Pacific Scientific 6430 Installation & Hardware Reference Manual

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6 4 3 0 D r i v e Installation & Hardware Reference Manual 110 Fordham Road Wilmington, MA 01887 (978) 988-9800 Fax (978) 988-9940 Part# MA6430 List Price $30 U.S. January, 1999 Rev 2 HIGH PERFORMANCE MOTORS & DRIVES Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

It is supplied to the user with the understanding that it will not be reproduced, duplicated, or disclosed in whole or in part without the express written permission of Pacific Scientific Company. Copyright © 1996 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Includes software provided by Pacific Scientific Pacific Scientific warrants its motors and controllers (“Product(s)”) to the original purchaser (the “Customer”), and in the case of original equipment manufacturers or distributors, to their original consumer (the “Customer”) to be free from defects in material and workmanship and to be made in accordance with Customer’s specifications which have been accepted in writing by Pacific Scientific. In no event, however, shall Pacific Scientific be liable or have any responsibility under such warranty if the Products have been improperly stored, installed, used or maintained, or if customer has permitted any unauthorized modifications, adjustments, and/or repairs to such Products. Pacific Scientific’s obligation hereunder is limited solely to repairing or replacing (at its option), at its factory any Products, or parts thereof, which prove to Pacific Scientific’s satisfaction to be defective as a result of defective materials or workmanship, in accordance with Pacific Scientific’s stated warranty, provided, however, that written notice of claimed defects shall have been given to Pacific Scientific within two (2) years after the date of the product date code that is affixed to the product, and within thirty (30) days from the date any such defect is first discovered. The products or parts claimed to be defective must be returned to Pacific Scientific, transportation prepaid by Customer, with written specifications of the claimed defect. Evidence acceptable to Pacific Scientific must be furnished that the claimed defects were not caused by misuse, abuse, or neglect by anyone other than Pacific Scientific. Pacific Scientific also warrants that each of the Pacific Scientific Motion Control Software Programs (“Program(s)”) will, when delivered, conform to the specifications therefore set forth in Pacific Scientific’s specifications manual. Customer, however, acknowledges that these Programs are of such complexity and that the Programs are used in such diverse equipment and operating environments that defects unknown to Pacific Scientific may be discovered only after the Programs have been used by Customer. Customer agrees that as Pacific Scientific’s sole liability, and as Customer’s sole remedy, Pacific Scientific will correct documented failures of the Programs to conform to Pacific Scientific’s specifications manual. PACIFIC SCIENTIFIC DOES NOT SEPARATELY WARRANT THE RESULTS OF ANY SUCH CORRECTION OR WARRANT THAT ANY OR ALL FAILURES OR ERRORS WILL BE CORRECTED OR WARRANT THAT THE FUNCTIONS CONTAINED IN PACIFIC SCIENTIFIC’S PROGRAMS WILL MEET CUSTOMER’S REQUIREMENTS OR WILL OPERATE IN THE COMBINATIONS SELECTED BY CUSTOMER. This warranty for Programs is contingent upon proper use of the Programs and shall not apply to defects or failure due to: (i) accident, neglect, or misuse; (ii) failure of Customer’s equipment; (iii) the use of software or hardware not provided by Pacific Scientific; (iv) unusual stress caused by Customer’s equipment; or (v) any party other than Pacific Scientific who modifies, adjusts, repairs, adds to, deletes from or services the Programs. This warranty for Programs is valid for a period of ninety (90) days from the date Pacific Scientific first delivers the Programs to Customer. i Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

