A product of Wild & Grabmaier Feinmechanik und Elektronik KG

STEPPING MOTOR CONTROL AMPLIFIER BOARDS AND EQUIPMENT

YOU NEED TO MOVE CONTROL POSITION ?

WE HAVE THE IDEAL SOLUTION FOR YOUR MOTION APPLICATION!

Zebotronics Schrittmotoren GmbH
Machtlfinger Strasse 24 Tel: (089) 15904070 E-Mail: info@zebotronics.de 81379 Mnchen Fax: (089) 15904079 Internet: http://www.zebotronics.de

Edition: October 2000 All rights reserved Without written approval we dont allow any reprint and partial copying. We reserve the right to make engineering changes, refinements and improvements to all products described herein. Mechanical and electrical ratings and dimensions are, therefore, subject to change without notice. No liability whatsoever is accepted.

A product of Wild & Grabmaier Feinmechanik und Elektronik KG

Index

4 4 4 5 5 6 12

General product overview

Control amplifier boards

Overview stepping motor power amplifier boards General function principle - step resolution and max. load angle (accuracy of positioning) General specifications Zebotronics - power amplifier boards Standard - series SE ... V1. and series SE ...E50 V1. (with control of load angle - E50) ( I : 0 until 12 A , U : 24 until 240 VDC , step angle : 200,400,500,800,1000 steps/rev. ) Microstepping series SE P05... ( I : 0 until 12 A , U : 24 until 240 VDC , step angle : 200 until 12800 steps/rev. )

14 14 15 16 17 17 18 19 19

Equipment
Mother boards for installing power amplifier boards into 19 inch / 3HE systems RP2/L60 for power amplifier board series SE 2.. RP/L60 for standard power amplifier boards with 32-pole standard connector RP/LE50 for power amplifier boards with 31-pole mixed connector Power supplies from 24VDC/350VA until 120VDC/1000VA Power amplifier boards with front panel series SEF... for installing into 19 inch systems Board holder for power amplifier boards Panel mount systems series ELK with power supply and plug ports for power amplifier boards series SE... V. or position controls series SERS

Stepping motor - position controls

Series SERS Free programmable with microstepping power amplifier (12800 steps/rev.) ( I : 0 until 12 A , U : 24 until 240 VDC , interfaces : RS232, RS485, Profibus-DP, CAN open, SERCOS )

General product over view

Overview stepping motor power amplifier boards

Overview power amplifier boards

Zebotronics stepping motor power amplifier boards

General function principle - step resolution and max. load angle (accuracy of positioning)
Switching onwards the stator field - shown in a field-vector-diagram :

Current characteristics at halfstep (400 steps/rev.)

Current characteristics at microstep (12800 steps/rev.)

Switching onwards the stator field shown in a load angle - operating torque - diagram :

Load angle: Excursion of the rotor to the zero position determined by the stator field, in case of a torque Md at the motor shaft

A stepping motor having 50 teeth on the rotor surface (motor with 50 poles) produces every 7,2 (mechanically) a stabile position (zero position) at motor stand still - regardless the number of phases (2, 3 or 5 phases)! The zero position is determined by the stator field. The stator field is moved from the power amplifier step by step and the rotor follows the stator field. In case of big steps (full step - 200 steps/rev. , half step - 400 steps/rev.) and low speed the motor is running rough with strong vibrations. Smaller steps result in smoother running. At high step resolutions (e.g. 12800 steps/rev.) there will be a very smooth true running without vibrations. General specifications Zebotronics - power amplifier boards:

At motor stand still, in case of a load (torque Md), the motor shaft will be moved the angle out of its zero position. The maximum possible movement away from the zero position is -1.8 at -Mmax and +1.8 at Mmax independent of the step resolution and 2, 3 or 5 phases (!!!) (in case of a rotor with 50 teeth)

