stick out

from your panel - the large portion

mounts behind your panel. You'll need

to cut a precise section from your panel.

There is a cardboard template in your

box for this purpose.

If you want the MMI to be dust proof

and watertight, you must place the black

rubber gasket between the thin part of the

MMI and your panel. Assemble the two

halves using the eight small screws.

Surface Mounting

An easier way to mount the MMI is to bolt the two halves

together ahead of time, using the eight small screws. If you want

the MMI to be dust proof and watertight, put the black rubber gasket between the

two halves before screwing them together.

Then cut a hole in your panel for the cable

that runs between the MMI and the controller.

The hole must be at least 5/8" in diameter

for the connector to fit through. You will

also need two holes that line up with the

big mounting holes in the MMI. The

mechanical outline on page 19 shows the

location of the big mounting holes.

When you mount the MMI to your panel,

you will need to use some kind of sealant

to keep dust and liquid out. Silicone or

latex caulking is okay, or you can make

your own gasket from a sheet of compliant

material like rubber or RTV.

Connecting to 110 Volts

The FSC-01 is set for 110 volt operation at the factory. All you need to do is connect an AC power

cord and the AC Power connector that comes with the FSC-01. If you want to directly wire the

FSC-01 to AC power, you must consult a qualified electrician and observe all building and

electrical codes.

The AC cord you can install yourself, but be careful: AC power can be dangerous.

Connecting to 220 Volts

The FSC-01 is set for 110 volt operation at the factory. In order to use 220 volts, you'll need to

change a switch setting inside the case. You will need a medium sized phillips screwdriver to

remove the cover.

Before you can change the 110/220 volt switch setting, you must remove all the connectors from

the FSC-01 front panel. Remove the four screws from the cover, as shown below.

If you plan to operate the FSC-01 at 220 volts, you must change the

setting of the 110/220V switch before applying power to the FSC-01.

The FSC-01 is factory preset for 110 volts.

123

➝

456

➝

789

YES NO

SPACE BKSP ENTER

panel

sealant (not included)

MMI

gasket

(included)

123

➝

456

➝

789

YES NO

SPACE BKSP ENTER

panel

MMI

(front section

and gasket)

MMI

(rear section)

Connecting AC Power

FSC-01

Motion Controller

POWER

PC/MMI

L2/N

AC POWER

STOP

STEP+

STEP–

DIR+

DIR–

GND

+5 VDC

24V GND

+24 VDC

OUT3+

OUT3–

IN/JOG COM

IN1

OUT2–

OUT2+

OUT1–

OUT1+

CCWJOG/IN6

LIMIT COM

CW LIMIT

CCW LIMIT

CWJOG/IN5

IN4

IN3

IN2

remove these four screws

Flush Mounting

-16- -5-

Mounting the PHD Optional MMI

Part Number 64725 MMI

The MMI is an easy to use, flexible device that allows an operator to enter move speeds, move

distances, or repeat loop counts. Messages can also be displayed and the program can be paused

until the user presses a key, such as ENTER, YES, or NO. Program branching can be

accomplished based on the response of YES or NO. The MMI connects directly to the FSC-01

motion controller using the standard programming cable. No special wiring is required. It has a 4

line, 20 character per line LCD display, and a 20 key keypad.

There are two ways to mount the MMI in your application. No matter which method you choose,

you‘ll need to connect the MMI to your FSC-01 with the programming cable. You will not,

however, need the adapter plug. The MMI has the same telephone style connector as the FSC-01.

Depending on how you mount the MMI and cable in your application, you may find that it is

difficult to remove the cable from the back of the MMI. If this is the case, and you need to

reprogram the FSC-01, you can use any telephone line cord as a programming cable. Please be

careful not to lose the adapter plug that connects the telephone cord to the COM port of your PC.

!Always unplug the line cord from the wall before attaching it

to the FSC-01

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 FSC-01 also comes with an insulating rubber boot.

• Connect the black or brown wire to the FSC-01 “L1” terminal of the AC power connector. That is

the line, or “hot” connection.

• Connect the white or blue wire to neutral. That’s the “L2/N” terminal.

• Finally, and most importantly, connect the green wire to the GND terminal. That connects the

FSC-01 metal enclosure and DC power supply ground to earth ground.