WARRANTIES (EXCEPT AS TO TITLE), WHETHER EXPRESSED OR IMPLIED, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR ANY PARTICULAR PURPOSE, AND ARE IN LIEU OF ALL OTHER OBLIGATIONS OR LIABILITIES ON THE PART OF PACIFIC SCIENTIFIC. PACIFIC SCIENTIFIC’S MAXIMUM LIABILITY WITH RESPECT TO THESE WARRANTIES, ARISING FROM ANY CAUSE WHATSOEVER, INCLUDING WITHOUT LIMITATION, BREACH OF CONTRACT, NEGLIGENCE, STRICT LIABILITY, TORT, WARRANTY, PATENT OR COPYRIGHT INFRINGEMENT, SHALL NOT EXCEED THE PRICE SPECIFIED OF THE PRODUCTS OR PROGRAMS GIVING RISE TO THE CLAIM, AND IN NO EVENT SHALL PACIFIC SCIENTIFIC BE LIABLE UNDER THESE WARRANTIES OR OTHERWISE, EVEN IF PACIFIC SCIENTIFIC HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES, FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, INCLUDING WITHOUT LIMITATION, DAMAGE OR LOSS RESULTING FROM INABILITY TO USE THE PRODUCTS OR PROGRAMS, INCREASED OPERATING COSTS RESULTING FROM A LOSS OF THE PRODUCTS OR PROGRAMS, LOSS OF ANTICIPATED PROFITS, OR OTHER SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, WHETHER SIMILAR OR DISSIMILAR, OF ANY NATURE ARISING OR RESULTING FROM THE PURCHASE, INSTALLATION, REMOVAL, REPAIR, OPERATION, USE OR BREAKDOWN OF THE PRODUCTS OR PROGRAMS, OR ANY OTHER CAUSE WHATSOEVER, INCLUDING NEGLIGENCE. The foregoing shall also apply to Products, Programs, or parts for the same which have been repaired or replaced pursuant to such warranty, and within the period of time, in accordance with Pacific Scientific’s date of warranty. No person, including any agent, distributor, or representative of Pacific Scientific, is authorized to make any representation or warranty on behalf of Pacific Scientific concerning any Products or Programs manufactured by Pacific Scientific, except to refer purchasers to this warranty. ii Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

..................................................... 1 Overview of the 6430 1-1 1.1 6430 Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Other System Components . . . . . . . . . . . . . . . . . . . . . . . . 1-4 1.3 How to Use this Manual . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 1.4 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 2 Installing the 6430 2-1 2.1 Unpacking and Inspecting . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Installing and Using the 6430 . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.3 Selecting Other System Components. . . . . . . . . . . . . . . . . . . 2-3 2.4 Mounting the 6430 Unit. . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.5 Connecting to the 6430 . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 2.5.1 J1 120/240 Vac Power Connector . . . . . . . . . . . . . . . . . 2-6 2.5.2 J3 Motor Connections . . . . . . . . . . . . . . . . . . . . . . . 2-8 2.5.3 J6 External 66 Vdc Output Connector. . . . . . . . . . . . . . 2-16 2.5.4 J12 Signal Interface Connector. . . . . . . . . . . . . . . . . . 2-18 3 Powering Up the 6430 Drive 3-1 3.1 Setting Switch S1 & Jumper J6 on Drive Board . . . . . . . . . . . . . 3-1 3.1.1 Step Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3.1.2 Digital Electronic Damping Control . . . . . . . . . . . . . . . 3-4 3.1.3 Idle Current Reduction. . . . . . . . . . . . . . . . . . . . . . . 3-5 3.1.4 Setting Motor Current . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.1.5 Enable Sense Control. . . . . . . . . . . . . . . . . . . . . . . . 3-6 3.1.6 Step Bandwidth Adjustment . . . . . . . . . . . . . . . . . . . . 3-6 3.2 Setting AC Switch on Power Board . . . . . . . . . . . . . . . . . . . 3-7 3.3 Testing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 6430 Installation & Hardware Reference Manual Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

4.2 Troubleshooting the 6430 Drive . . . . . . . . . . . . . . . . . . . . . 4-1 4.2.1 Troubleshooting the Power Board. . . . . . . . . . . . . . . . . 4-2 4.2.2 Troubleshooting the Drive Board . . . . . . . . . . . . . . . . . 4-4 Appendix A Specifications A-1 Appendix B Ordering Information B-1 Index Rev 1 6430 Installation & Hardware Reference Manual Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

In this chapter This chapter introduces the 6430 stepper drive. Topics covered are: • 6430 definition • Other system components • System diagram • How to use this manual • Warranty information 1.1 6430 Definition Overview The Pacific Scientific 6430 converts step and direction inputs into motor winding currents to control a two-phase stepper motor. Principal features include microstepping and digital electronic damping for high resolution and smooth operation through both the low speed and mid-band resonance regions. The output current of the 6430 is dip switch selectable from 0.625A rms (0.88A peak in microstep mode) to 5A rms (7.1 A peak in microstep mode). The Pacific Scientific 6430 can be powered from 120 or 240 Vac (60/50 Hz). This input is switch selectable for either 120 or 240 Vac. An internal PWM switching power supply provides up to 300 W ± 10% of power to the stepper drive. 6430 Installation & Hardware Reference Manual - Rev 1 1 - 1 Overview Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