Q Q

All boards can be configurated easily via solder bridges (e.g. selction of step angle, Low/High-active or enabling current reduction at motor stand still) The integrated load angle control of the series SE ... E50 V.. together with a stepping motor with mounted encoder E50 enables the control of a mechanical overload of the stepping motor. Therefore the load angle of the stepping motor will be controlled. LEDs provide easy diagnostics of error and status. During operation the phase status is indicated via four red LEDs. An electrical error - short circuit, over temperature or under voltage - is indicated via a yellow LED. At the series SE ...E50 V1 a mechanical error (exceeding the max. load angle e.g. in case of a mechanical overload) will be indicated via an additional yellow LED. Error signals (respective the ready signal) are provided as outputs free of potential (relay output). Zebotronics power amplifer boards are plug compatible to each other and also to former series SE 11 ...60 and SE ...120. Series SE ...E50 V1.. is compatible to the former series SE...E50 and SE...E50D. Series SE...V1.. is compatible to the former standard series SE... (e.g. SE 400.06.60) and to the series SE...B2.

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Stepping motor control amplifier board series SE...V1 and SE...E50 V1

General notes

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Control of 2-phase-stepping motors Compatible with Zebotronics standard amplifier boards series SE ...., SE ... E50, SE ... E50 D. Supply voltage - nominal voltage : 24 VDC to 240 VDC Phase current range 0 A/phase - 14,5 A/phase Boards SE ... E50 V1.. with integrated load angle control - together with Zebotronics E50 encoder (50 impulses per channel and revolution) at the motor ( also available SE ... E200 V1.. for HP H200 encoder - 200 impulse per channel and revolution)

Q Protection against shortcircuit, overtemperature and undervoltage Q Via solder bridges adjustable step angles: 200, 400 , 500 , 800 and 1000 steps per revolution Q EMC according to EN55011 class B and EN50082-2
Versions - connector system and signal level of the inputs

Q Q Q Q Q Q

SE ... E50 V11 : Encoder connections via 9 pole D-Sub , all other signals and connections via 32 pole male connector (DIN 41612 type D) and SPS(PLC)-input signal level SE ... E50 V12 : All signals and connectors (incl. encoder signals) via 31 pole male connector (mixed connector) (DIN 41612 type H7F24) and SPS(PLC)-input signal level SE ... E50 V13 : Encoder connections via 9 pole D-Sub , all other signals and connections via 32 pole male connector (DIN 41612 type D) and TTL-input signal level SE ... E50 V14 : All signals and connectors (incl. encoder signals) via 31 pole male connector (mixed connector) (DIN 41612 type H7F24) and TTL-input signal level SE ... V11 : All signals and connections via 32 pole male connector (DIN 41612 type D) and SPS(PLC)-input signal level SE ... V13 : All signals and connections via 32 pole male connector (DIN 41612 type D) and TTL-input signal level

SE... V11/13

Dimensions series SE... V11/13

SE...E50 V11/13

Dimensions series SE...E50 V11/13

Stepping motor control amplifier board series SE...V1 and SE...E50 V1

Dimensions series SE...E50 V12/14

SE...E50 V12/14

Selectable adjustments
All adjustments can be made via (marked) solder bridges on the rearside of the logic board.
selectable adjustments series SE ...V1.. and SE ... E50 V1..

marker R

denotes open: automatic current reduction 50% standstill closed: no current reduction step angle adjustment (see table below) open: a mechanical error will be signaled. closed: a mechanical error will be ignored. marker must be closed.

standard adjustment open

W0,W1 M (SE ... E50 V1..) M (SE ...V1..) F L-H

open

closed

internal function L open, H closed: input signals HIGH - active (The rising edge of the pulse signal is significant) L closed, H open: input signals LOW-active (The falling edge of the pulse signal is significant) ! Attention: Dont close L and H ! ( short circuit! ) H closed

Automatic current reduction ( marker R open )

The phase current - adjustable via potentiometer- is set for nominal operation. If marker R is open, the phase current will be reduced by 50% at standstill of the motor. The first pulse increases the phase current again to the adjusted nominal value. At active Reset input, the current reduction will be disabled.