To Earth Ground

To Neutral

To Line (Hot)

AC Power Plug

!Never use your drive in a space where there is no air flow or where

the ambient temperature exceeds 70°C.

Never put the drive where it can get wet.

Never allow metal particles near the drive.

Mounting the FSC-01

The FSC-01 has two mounting slots in the back panel. They’re 0.2 inches wide, large enough for

number 10 screws. (No screws are included with the FSC-01. You'll have to supply your own.)

The FSC-01 is not heavy, nor does it generate much heat. Your only concerns for placement

should be:

• routing wires to and from the FSC-01: keep signal wires away from motor wires

and AC power cables

• protecting the FSC-01 from anything that might short out the internal circuitry,

like water or metal chips.

L2/N

AC POWER

Once you've done that, find the 110/220V

switch, which is next to the AC Power

connector. Slide the switch toward the label

marked “220V”, as shown in the sketch.

Then replace the cover and secure it with the

four screws.

-6- -15-

220V

Microstep Resolution

The microstep resolution of the FSC-01 is set by the PHD Programmer software.

Make sure the step resolution of the FSC-01 is the same as the servo drive it is connected to.

Consult the PHD Quick Start Manual for additional information (part #6441-334).

Connecting the Step and Direction

Outputs

The FSC-01 Motion Controller can work with most pulse and direction step motors or servo drives.

Different step motor drives use different input configurations. There are three basic types that the

FSC-01 can be used with:

• Differential: Driver has STEP+, STEP-, DIR+, and DIR- inputs. Many high speed

microstep drivers use differential inputs.

• Common anode: Driver has STEP and DIR inputs that require sinking signals

and a common terminal named “VOPTO” or “+5V”

• Common cathode: Driver inputs are STEP and DIR (requiring sourcing signals)

and a common terminal named “common” or “ground.”

Wiring diagrams for each type of driver are shown below and on the next page. The first sketch

shows the output circuits for the FSC-01.

FSC-01

STEP+

STEP–

DIR+

DIR–

Driver

STEP+

STEP–

DIR+

DIR–

Connecting to a Driver with Differential Inputs

FSC-01 Step & Direction Output Circuit

inside

FSC-01

26C31

+5 VDC

GND

STEP+

STEP–

DIR+

DIR–

+5V

-14- -7-

Continued from previous page.

Note: Please consult the PHD Quickstart Manual (part number #6441-334) for

connection details.

(Note: Power supply may be built into PLC and internally wired to the common)

Typical diagram for interfacing an FSC-01 output to an PNP type PLC input.

OUTPUT -

OUTPUT +

COMMON

INPUT

FSC-01

Motion

Controller

+ 24 VDC

24 VDC GND

PLC With

PNP Input

Wiring Outputs

Before we discuss the output conditions, we need to talk about the circuitry. All three FSC-01

outputs are optically isolated. That means that there is no electrical connection between the

motion controller and the output terminals. The signal is transmitted to the output as light. What

you “see” is a transistor (NPN type) that closes, or conducts current, when the output is “low.”

When the output is high, the transistor is open.

At power-up, the FSC-01 sets all three programmable outputs high (open circuit).

The maximum voltage between any pair of + and - output terminals is 24 volts DC.

Never connect AC voltages to the FSC-01 output terminals. Maximum current is

100 mA per output.

Since there is no electrical connection to the FSC-01, you must provide the source of current and

voltage, typically from an external power supply. You must also limit the current to less than 100

mA so that the output transistor is not damaged. You would normally use a resistor for this, but

some loads (such as PLC inputs) limit the current automatically.

The diagrams below shows how to connect an FSC-01 output to various types of optically isolated

PLC inputs.

330

Ω

+5V

OUT1–

OUT1+

Optoisolator

NEC PS2502

or equiv.

FSC-01

Controller Chip

inside FSC-01

Schematic Diagram of FSC-01 Output Circuit

Installing the PHD Programmer

Software

• Please refer to the PHD Programmer Software Manual under “Installing the Programmer

Software” for detailed installation instructions.

Connecting to the PC

• Locate your computer within 6 feet of the FSC-01.