modulation) chopping electronically controls the motor winding currents at 20 KHz frequency. This combines the best of recirculating and non-recirculating current regulation producing high back EMF rejection with low chopping ripple current. Benefits include: reduced heat dissipation, low electric noise and improved current control during motor braking. Microstepping - switch selectable: full, 1/2, 1/5, 1/10, 1/25, 1/50, 1/125, and 1/250 step capability with decimal jumper installed and 1/2, 1/4, 1/8, 1/16, 1/32, 1/64, 1/128, and 1/256 with decimal jumper removed. Digital Electronic Damping - patented circuit eliminates torque and/or motor stalling through mid-speed region that is inherent in all open loop stepper applications. Short circuit protection circuitry - disables the drive if a short circuit occurs on the motor outputs. The drive must be power cycled to clear fault. MOSFET power devices - allows chopper frequency of approximately 20 KHz, eliminating acoustical noise often associated with choppers. Optically isolated signal interface connection - optical isolation is provided on the step, direction and enable inputs in addition to the enabled output. The use of optical isolation increases the options available for system grounding. The source commanding the step and direction lines is not tied directly to the motor power supply ground, allowing the system ground point for these signals to be made external to the unit. UL Recognition - 508C (Type R) PENDING - File Number E-137798. This will also comply with CSA Standard for Process Control Equipment, C22.2 No. 142-M1987. Power supply features 66 Vdc Output - three pin pluggable connector (J6) designed to supply 66 Vdc to power an additional drive. The total power available for both the internal and external drives is 66 Vdc @ 4.6 A or 300 W ± 10%. 1 - 2 6430 Installation & Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

3.75, 3.125, 2.5, 1.875, 1.25, or 0.625 A rms. using DIP switch S1 Step size - sets the amount of shaft rotation per step (with the decimal jumper installed). The settings are full, half, 1/5, 1/10, 1/25, 1/50, 1/125, and 1/250 steps per (micro)step. This corresponds to 200, 400, 1000, 2000, 5000, 10,000, 25,000, and 50,000 (micro) steps per revolution with a standard 1.8° motor. With the decimal jumper removed, the settings are 1/2, 1/4, 1/8, 1/16, 1/32, 1/64, 1/128, and 1/256 steps per (micro) step. This corresponds to 400, 800, 1600, 3200, 6400, 12,800, 25,600, and 51,200 (micro) steps per revolution. Digital Electronic Damping control - enables this patented feature which eliminates loss of torque and possible motor stalling conditions when operating at mid-range speeds. This instability is a phenomenon of the electronic, magnetic and mechanical characteristics of a stepping motor system. The compensation circuit damps mid-range oscillations by advancing or delaying switching of the output current relative to the incoming pulse train. Idle current reduction (ICR) - enables or disables idle current reduction which reduces motor winding current by 50% of its rated value during motor dwell periods. ICR begins 0.1 second after the last input step pulse occurs. This delay can also be set to 0.05 seconds or 1 second using a plug-on jumper. Note: The current will return to 100% at the next step pulse. using plug-on jumpers Step filter - when enabled (jumper installed) rejects noise pulses on step input less than 500ηs wide. Useful if maximum step rate is 500 KHz. Enable sense - allows the polarity of the enable input to be reversed. With the jumper installed, the enable input opto-isolator must be driven to enable drive. With the jumper removed, enable input opto-isolator must be driven to disable. using AC Switch SW1 Off line 120/240 Vac - switch selects AC input. DO NOT apply 240 Vac with AC Switch in 120 Vac position. 6430 Installation & Hardware Reference Manual - Rev 1 1 - 3 Overview Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

• X-Y tables and slides • Packaging machinery • Robotics • Specialty machinery • Index feed of material • Labeling machines 1.2 Other System Components Overview The other components that, along with the drive, comprise a complete motor control system are: • Indexer or step source • Motor Installation guidelines for these components are described in Chapter 2, “Installing the 6430 Stepper Motor Drive.” 1 - 4 6430 Installation & Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

typical system. Note: Your installation may vary from this configuration. 6430 Installation & Hardware Reference Manual - Rev 1 1 - 5 Overview 120 - 240 Vac 60/50 Hz Power USER SUPPLIED INDEXER 6430 MOTOR CASE GROUND 66 VDC OUT 2 PHASE STEPPING MOTOR 1 2 3 4 5 1 2 3 1 2 3 - + J3 J1 Stud J6 J12 A B A B 1 6 2 7 3 8 4 9 STEP + STEP - DIRECTION + DIRECTION - ENABLE + ENABLE - ENABLED (C) ENABLED (E) Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