Step angle adjustments via marker W0 and W1 X = Marker closed 0 = Marker open

W1 0 0 X X

W0 0 X 0 X

steps per revolution 800 400 1000 500

Stepping motor control amplifier board series SE...V1 and SE...E50 V1

Current adjustment
Ex factory the amplifier board is set to the nominal current. If required the motor phase current can be changed. To change the phase current the Reset input has to be set. Then only LED 0 is active (see below figures with LEDs) ! When measuring point B against point GND there can be measured a voltage which is proportional to the phase current. 300 mV corresponds to the nominal current of the amplifier board. Meaning that the phase current is set to 4A/Ph. at an amplifier board type SE 400.04.60 E50 V14, if the voltmeter shows 300mV. 225mV corresponds to 3A/Ph. The exceptions are amplifier boards with a nominal current of 8 A/Ph. - see table below. The phase current can be adjusted via the potentiometer on the boards frontside.

SE ... V11 and SE ... V13 SE ... E50 V12 and SE ... E50 V14 (above) SE ... E50 V11 and SE ... E50 V13 (below)

nominal current for example:

1 A/Ph. SE 400.01.24 V13

4 A/Ph. SE 400.04.85 E50 V12

12 A/Ph. 6 A/Ph. SE 500.06.85 SE 800.12.120 E50 V14 V11

8 A/Ph. SE 800.08.120 E50 V13

measured voltage % 375 mV 300 mV 225 mV 150 mV 125% 100% 75% 50% [A/Ph] 1,25 1 0,75 0,50 1.4

phase cur rent [A/Ph] 5 4 3 2 5.6 [A/Ph] 7,5 6 4,5 3 8.4 [A/Ph] 15 12 9 6 14.5 measured volt. [A/Ph] 333 mV 267 mV 200 mV 133 mV 10 8 6 4 11.2

max. adjustable current A/Ph.

Supply voltage
Maximum allowed supply voltage: Nominal voltage of control amplifier board plus 15% (mains fluctuations!) The nominal output voltage of the power pack unit ( = supply voltage of control amplifier board) may not be higher than the nominal supply voltage of the control amplifier board. for example: Calculation of a power pack unit for a SE 800.06.120 E50 V13 : Output voltage of power pack = 120 VDC (and not (!) 138 VDC = 120 VDC + 15%) Working range - supply voltage (see diagram with Ready signal on page 9) (Nominal-) supply voltage control amplifier board [VDC] 24 60 and 85 120 240 UB [VDC] (Motor enabled) 18 43 50 120 UM [VDC] (Motor current on) 16 32 38 100 UB and UM + 5%

Stepping motor control amplifier board series SE...V1 and SE...E50 V1

Outputs
SE ... E50 V12 and SE ... E50 V14 : electrical error / Ready signal: Is indicated in case of undervoltage, shortcircuit or overtemperature. In non-error-condition the relay contact is closed. mechanical error : Indicates a load angle error of the stepping motor (load angle > 7,2). In non-error-condition the relay contact is closed. Phase zero: Indicates the electrical zero-position (every 7,2 - mechanically) - open collector output. (no figure) SE ... E50 V11 and SE ... E50 V13 : Ready signal: Is indicated in case of an electrical or mechanical error (for error definition see SE ... E50 V12) In non error condition the relay is closed. SE ... V11 und SE ... V13 : electrical error / Ready signal: For error definition see SE ... E50 V12
electrical error a12 Ready signal potential free contact

mechanical error

I = 100mA U = 50 VDC c12

Output signal SE...E50 V11 and SE...V13 z2

Ready signal electrical error I = 100mA U = 50 VDC

Timing Ready signal electrical error a12 Ready signal - electrical error potential free contact I = 100mA U = 50 VDC

b2

mechanical error

c12 Output signal SE...V11 and SE...V13

Output signal SE...E50 V12 and SE... V14

Inputs
Boost: Increases the phase current by 20%. Disable: Switches off the phase current. Reset: Sets the unit in zero position - phase zero. A pulse signal is ignored and errors are reset. Direction: Controls the motor direction. Pulse: With every pulse the motor will execute one step. Step angle: Divides the step resolution by two from 1000 or 800 to 500 or 400 steps per revolution. The input is always LOW-active - works only with open marker W0. Change direction: Turns the motor direction - coordination between the motor direction and the signal Direction. (only SE ... E50 V12 The signal is always Low-active. and SE ... E50 V14)