• Your FSC-01 was shipped with a black adapter plug. It has a telephone style jack at one end

and a larger 9 pin connector at the other. Plug the large end into the COM1 serial port of your

PC. Secure the adapter with the screws on the sides. If the COM1 port on your PC is already

used by something else, you may use the COM2 port for the FSC-01. On some PCs, COM2

will have a 25 pin connector that does not fit the black adapter plug. If this is the case, and

you must use COM2, you will have to purchase a 25 to 9 pin serial adapter at your local

computer store.

• Your FSC-01 was also shipped with a 7 foot telephone line cord. Plug one end into the

adapter we just attached to your PC, and the other end into the RS232 jack on your FSC-01.

Never connect the FSC-01 to a telephone circuit. It uses the same connectors and

cords as telephones and modems, but the voltages are not compatible.

Programming Note: Always apply power to FSC-01 after the PHD Programmer

software is running on your PC.

FSC-01

+5 VDC

STEP–

DIR–

Driver

+5 VDC

STEP

DIR

Connecting to a Driver with Common Anode Inputs

Connecting to a Driver with Common Cathode Inputs

FSC-01

GND

STEP+

DIR+

Driver

GND

STEP

DIR

-8- -13-

OUTPUT -

OUTPUT +

COMMON

INPUT

24 VDC Power

Supply+

FSC-01

Motion

Controller

PLC With

NPN Input

Diagrams continued on next page.

Typical diagram for interfacing an FSC-01 output to an NPN type PLC input.

(Note: Power supply may be built into PLC and internally wired to the common)

Limit Switches

The FSC-01 has two limit switch inputs, LIMIT CW and LIMIT CCW. By connecting switches or

sensors that are triggered by the motion of the motor or load, you can force the FSC-01 to operate

within certain limits. This is useful if a program error could cause damage to your system by

traveling too far.

The limit inputs are optically isolated. This allows you to choose a voltage for your limit circuits of

5 to 24 volts DC. It also allows you to have long wires on limit sensors that may be far from the

FSC-01 with less risk of introducing noise to the FSC-01. The schematic diagram of the limit

input circuit is shown below.

Front Panel Stop Button

On the front panel of the FSC-01 is a button marked “STOP.” This button can be used to interrupt

motion at any time. After pressing the STOP button, the output pulses to the motor driver will stop.

The front panel Power LED will then flash until the AC power is removed from the indexer. If the

FSC-01 is connected to a PC running the Windows Programming Software, the software will alert

the user on screen to the condition, and ask if you want to reset the indexer from the PC.

Jogging

Two of the FSC-01 input terminals are provided for jogging the motor. The inputs are labeled “JOG

CW” and “JOG CCW.” Taking one of the inputs low commands the drive to move the motor at a

pre-defined speed until the contact is opened. A relay or mechanical switch can be used to activate

the jog inputs. 5 volt circuitry can also be used. The schematic diagram of the input circuit is

shown below.

•If you’re using a switch or relay, wire one end to the JOG input and the other to the 24V GND

terminal. Then connect the IN/JOG COM and +24 VDC terminals.

2200

inside FSC-01

IN/JOG COM

+24 VDC

24V GND

CWJOG

CCWJOG

inside FSC-01

LIMIT COM

CW LIMIT

CCW LIMIT

2200

Connecting an NPN Type

Proximity Sensor

to an FSC-01 Input

(When prox sensor activates,

FSC-01 input goes low.)

Connecting a PNP Type

Proximity Sensor to an

FSC-01 input

(When prox sensor activates,

FSC-01 input goes low.)

-12- -9-

Switch Model Number Output Type Wire # 1 Wire # 2 Wire # 3

18431-001-02 Ind. Prox

18431-002-02 Ind. Prox

51422-005-02

51422-006-02

55802 or 55822 Reed

55803 or 55823 Hall

55804 or 55824 Hall

62505 or 62515

62506 or 62516

NPN

PNP

NPN

PNP

NPN

PNP

NPN

PNP

NPN

PNP

Brown

Blue

Brown

Blue

Brown

Blue

Black

PHD Switch Color Code Cross Reference Chart

INPUT

In/Jog Com

Power

Supply

+PHD FSC-01

Motion Controller

Output

NPN

Proximity

Sensor

+Wire # 1

Wire # 2

Wire # 3

Wire # 1

Wire # 2

Wire # 3

INPUT

In/Jog Com

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

Wire

# 1

PLC with

Source (PNP)