This manual contains information and procedures to install, setup, and troubleshoot the 6430 stepper motor drive. The most effective way to use this manual is to follow the installation and power up instructions contained in Chapter 2 and Chapter 3. 1.4 Warranty The Pacific Scientific 6430 drives have a two year warranty against defects in material and assembly. Products that have been modified by the customer, physically mishandled, or otherwise abused through miswiring, incorrect switch settings, and so on, are exempt from the warranty plan. 1 - 6 6430 Installation & Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

In this chapter This chapter explains how to install the 6430 stepper motor drive. Topics covered are: • Unpacking and inspecting the 6430 • Installing and using the 6430 unit safely • Selecting other system components • Mounting the 6430 in your installation • Connecting input/output cables 2.1 Unpacking and Inspecting Unpacking procedure 1. Remove the 6430 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 inside the chassis 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 within 10 days of receipt of the unit. Storing the unit After inspection, store the controller in a clean, dry, place. The storage temperature must be between -40 degrees C and 70 degrees C. To prevent damage during storage, replace the unit in the original shipping carton. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 1 Installation Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

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 misuse of this product. Note: Read this manual completely to effectively and safely operate the 6430 unit. Warning The circuits in the 6430 drive 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 6430 unit: • Do not operate the drive without the motor case tied to earth ground. Note: This is normally done by connecting the motor’s case to J3-5 of the 6430 and connecting J1-3 of the 6430 to earth ground. These pins are marked by a symbol on the silkscreen and are shown on the diagram on page 2-4. • Do not make any connections to the internal circuitry. The input and output signals are the only safe connection points. • Always remove power before making or removing connections from the unit. • Be careful of the J3 motor terminals when disconnected from the motor. With the motor disconnected and power applied to the drive, these terminals have high voltage present, even with the motor disconnected. • Do not use the ENABLE input as a safety shutdown. Always remove power to the drive for a safety shutdown. 2 - 2 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Selecting an indexer The 6430 drive requires STEP and DIRECTION inputs. Select an indexer that provides, as a minimum, these commands. A compatible indexer will provide the capability to drive the input circuits shown in Section 2.5.4. For most applications that operate at speeds above 300 RPM, an indexer that can ramp the step frequency is required. Selecting a motor The 6430 is designed for use with Pacific Scientific’s line of hybrid stepper motors or most other 2 phase stepper motors. The drive works with either the standard line or the enhanced high performance line of stepper motors. The motor winding current rating must be compatible with the output current of the drive package. Refer to the Torque/Speed Curves in the Pacific Scientific “Motion Control Solutions Catalog” or contact your local Pacific Scientific distributor for sizing and motor compatibility assistance. 2.4 Mounting the 6430 Unit Mounting guidelines Your installation should meet the following guidelines: • Vertical orientation for the unit. • Flat, solid surface capable of supporting the approximate 6.0 lbs. weight (2.7 kg. mass) of the unit. • Free of excessive vibration or shock. • Minimum unobstructed space of 4 inches (10 cm) above and below the unit. • Maximum ambient temperature of 50°C 6430 Installation and Hardware Reference Manual - Rev 1 2 - 3 Installation Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

below: 2 - 4 6430 Installation and Hardware Reference Manual - Rev 1 6430 6.25 [158.75mm] 2.25 [57.15mm] 1.24 [31.50mm] 0.50 [12.70mm] 0.30 [7.62mm] 12.50 [317.50mm] 1.12 [28.45mm] JI POWER 120/240 VAC J3 MOTOR J12 CONTROL J6 66Vout POWER ON FAULT L1 A B A B L2 11.61 [294.89mm] + 10.75 [273.05mm] Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Introduction The four input/output (I/O) connectors are: • J1 - Power connector • J3 - Motor connector • J6 - External 66 Vdc Output connector • J12 - Signal connector These inputs and outputs are shown in the diagram below. Connection diagram 6430 Installation and Hardware Reference Manual - Rev 1 2 - 5 Installation 120 - 240 Vac 60/50 Hz Power USER SUPPLIED INDEXER 6430 MOTOR CASE GROUND 66 VDC OUT 2 PHASE STEPPING MOTOR 1 2 3 4 5 1 2 3 1 2 3 - + J3 J1 Stud J6 J12 A B A B 1 6 2 7 3 8 4 9 STEP + STEP - DIRECTION + DIRECTION - ENABLE + ENABLE - ENABLED (C) ENABLED (E) Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