Input circuit e.g.: HIGH-active

Input signals SPS(PLC) - V11 and V12

Input signals TTL - V13 and V14

Circuits of the other input signals are equal to the circuit of the signal Direction

Rising time max.: 1s , Fall time max.: 1s , frequency pulse max.: 45 KHz

Input signals

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Stepping motor control amplifier board series SE...V1 and SE...E50 V1

Pin 1 2 3 Output Ready signal potential-free contact open: error (electrical or mechanical) closed: no error 4 5 6 7 8 9

connection A +5VDC n. c. shield B _ A n. c. GND _ B

24 26 28 30

32

Compatible with motherboard RP/L 60

Connections SE ... E50 V11 and SE ... E50 V13 32 pole male connector DIN41612 type D

Compatible with motherboard RP/L E50

Connections SE ... E50 V12 and SE ... E50 V14 31 pole male connector DIN41612 type H7F24

Stepping motor control amplifier board series SE...V1 and SE...E50 V1

11

Compatible with motherboard RP/L 60

Connections SE ... V11 and SE ... V13 32 pole male connector DIN41612 type D

Unused inputs of the series SE ... E50 V1.. and SE ... V1.. may stay open, there is no need to connect to an external potential.

Specifications
Protection of the device Protection IP 00 Protection against shortcircuit, overtemperature and undervoltage Weight nominal current 1 A/Ph weight 0,2 Kg Ambient conditions Ambient temperature : 0C to 50C max. heat sink temperature : 85C Forced draft: Necessary for power amplifier cards with nominal current 8A and 12A 4 A/Ph 0,52 Kg 6 A/Ph 0,77 Kg 8 A/Ph 1,1 Kg 12 A/Ph 1,1 Kg Noise immunity In case of correct installation: according to EN50082-2: - at V13 and V14 (TTL-level) the signal inputs are not immune to fast transients (burst)

Noise radiation In case of correct installation and shielding or/and filtering of the lines and signals according to EN55011 class B

Available types: Example: SE 800.06.120 E50 V14 or SE 1000.04.85 V13

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Series SE P05 - Microstep

Q Q Q Q Q Q Q Q

Resolutions adjustable and externally switchable Excellent truth micro stepping over the entire velocity range Electrically and mechanically compatible to standard Zebotronics amplifier boards (SE 11... , SE... , SE...V13..) Shortcircuit, overtemperature and undervoltage protected Voltage range from 24 VDC to 240 VDC Current range from 0 A / Ph. to 14,5 A / Ph. Constant torques in all pre-selected resolutions Resolutions from 200 to 12800 steps per revolution

SE P05 Microstep

All dimensions, input- and output signals (except input circuits), current adjustments, supply voltage and connections are identical to the series SE...V1... (see page 6 to 11)

Input circuits
Example: HIGH - active Inputs SPS(PLC)-level Inputs TTL-level

Input signals

The circuit and the levels of the other inputs are equivalent to Direction Max. pulse frequency : 200 kHz

Adjustments
Via solder bridges on the rearside of the control board: marking S0, S1 C0 - C3 C4 W denotes internal function selection of step angle ( see table page 13 ) internal function activates row Pin a2 active of step angle table on page 13 Pin a2 (external switching of step angle) is deactivated open: "TTL"- input level closed: "SPS"- input level automatic current reduction (see SE...V1... page 7) open: signals High-active - closed signals : Low-active
o o o
o

o
o

o o o o o o

o o

o o o o o

o o o o o o o o o o o

o o

o o o o o o

o o o o o o

o o o o o o

selectable adjustments

o o o o o o

SPS

R L

Series SE P05 - Microstep

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Step angle adjustment on the board

Different step angles can be selected via the markings C0, C1, C2 and C3. With the input step angle (Pin a2) the step angle can be switched externally between two values (only if marker W is open !). During motion, switching the step angle is possible within the motor start-stop - frequency. When changing simultaneously the pulse frequency, switching the step angle is possible at any frequency. Resolutions switchable externally steps per revolution PIN a2 not active 2000 2500 3200 4000 active 200 400 500 800 400 800 1000 500 1000 800 2000 400 1000 2000 800 1600

Markings for selection of step angle X = Marking closed, else = Marking open C3 X X X X X X X X C2 X X X X C1 X X C0 X X X X X X X X X X X X X X X X X X There are available more step angles ! Please ask at our sales office.