Outputs

FSC-01

Motion

Controller

+24 VDC

IN/JOG COM

24 VDC GND

Output

Common

24 VDC

Power

Supply

PLC with

Sink (NPN)

Outputs

2 Wire PNP (Source) Schematic

Wire

# 2

62507/62517

Reed Switch

INPUT

In/Jog Com

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

2 Wire NPN (Sink) Schematic

Wire

# 1 Wire

# 2

Switch Model Number Output Type Wire # 1 Wire # 2

62507 or 62517 Reed PNP

NPN Brown

Blue Blue

Brown

PHD Switch Color Code Cross Reference Chart

62507/62517

Reed Switch

Typical Diagram For Interfacing NPN

Sinking PLC Outputs to FSC-01 Inputs Typical Diagram For Interfacing PNP

Sourcing PLC Outputs to FSC-01 Inputs

PNP

Proximity

Sensor

Power

Supply

+PHD FSC-01

Motion Controller

Output INPUT

IN/JOG COM

FSC-01

Motion

Controller

+24 VDC

IN/JOG COM

24 VDC GND

Output

Common

The maximum voltage that can be applied to an input terminal is 24 volts DC.

Never apply AC voltage to an input terminal.

If the sensor output goes high at the limit,

choose the program option “closed.” If the

output is low at the limit, select “open.”

Wiring a Mechanical Limit Switch

If the sensor output goes low at the limit,

select the option “closed.” If the output is

open, or high voltage, choose “open.”

Limit Sensors

Some systems use active limit sensors that produce a voltage output rather than a switch or relay

closure. These devices must be wired differently than switches.

Wiring for Sourcing Output

Wiring for Sinking or

Open Collector Output

2200

inside FSC-01

IN/JOG COM

IN1

IN2

IN3

IN4

CWJOG

CCWJOG

Wiring Inputs

The FSC-01 input circuits can be used with sourcing or

sinking signals, 5 to 24 volts. This allows connection to

TTL circuits, PLCs, relays, and mechanical switches.

Because the input circuits are isolated, they require a

source of power. If you are connecting to a TTL circuit

or to a PLC, you should be able to get power from the

PLC or TTL power supply. If you are using relays or

mechanical switches, you can use the FSC-01's built-in

24 volt power supply.

Note: If current is flowing into or out of an FSC-01

input, the logic state of that input is low. If no current is

flowing, or the input is not connected, the logic state is

high.

The diagrams on the following pages show how to

connect the FSC-01 inputs to various devices.

FSC-01

5-24

VDC

SUPPLY

LIMIT COM

CCW LIMIT

CW LIMIT

FSC-01

switch or relay

(closed=logic low)

24V GND

+24 VDC

IN/JOG COM

Connecting an Input to a Switch or Relay

Use normally open momentary switch to trigger FSC-01 using

Wait Input

instruction.

Use single throw switch for parameter selection using

If Input

instruction.

Use normally open momentary switch for jogging.

-10- -11-

Switch Model Number Output Type Wire # 1 Wire # 2 Wire # 3

18431-001-02 Ind. Prox

18431-002-02 Ind. Prox

51422-005-02

51422-006-02

55802 or 55822 Reed

55803 or 55823 Hall

55804 or 55824 Hall

62505 or 62515

62506 or 62516

NPN

PNP

NPN

PNP

NPN

PNP

NPN

PNP

NPN

PNP

Brown

Blue

Brown

Blue

Brown

Blue

Black

PHD Switch Color Code Cross Reference Chart

If your sensor has an open collector output or

a sinking output, wire it like this: Other sensors have sourcing outputs. That

means that current can flow out of the sensor

output, but not into it. In that case, wire the

sensor this way:

You can use normally open or normally

closed limit switches. Either way, wire

them as shown here. CW LIMIT

LIMIT COM

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

Wire

# 1

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

Switch Model Number Output Type Wire # 1 Wire # 2

62507 or 62517 Reed PNP

NPN Brown

Blue Blue

Brown

PHD Switch Color Code Cross Reference Chart

CW LIMIT

LIMIT COM

CW Limit

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

Output

NPN

Proximity

Sensor

+Wire # 1

Wire # 2

Wire # 3

Limit Com

In/Jog Com CW Limit

24 VDC

Power

Supply

+PHD FSC-01

Motion

Controller

PNP

Limit

Sensor

Limit Com

2 Wire PNP (Source) Schematic

Wire

# 2

62507/62517

Reed Switch

2 Wire NPN (Sink) Schematic

Wire

# 1 Wire

# 2

62507/62517

Reed Switch

Wire # 1

Output

Wire # 3

Wire # 2

The maximum voltage that can be applied to an input terminal is 24 volts DC.