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 then described here. Noise pickup reduction Use shielded and twisted cabling for the signal and power cables as described below. This precaution reduces electrical noise. Shock hazard reduction Refer to section 2.2 for safety information that must be followed to reduce shock hazard. 2.5.2 J1 120/240 Vac Power Connector Introduction The J1 power connector should be used to power the 6430 from 120/240 Vac (60/50 Hz). Mating connector The J1 120/240 Vac power connector mates to a PCD 3-pin screw cable connector. The mating connector, supplied with the unit, is type ELFP03210. Cable requirements Use 16- to 14-gauge shielded wire for the cabling. 2 - 6 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

J1 power cable Procedure 1. Strip the wires 0.27 inch (7mm). 2. Attach the wires to the connector as indicated in the diagram. Note: Make sure the screws on the PCD connector are tightened down firmly on the wiring. Caution Do not solder the tips of the cables going into the PCD connector. This can result in a loose connection. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 7 Installation 1 2 3 Green - Earth Ground White - AC L1 Black - AC L2 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Introduction The J3 motor cable connects the drive to the motor windings and motor case. J3 utilizes a plug-in screw terminal/type connector to simplify assembly and allow quick connect and disconnect. Pacific Scientific cable Pacific Scientific makes cables that connect directly from J3 to our system motors. To order the cable from Pacific Scientific, use the order number SPC-xxx-6410, where “xxx” is the length, in feet (one-foot increments) up to 50 feet. For example, SPC-050 is a 50 feet long cable. Pacific Scientific makes cables for both E and H series stepper motors (SPC-xxx-6410) and K and N series stepper motors (SPC-xxx-6410-KN). Please refer to the correct diagram on the following page. Pacific Scientific cabling diagram If you are using Pacific Scientific E and H series motor cable, with the mating connectors already attached, install as follows: 2 - 8 6430 Installation and Hardware Reference Manual - Rev 1 1 5 J3 5 Pin PCD ELVP05100 SPC - XXX - 6410 5 Pin MS Connector MOTOR JACKET 16 AWG SHIELD SHIELD 16 AWG MOTOR PHASES A B CASE GND A B 1 2 3 4 5 A B C D E BLK ORG RED YEL GRN Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

motors, install as follows: Making your own cable To make your own motor cable, follow the guidelines given below for wiring to the J3 mating connector. Depending on your motor configuration, refer to the appropriate diagram at the end of this section to determine the motor connections required. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 9 Installation 1 5 J3 5 Pin PCD ELVP05100 SPC - XXX - 6410 - KN 5 Pin MS Connector MS31 06A1 4S-5S MOTOR JACKET SHIELD SHIELD 16 AWG 16 AWG MOTOR PHASES A B CASE GND A B 1 2 3 4 5 A B C D E BLK ORG RED YEL GRN Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

J3-1 Motor Phase A excitation. Twisted Pair. Motor Phase A J3-2 Motor Phase B J3-3 Motor Phase B excitation. Twisted Pair. Motor Phase B J3-4 Drive Case (Earth) Ground J3-5 Connected to the motor case ground. Mating connector The J3 motor connector on the 6430 mates to a 5-pin PCD screw cable connector. The mating cable connector is type ELVP05100. Cable requirements The mating connector terminals will accept #16 to #18 AWG wire. Pacific Scientific recommends using #16 AWG. For the motor cable, use cable with two twisted pairs twisted at about 3 to 4 turns per inch (1 to 1.5 turns per centimeter) for the motor phase excitations and a fifth wire for the case ground. As an option, the cable may be shielded to reduce radiated noise. A single shield can be used around both phase excitations and the ground wire or each phase excitation (twisted pair) can be individually shielded as in the Pacific Scientific cables. Connect shields to pin 5 of the mating connector. 2 - 10 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

J3 motor Note: The colors in the diagram follow the Pacific Scientific stepper motor cable color code. Procedure 1. Strip the wires to 0.27 in (7mm). 2. Attach wires to connector as indicated in the diagram. Note: Make sure the screws on the PCD connector are tightened down firmly on the wiring. Caution Do not solder the tips of the cables before insertion into the connector. Solder can contract and cause a loose connection over time. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 11 Installation 5 4 3 2 1 To Drive To Motor A (Black) A (Orange) B (Red) B (Yellow) Motor Case Gnd (Green) .27 in .27 in .27 in .27 in .27 in (7 mm) (7 mm) (7 mm) (7 mm) (7 mm) Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