5000 8000

10000

12800

Specifications
Protection of the device Protection IP 00 Protection against shortcircuit, overtemperature and undervoltage Weight nominal current 1 A/Ph weight 0,2 Kg Ambient conditions Ambient temperature : 0C to 50C max. heat sink temperature : 85C Forced draft: Necessary for power amplifier boards with adjusted current from 5A 4 A/Ph 0,52 Kg 6 A/Ph 0,77 Kg 8 A/Ph 1,1 Kg 12 A/Ph 1,1 Kg Noise immunity In case of correct installation: according to EN50082-2: - at TTL-level the signal inputs are not immune to fast transients (burst)

Noise radiation In case of correct installation and shielding or/and filtering of the lines and signals according to EN55011 class B

Available types:
Example: SE P05.06.85

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Zebotronics mother boards

There are three different motherboards for mounting the control amplifier boards into 3 HE - 19 racks. Type RP2/L60 RP/L60 used for 2-axis board SE 2.800.04.36 control amplifier board with 32 pole connectors - series SE...V1.., SE...E50 V11, SE...E50 V13, SE P... control amplifier boards with 31 pole mixed connector - Series SE...E50 V12 and SE...E50 V14

RP/LE50

RP2/L60

Figure with mother board RP2/L60 and two stepping motors with cast connection box

RP2/L60

Zebotronics mother boards

15

RP/L60

Stepping motor

Figure with mother board RP/L60 and a stepping motor with cast connecting box (the shown colours of the leads refer to a stepping motor with leads)

RP/L60

RP/LE50

Figure with mother board RP/LE50 and a stepping motor with encoder (E50)

RPLE50

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Zebotronics power supplies

NT-power supplies are non stabilized voltage supplies - fixed on an aluminium-mounting plate. A couple of control amplifier boards can be supplied by one NT-power supply. The calculation of a power supply depends on the used motors - by taking into consideration the maximum load current (which also depends on the motor speed).

Type NT 350 NT 500 NT 1000

Power 350 VA 500 VA 1000 VA

Mains supply 230 VAC 50/60 Hz 230 VAC 50/60 Hz 230 VAC 50/60 Hz

Output 24, 36, 60, 85 or 120 VDC 24, 36, 60, 85 or 120 VDC 60, 85 or 120 VDC

In the standard version a 120 VDC power suppliy includes a 60 VDC and a 120 VDC output.

NT 350... NT 500...

NT 1000...

Power supply NT500.120

Dimensions NT

Power supply key:

Example: The order number of a power supply with output 120 VDC and 500 VA power is NT 500.120 Power supplies for 115 VAC 50/60 Hz mains supply are available, too.

Zebotronics front panels and boards holder

17

Front panels
SEF-front panels for mounting 19 units (3 HE) are available for all Zebotronics control amplifier boards. In addition to the optical board function control there are two further functions on the front panel for easy adjustments.

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The adjustment of the motor current can be made direct on the front panel. Simultaneously the motor current can be measured at two sockets.

Dimensions

Control amplifier board with front panel

Front panel key: Add a F to the type designation of the chosen control amplifier board. Example: The type designation of a SE 400.06.85 V13 with front panel will be SEF 400.06.85 V13

Board holder KH D32

Q Q Q Q Q Q Q

Comfortable mounting of control amplifier boards into a switch cupboard Suitable for all Zebotronics control amplifier boards up to 12 A, with 32-pole connector. Automatic locking Easy mounting Easy exchange of boards Adjustment of current and LED indication are not covered Ideal for test operation

Dimensions board holder - with control amplifier board

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Zebotronics panel mount system series ELK

The panel mount (19 inch rack) system series ELK is a mains ready single or multiple axis stepping motor control which can be mounted e.g. in a switch cabinet and can be connected easily via screw terminals. ELK-systems include plug ports for Zebotronics amplifier boards series SE...[E50] V11/V13 with 32-pole connector VG (DIN 41612 type D). SERS and SERC position controls from STGRA also can be pluged into ELK-racks. Each power amplifier plug port additionally includes a plug port for a ventilator. In that way ventilators can be installed easily also later. All connections (mains, motor and control signals) are via screw terminals. ELK racks are available with and without integrated power supply. (Connection to 230VAC/50Hz - also available for 115 VAC/60Hz).