Never apply AC voltage to an input terminal.

If the sensor output goes high at the limit,

choose the program option “closed.” If the

output is low at the limit, select “open.”

Wiring a Mechanical Limit Switch

If the sensor output goes low at the limit,

select the option “closed.” If the output is

open, or high voltage, choose “open.”

Limit Sensors

Some systems use active limit sensors that produce a voltage output rather than a switch or relay

closure. These devices must be wired differently than switches.

Wiring for Sourcing Output

Wiring for Sinking or

Open Collector Output

2200

inside FSC-01

IN/JOG COM

IN1

IN2

IN3

IN4

CWJOG

CCWJOG

Wiring Inputs

The FSC-01 input circuits can be used with sourcing or

sinking signals, 5 to 24 volts. This allows connection to

TTL circuits, PLCs, relays, and mechanical switches.

Because the input circuits are isolated, they require a

source of power. If you are connecting to a TTL circuit

or to a PLC, you should be able to get power from the

PLC or TTL power supply. If you are using relays or

mechanical switches, you can use the FSC-01's built-in

24 volt power supply.

Note: If current is flowing into or out of an FSC-01

input, the logic state of that input is low. If no current is

flowing, or the input is not connected, the logic state is

high.

The diagrams on the following pages show how to

connect the FSC-01 inputs to various devices.

FSC-01

5-24

VDC

SUPPLY

LIMIT COM

CCW LIMIT

CW LIMIT

FSC-01

switch or relay

(closed=logic low)

24V GND

+24 VDC

IN/JOG COM

Connecting an Input to a Switch or Relay

Use normally open momentary switch to trigger FSC-01 using

Wait Input

instruction.

Use single throw switch for parameter selection using

If Input

instruction.

Use normally open momentary switch for jogging.

-10- -11-

Switch Model Number Output Type Wire # 1 Wire # 2 Wire # 3

18431-001-02 Ind. Prox

18431-002-02 Ind. Prox

51422-005-02

51422-006-02

55802 or 55822 Reed

55803 or 55823 Hall

55804 or 55824 Hall

62505 or 62515

62506 or 62516

NPN

PNP

NPN

PNP

NPN

PNP

NPN

PNP

NPN

PNP

Brown

Blue

Brown

Blue

Brown

Blue

Black

PHD Switch Color Code Cross Reference Chart

If your sensor has an open collector output or

a sinking output, wire it like this: Other sensors have sourcing outputs. That

means that current can flow out of the sensor

output, but not into it. In that case, wire the

sensor this way:

You can use normally open or normally

closed limit switches. Either way, wire

them as shown here. CW LIMIT

LIMIT COM

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

Wire

# 1

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

Switch Model Number Output Type Wire # 1 Wire # 2

62507 or 62517 Reed PNP

NPN Brown

Blue Blue

Brown

PHD Switch Color Code Cross Reference Chart

CW LIMIT

LIMIT COM

CW Limit

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

Output

NPN

Proximity

Sensor

+Wire # 1

Wire # 2

Wire # 3

Limit Com

In/Jog Com CW Limit

24 VDC

Power

Supply

+PHD FSC-01

Motion

Controller

PNP

Limit

Sensor

Limit Com

2 Wire PNP (Source) Schematic

Wire

# 2

62507/62517

Reed Switch

2 Wire NPN (Sink) Schematic

Wire

# 1 Wire

# 2

62507/62517

Reed Switch

Wire # 1

Output

Wire # 3

Wire # 2

Limit Switches

The FSC-01 has two limit switch inputs, LIMIT CW and LIMIT CCW. By connecting switches or

sensors that are triggered by the motion of the motor or load, you can force the FSC-01 to operate

within certain limits. This is useful if a program error could cause damage to your system by

traveling too far.

