PLC545 4-channel LPT-port CNC step motor driver

Transcription

1 User manual PLC545 4-channel LPT-port CNC step motor driver CONTENTS: 1. General information Delivery set Technical specifications Key features Connections Step motor connection Сurrent and voltage selection Coolant pump timer PWM > Voltage converter MIcrostep mode selection Common problems... 17

2 revison! Check wiki.purelogic.ru for more information 1. GENERAL INFORMATION PLC545 is a 4-channel LPT-port CNC step motor driver in box. Each channel (step motor driver) supports microstep 2/4/8/16 devison, 45V/5A power rating, up to 200kHz STEP pulse frequency, mid-band resonance compensation and step motor phase-currents morphing. Each step motor driver has build in Оver-voltage, Back EMF, Over-current, Short-circuit, Reversed-polarity protection and automatic Idle-current reduction, activated on STEP pulse absence. PLC545 has 3 power relays, 5 opto-inputs (to connect limit switches, E-STOP button, etc.) cooling pump timer and PWM>Voltage converter to control spindle Frequency Converter (FC). Device is compatible with MACH3/TurboCNC/LinuxCNC and similiar CNC software. All input signals from PC LPT-port are buffered and optoisolated. PLC545 is optimized to control bipolar and unipolar step motors NEMA 17, 23 size and other similar with 4, 6 and 8 wires. 2. DELIVERY SET 4-channel LPT-port CNC step motor driver PLC545 1 pcs. LPT cable 1 pcs. User manual 1 pcs.

3 PLС545 4-channel LPT-port CNC step motor driver 3 3. TECHNICAL SPECIFICATIONS Control method Power supply voltage Operating current, each channel STEP/DIR/ENABLE via LPT-port v (40v typical) A (potentiometer) Microstep mode 1:2, 1:4, 1:8, 1:16 Maximum STEP pulse frequency Relay ratings Coolant timer parameters PWM>voltage converter parameters Isolation resistance 200 кгц 220v/7A Switching frequency seconds. Holding time seconds. Vout = V (duty ratio Q = ) at 10v power supply 500 MOhm Operating temperature С Net weight Dimensions (WхHхD) 1,5 kg 225 х 185 х 45 mm! POWER OFF DEVICE BEFORE MAKING ANY CONNECTIONS AND CHANGING OPERATION MODES. POWER SWITCH SHOULD BE INSTALLED BEFORE POWER SUPPLY, AT ~220V SIDE. GND (NEGATIVE WIRE OF POWER SUPPLY) TO GROUND CONNECTIONS PROHIBITED. STRICTLY OBSERVE THE POLARITY OF POWER SUPPLY AND CONTROL SIGNALS CONNECTIONS.

4 revison 4. KEY FEATURES Device is compatible with MACH3/TurboCNC/LinuxCNC and similar CNC software. Single power supply can be used to power up the device, soft start system. Device is optimized to control up to 4 bipolar or unipolar step motors NEMA 17, 23 size and other similar with 4, 6 and 8 wires. Each channel (step motor driver) supports microstep 2/4/8/16 devison, 45V/5A power rating, up to 200kHz STEP pulse frequency, mid-band resonance compensation and step motor phase-currents morphing. Phase currents are set up by potentiometer. Each step motor driver has build in Оver-voltage, Back EMF, Overcurrent, Short-circuit, Reversed-polarity protection and automatic Idle-current reduction, activated on STEP pulse absence. LPT-port signals are optoisolated and buffered. 3 power relays 7A/220v to control spindle, fan and etc. Coolant pump timer with adjustable frequency and hold time. PWM>Voltage convertor to control spindle Frequency Converter (FC). 5 optoisolated inputs to connect limit switches, E-STOP button, etc. Convenient terminal connections for step motors, power supply and relays load.