Available versions:
ELK2 with 1 plug port and power supply:

Zebotronics panel mount system series ELK

19

ELK3 with 2 plug ports and power supply:

Options for ELK3:

Q
ELK4 with 3 plug ports and power supply:

ELK3 without power supply and connection for external DC-supply and 3 plug ports

Options for ELK4:

ELK4 without power supply and connection for external DC-supply and 4 plug ports inclusive plug ports for ventilators ELK4 without power supply and connection for external DC-supply and 5 plug ports without plug ports for ventilators

ELK type key:

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Position controls - series SERS

Position control with Microstepping and RS232/RS485/Profibus-DP/CAN open or SERCOS-interface. The stepping motor position controls series SERS are for driving 2-phases-stepping motors. A unit consists of a power amplifier, microstepping power amplifier control and the position control. The position control can be programmed via the interface. The SERS guarantees excellent truth running because of its microstepping operation with 12800 steps/revolution and the possibility to set the current characteristics to match the characteristics of the used stepping motor type. The rough step by step operation of conventional stepping motor drives at low speed ranges has been improved extremely by the SERS to a very smooth running (comparable with servo motors). In standard version the SERS can be operated in four different modes:

The four operating modes:

Serial mode Operation with a PC/PLC/NC as higher order control (master) and communication via the serial fieldbus with SERS - Slaves Master mode Operation with a SERS as higher order intelligent control (master), which controls other SERS - slaves via the serial interface. Parallel mode Operation with a PLC/NC as higher order control, which calls and starts different operational programs in the SERS via the digital-parallel inputs. Up to 64 different operational programs per SERS can be called. Standalone mode Operation with SERS - slaves as independent working axis, with stored operational programs, controlled by events at the digital inputs - e.g. manual start switch, limit switch, light barriers.

Available versions:
SERS 01.24 V01 Phase current: 0 until 1,4 A/Ph Power supply: 24 VDC

optionally SERS 01.85 V01 with 85 VDC is available

SERS 06.85 V01 Phase current: 0 until 8,4 A/Ph Power supply: 85 VDC

optionally SERS 06.24 V01 and SERS 06.120 V01 with 24 VDC/120 VDC is available

SERS 12.120 V01 Phase current: 0 until 14,5 A/Ph Power supply: 120 VDC

Q
Optionally to control/program the SERS by PC, the hand programming device SERS-Programmer is available.

optionally SERS 12.85 V01 and SERS 12.240 V01 with 85 VDC/240 VDC is available

Ordering key:
SERS X.Y V01 [RS485] [PB-DP] [CAN] e.g. SERS 06.85 V01 or SERS 12.120 V01 PB-DP X: Y:

Specifications
Protection of device: Protection class IP 00 (ELK: IP 20) Protection against shortcircuit, overtemperature and undervoltage Weight: SERS 01 0,37 kg SERS 06 0,77 kg SERS 12 1,1 kg

Phase current [A]: 01, 06, 12 Supply voltage [VDC]: 24, 85, 120, 240 Version 01 with RS485 with Profibus-DP interface with CAN open interface without interface specification RS232C/V24

Ambient conditions: Ambient temperature: 0C - 50C max. heat sink temperature: 85C Forced draft: Necessary from 6A phase current Noise immunity: In case of correct installation: According to EN50082-2 Noise radiation: In case of correct installation and shielding of the leads according to EN55011 class B

V01: RS485: PB-DP: CAN:

Zebotronics Schrittmotoren GmbH

Machtlfinger Str. 24 81379 Mnchen Tel++49-89-15904070 Fax++49-89-15904079 E-Mail info@zebotronics.de Internet URL http://www.zebotronics.de