The limit inputs are optically isolated. This allows you to choose a voltage for your limit circuits of

5 to 24 volts DC. It also allows you to have long wires on limit sensors that may be far from the

FSC-01 with less risk of introducing noise to the FSC-01. The schematic diagram of the limit

input circuit is shown below.

Front Panel Stop Button

On the front panel of the FSC-01 is a button marked “STOP.” This button can be used to interrupt

motion at any time. After pressing the STOP button, the output pulses to the motor driver will stop.

The front panel Power LED will then flash until the AC power is removed from the indexer. If the

FSC-01 is connected to a PC running the Windows Programming Software, the software will alert

the user on screen to the condition, and ask if you want to reset the indexer from the PC.

Jogging

Two of the FSC-01 input terminals are provided for jogging the motor. The inputs are labeled “JOG

CW” and “JOG CCW.” Taking one of the inputs low commands the drive to move the motor at a

pre-defined speed until the contact is opened. A relay or mechanical switch can be used to activate

the jog inputs. 5 volt circuitry can also be used. The schematic diagram of the input circuit is

shown below.

•If you’re using a switch or relay, wire one end to the JOG input and the other to the 24V GND

terminal. Then connect the IN/JOG COM and +24 VDC terminals.

2200

inside FSC-01

IN/JOG COM

+24 VDC

24V GND

CWJOG

CCWJOG

inside FSC-01

LIMIT COM

CW LIMIT

CCW LIMIT

2200

Connecting an NPN Type

Proximity Sensor

to an FSC-01 Input

(When prox sensor activates,

FSC-01 input goes low.)

Connecting a PNP Type

Proximity Sensor to an

FSC-01 input

(When prox sensor activates,

FSC-01 input goes low.)

-12- -9-

Switch Model Number Output Type Wire # 1 Wire # 2 Wire # 3

18431-001-02 Ind. Prox

18431-002-02 Ind. Prox

51422-005-02

51422-006-02

55802 or 55822 Reed

55803 or 55823 Hall

55804 or 55824 Hall

62505 or 62515

62506 or 62516

NPN

PNP

NPN

PNP

NPN

PNP

NPN

PNP

NPN

PNP

Brown

Blue

Brown

Blue

Brown

Blue

Black

PHD Switch Color Code Cross Reference Chart

INPUT

In/Jog Com

Power

Supply

+PHD FSC-01

Motion Controller

Output

NPN

Proximity

Sensor

+Wire # 1

Wire # 2

Wire # 3

Wire # 1

Wire # 2

Wire # 3

INPUT

In/Jog Com

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

Wire

# 1

PLC with

Source (PNP)

Outputs

FSC-01

Motion

Controller

+24 VDC

IN/JOG COM

24 VDC GND

Output

Common

24 VDC

Power

Supply

PLC with

Sink (NPN)

Outputs

2 Wire PNP (Source) Schematic

Wire

# 2

62507/62517

Reed Switch

INPUT

In/Jog Com

24 VDC

Power

Supply

+PHD FSC-01

Motion Controller

2 Wire NPN (Sink) Schematic

Wire

# 1 Wire

# 2

Switch Model Number Output Type Wire # 1 Wire # 2

62507 or 62517 Reed PNP

NPN Brown

Blue Blue

Brown

PHD Switch Color Code Cross Reference Chart

62507/62517

Reed Switch

Typical Diagram For Interfacing NPN

Sinking PLC Outputs to FSC-01 Inputs Typical Diagram For Interfacing PNP

Sourcing PLC Outputs to FSC-01 Inputs

PNP

Proximity

Sensor

Power

Supply

+PHD FSC-01

Motion Controller

Output INPUT

IN/JOG COM

FSC-01

Motion

Controller

+24 VDC

IN/JOG COM

24 VDC GND

Output

Common

Wiring Outputs

Before we discuss the output conditions, we need to talk about the circuitry. All three FSC-01

outputs are optically isolated. That means that there is no electrical connection between the

motion controller and the output terminals. The signal is transmitted to the output as light. What

you “see” is a transistor (NPN type) that closes, or conducts current, when the output is “low.”

When the output is high, the transistor is open.

At power-up, the FSC-01 sets all three programmable outputs high (open circuit).