5 PLС545 4-channel LPT-port CNC step motor driver 5 Fig. 1. PLС545 dimensions

6 revison Microstep selection ENBx 1:2 1:4 1:8 1:16 Inputs LED indication Alarms LED indication Relays LED indication J1 J2 Idle current selection Full Half J4 LED indication description 1,2,3,4 INPUTS ALARMS RELAYS ENBx Channel on/off IN1 IN1 active DISAB Channel disable K1 RL1 on EMx Channel error IN2 IN2 active ESTOP IN1 active K2 RL2 on STEPx STEP occur IN3 IN3 active E-CH Channel error K3 RL3 on DIRx DIR occur IN4 IN4 active IN5 IN5 active Fig. 2. Setup and indication information

7 PLС545 4-channel LPT-port CNC step motor driver 7 Step motors connection FC and switches connection Power supply and relay connection PLL01 switch connection IN1, IN2, IN3, IN4, IN5 1 GND, common 2 Signal out 3 +12v Blue Black Brown LPT-port 1 ENABLE 2 STEP1 3 STEP2 4 STEP3 5 STEP4 6 DIR1 7 DIR2 8 DIR3 9 DIR4 10 IN1 11 IN2 12 IN3 13 IN4 14 PWM 15 IN5 16 RELAY1 17 RELAY GND Ralays load connection Relays commutation when signal RELAY1= 0 or signal RELAY2= 0 Step motor connection Standard switch connection IN1, IN2, IN3, IN4, IN5 1 GND, common 2 Signal out 3 +12v FC connection 1 Control voltage v 2 FC GND 3 FC power supply +10v Fig. 3. Connection information

8 revison 5. CONNECTIONS Control signals connections 4-channel LPT-port CNC step motor driver PLC545 use STEP/ DIR/ENABLE signals. Each channel driver has its own signals pairs - STEP1/2/3/4 и DIR1/2/3/4. ENABLE signal is common for all channels. STEP/DIR/ENABLE signals are optoisolated and buffered. These signals are placed in DB-25M connector (LPT-port of PC). DB-25M pinout is shown in Fig. 3. STEP/DIR/ENABLE signals activity is indicated on the front panel of the device by LEDs. STEP signal parameters input voltage v, input current mA, pulse width minimum 10us. Step occurs at falling edge of STEP pulse. DIR signal parameters input voltage v, input current mA. Setup time - 1us. ENABLE signal parameters input voltage v, input current mA. Setup time - 1us. Logic 1 ENABLE the drive and logic 0 DISABLE it. Limit switches connection 4-channel LPT-port CNC step motor driver PLC545 has 5 optoisolated inputs to connect limit switches and ESTOP button IN1(ESTOP)/IN2/IN3/IN4/IN5. Input IN1 acts as ESTOP function. When triggered module goes to disabled state. For recovery user need to remove alarm from IN1 and power off/on the device. The states of all inputs IN1 (ESTOP) / IN2/IN3/IN4/IN5 broadcast to LPT port and are indicated on the front panel of the device by LEDs. PLC545 can accept connection of standard limit switches (buttons) and proximity sensors (inductive, capacitive) with

9 PLС545 4-channel LPT-port CNC step motor driver 9 alarm signal output. Each input group has +12v, GND and signal input. Connection is shown in Fig. 3. Relay К1, К2, К3 loads connection PLC545 can operate 3 power relays K1, K2, K3 to control spindle, fan and etc. of the machine. Relays statuses are indicated on the front panel of the device by LEDs. Relay K1 is controlled by signal RELAY1, Relay K1 is controlled by signal RELAY2. Logic 1 enables relays K1/K2, logic 0 disables relays K1/K2. Relay K3 operates according to DIP-switch SW1 settings (position 1-4). Description of operating modes is shown in Fig. 7 and Table 1. Power supply connection Power supply connection is shown in Fig. 6

10 revison Step motors Power supply ~220 Spindle Frequency converter ~220,, Damper 36V

11 PLС545 4-channel LPT-port CNC step motor driver 11 CNC controller Ethernet / USB PC with MACH3 Control 36V 4-channel LPT-port CNC step motor driver LPT-cable Power supply Hoover Fig. 4. General CNC control system diagram Vacuum clamping Limit switch Up to 3 loads connection Fan LPT-cable 12V Colant pump, ~220

12 revison 6. STEP MOTOR CONNECTION Device is optimized to control up to 4 bipolar or unipolar step motors NEMA 17, 23 size with 4, 6 and 8 wires. Connect step motors to PLC545 according Fig. 6. Please note that the motor will rotate in the opposite direction if motor phases are swapped (same as signal DIR invertion). PLC545 has build in short-circuit and reversed-polarity protection circuits. It is strongly recommended to twist each phase wires together and put them in shielding metal braid. Braids and stepmotor body must be grounded. Purelogic R&D step motors phase wires colors are shown in Fig. 5. PH1.1 [+А] PH1.2 [-А] PH2.1 [+B] PH2.2 [-B] Red Orange Blue Green Fig. 5. Purelogic R&D step motors wires colors