The maximum voltage between any pair of + and - output terminals is 24 volts DC.

Never connect AC voltages to the FSC-01 output terminals. Maximum current is

100 mA per output.

Since there is no electrical connection to the FSC-01, you must provide the source of current and

voltage, typically from an external power supply. You must also limit the current to less than 100

mA so that the output transistor is not damaged. You would normally use a resistor for this, but

some loads (such as PLC inputs) limit the current automatically.

The diagrams below shows how to connect an FSC-01 output to various types of optically isolated

PLC inputs.

330

Ω

+5V

OUT1–

OUT1+

Optoisolator

NEC PS2502

or equiv.

FSC-01

Controller Chip

inside FSC-01

Schematic Diagram of FSC-01 Output Circuit

Installing the PHD Programmer

Software

• Please refer to the PHD Programmer Software Manual under “Installing the Programmer

Software” for detailed installation instructions.

Connecting to the PC

• Locate your computer within 6 feet of the FSC-01.

• Your FSC-01 was shipped with a black adapter plug. It has a telephone style jack at one end

and a larger 9 pin connector at the other. Plug the large end into the COM1 serial port of your

PC. Secure the adapter with the screws on the sides. If the COM1 port on your PC is already

used by something else, you may use the COM2 port for the FSC-01. On some PCs, COM2

will have a 25 pin connector that does not fit the black adapter plug. If this is the case, and

you must use COM2, you will have to purchase a 25 to 9 pin serial adapter at your local

computer store.

• Your FSC-01 was also shipped with a 7 foot telephone line cord. Plug one end into the

adapter we just attached to your PC, and the other end into the RS232 jack on your FSC-01.

Never connect the FSC-01 to a telephone circuit. It uses the same connectors and

cords as telephones and modems, but the voltages are not compatible.

Programming Note: Always apply power to FSC-01 after the PHD Programmer

software is running on your PC.

FSC-01

+5 VDC

STEP–

DIR–

Driver

+5 VDC

STEP

DIR

Connecting to a Driver with Common Anode Inputs

Connecting to a Driver with Common Cathode Inputs

FSC-01

GND

STEP+

DIR+

Driver

GND

STEP

DIR

-8- -13-

OUTPUT -

OUTPUT +

COMMON

INPUT

24 VDC Power

Supply+

FSC-01

Motion

Controller

PLC With

NPN Input

Diagrams continued on next page.

Typical diagram for interfacing an FSC-01 output to an NPN type PLC input.

(Note: Power supply may be built into PLC and internally wired to the common)

Microstep Resolution

The microstep resolution of the FSC-01 is set by the PHD Programmer software.

Make sure the step resolution of the FSC-01 is the same as the servo drive it is connected to.

Consult the PHD Quick Start Manual for additional information (part #6441-334).

Connecting the Step and Direction

Outputs

The FSC-01 Motion Controller can work with most pulse and direction step motors or servo drives.

Different step motor drives use different input configurations. There are three basic types that the

FSC-01 can be used with:

• Differential: Driver has STEP+, STEP-, DIR+, and DIR- inputs. Many high speed

microstep drivers use differential inputs.

• Common anode: Driver has STEP and DIR inputs that require sinking signals

and a common terminal named “VOPTO” or “+5V”

• Common cathode: Driver inputs are STEP and DIR (requiring sourcing signals)

and a common terminal named “common” or “ground.”

Wiring diagrams for each type of driver are shown below and on the next page. The first sketch

shows the output circuits for the FSC-01.

FSC-01

STEP+

STEP–

DIR+

DIR–

Driver

STEP+

STEP–

DIR+

DIR–

Connecting to a Driver with Differential Inputs

FSC-01 Step & Direction Output Circuit

inside

FSC-01

26C31

+5 VDC

GND

STEP+

STEP–

DIR+

DIR–

+5V

-14- -7-

Continued from previous page.

Note: Please consult the PHD Quickstart Manual (part number #6441-334) for

connection details.

(Note: Power supply may be built into PLC and internally wired to the common)

Typical diagram for interfacing an FSC-01 output to an PNP type PLC input.

OUTPUT -

OUTPUT +

COMMON

INPUT

FSC-01

Motion

Controller

+ 24 VDC

24 VDC GND

PLC With

PNP Input