13 PLС545 4-channel LPT-port CNC step motor driver 13 Fig. 6. Power supply and step motors connection diagram

14 revison 7. CURRENT AND VOLTAGE SELECTION Power supply voltage depends on used step motor type and desired maximum rotation speed. The optimum voltage can be calculated by formula U = 32 * (step motor phase inductance in mh). Voltage must be lower than 45V (PLC545 maximum voltage). Power supply current must be 4*( % step motor winding current) Potentiometer on front panel of each channel sets up operation current. All adjustment must be done at power off. Automatic Idle-current reduction activates on STEP pulse absence (>1sec). J4 on front panel of each channel sets up idle current amount. We propose to use dumper curcuit (device PLZ005) to compensate step motors back-emf. Power supply and dumper connections are shown in Fig.6 8. COOLANT PUMP TIMER PLC545 has coolant pump timer with adjustable frequency and hold time. Timer controls relay K3. Timer operates according to DIP-switch SW1 settings (position 1-4). Description of operating modes is shown in Fig. 7 and Table 1. Timer switching frequency is controlled by potentiometer R1, holding time (duty) is controlled by potentiometer R2. Changes takes effect after power off/on the device.

15 PLС545 4-channel LPT-port CNC step motor driver 15 SW1 Fig. 7. Relay K3 and coolant pump timer setup Table.1. Description of DIP-switch SW1 parameters ON. Relay К3 operates according to paragraph 2 and 3. «1» OFF. Relay К3 forced to disable state. ON. Coolant timer enabled/disabled by signal on RELAY2 pin and paragraph 1. «2» OFF. Coolant timer enabled/disabled by signal on PWM pin and paragraph 1. ON. Coolant timer operates according to paragraph 1 and 2. «3» OFF. Coolant timer always enabled, can be disabled only by 1 OFF ON. Coolant timer disabled. Relay К3 operates by signal on PWM pin. «4» OFF. Coolant timer enabled. Relay К3 operates according to paragraph 1, 2 and PWM>VOLTAGE CONVERTER 4-channel LPT-port CNC step motor driver PLC545 has built-in PWM>Voltage converter to control spindle FC. Converter converts duty cycle of the control signal to voltage - duty factor Q = > voltage U = V. Converter is optically isolated from the module and is powered by inverter internal power supply +10v. Usually, FC has 3 pins for connect to converter - +10V, GND and control voltage input (spindle rotation speed changes according this voltage). PWM control signal is generated by CNC program (Mach3) and applied to the corresponding pin in DB-25 connector (14 pin, PWM). Connections are shown in Fig.3

16 revison 10. MICROSTEP MODE SELECTION PLC545 can electronically divide physical step of step motor to an integer - 2, 4, 8, 16 (microstep mode), so higher positioning accuracy is achieved. Microstep mode reduces resonances at low speed, but some torque loss occurs (compared to full step mode). Recommended microstep mode - 1:8, 1:16. In these modes the step motor rotates smoothly, low-frequency vibration is minimal and mid-range resonance compensation circuit works optimal. J1 and J2 on front panel of each channel set up microstep mode according Fig.2. All adjustment must be done at power off.

17 PLС545 4-channel LPT-port CNC step motor driver COMMON PROBLEMS Common problems and remedies are shown in Table 2. Green LED on (ENBx) Green LED off (ENBx) Red LED on (EMx) Red LED off (EMx) DISAB ESTOP E-CH Step motor drivers. Channel 1, 2, 3, 4 Channel driver on, no alarm DISAB. Check signal ENABLE = 1 in DB-25. Channel driver off, alarm DISAB present. Check signal ENABLE = 0 in DB-25. Channel driver error (over-current, over-voltage) condition occurs. Driver is in disabled state. Alarms DISAB, ESTOP and E-CH are present. Need to eliminate over-current and over-voltage conditions. Normal channel driver operation. ALARMS All channel drivers are in disabled state. Green LEDs (ENBx) are off. Check signal ENABLE = 0 in DB-25. Emergency stop condition uccurs. Input IN1 activated. Error of any channel driver (over-current, over-voltage). Table.2. Common problems and remedies

18 ! Pay attention that documentation can be changed due to constant technical upgrading of production. You can download last versions from address: Bld. 160, Leninsky prospect, Voronezh city, , Russia phone: +7 (495) , +7 (473)