6430 connector J3 and Pacific Scientific motors having flying leads. Connections are shown for 4 lead motors, 8 lead motors with paralleled windings, and 8 lead motors with series windings. Wire nuts may be used for the winding connections at the motor end. 2 - 12 6430 Installation and Hardware Reference Manual - Rev 1 TO J3-4 TO J3-4 TO J3-4 TO J3-5 TO J3-5 TO J3-5 TO J3-3 TO J3-3 TO J3-3 TO J3-2 TO J3-2 TO J3-2 TO J3-1 TO J3-1 TO J3-1 A A A A A A B B B B B B DRIVE/EARTH GROUND DRIVE/EARTH GROUND DRIVE/EARTH GROUND FOUR LEAD MOTOR EIGHT LEAD MOTOR CONNECTED IN PARALLEL EIGHT LEAD MOTOR CONNECTED IN SERIES BLK BLK ORG ORG WHT/ORG WHT/BLK RED RED WHT/RED WHT/YEL YEL YEL BLK ORG WHT/ORG WHT/BLK RED WHT/RED WHT/YEL YEL CASE CASE CASE Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

6430 connector J3 and Pacific Scientific stepper motors having a terminal board in the rear end bell. Connections are shown for 4 lead motors, 8 lead motors with paralleled windings, and 8 lead motors with series windings. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 13 Installation TERMINAL TERMINAL TERMINAL CASE CASE CASE FOUR LEAD MOTOR EIGHT LEAD MOTOR CONNECTED IN PARALLEL EIGHT LEAD MOTOR CONNECTED IN SERIES DRIVE/EARTH GROUND DRIVE/EARTH GROUND DRIVE/EARTH GROUND A A A A A A B B B B B B 1 3 2 4 TO J3-1 TO J3-1 TO J3-1 TO J3-2 TO J3-2 TO J3-2 TO J3-3 TO J3-3 TO J3-3 TO J3-4 TO J3-4 TO J3-4 TO J3-5 TO J3-5 TO J3-5 1 6 5 3 2 8 7 4 1 6 5 3 2 8 7 4 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

6430 J3 connector and Pacific Scientific stepper motors having MS connectors. Connections are shown for 4 lead motors, 8 lead motors with paralleled windings, and 8 lead motors with series windings. 2 - 14 6430 Installation and Hardware Reference Manual - Rev 1 MS CONNECTOR MS CONNECTOR MS CONNECTOR CASE CASE CASE DRIVE/EARTH GROUND DRIVE/EARTH GROUND DRIVE/EARTH GROUND FOUR LEAD MOTOR EIGHT LEAD MOTOR CONNECTED IN PARALLEL EIGHT LEAD MOTOR CONNECTED IN SERIES A A A A A A B B B B B B A B C D E TO J3-1 TO J3-1 TO J3-1 TO J3-2 TO J3-2 TO J3-2 TO J3-4 TO J3-4 TO J3-4 TO J3-5 TO J3-5 TO J3-5 TO J3-3 TO J3-3 TO J3-3 A E F B C G H D M A E F B C G H D M Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

connections The figure below shows the connections required between the 6430 and Pacific Scientific Power Max Motors. Power Max motors have an eight pin connector and can be configured with either parallel or series windings. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 15 Installation CONNECTOR CONNECTOR PARALLELED WINDINGS SERIES WINDINGS CASE CASE MOTOR MOTOR DRIVE/EARTH GROUND DRIVE/EARTH GROUND TO J3-1 TO J3-1 TO J3-2 TO J3-2 TO J3-3 TO J3-3 TO J3-4 TO J3-4 TO J3-5 TO J3-5 6 2 5 1 8 4 7 3 A A A A B B B B 6 2 5 1 8 4 7 3 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Introduction The J6 external 66 Vdc output allows the 6430 to power additional drives. Mating connector The J6 output connector mates to a PCD 3-pin screw cable connector. The mating connector, supplied with the unit, is type ELVP03100. Cable requirements Use 18- to 16-gauge shielded wire for the cabling. Cable diagram - 66 Vdc Output 2 - 16 6430 Installation and Hardware Reference Manual - Rev 1 1 2 3 Black - ( - ) Red - ( + ) Green - Earth Ground Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

preferable to run each power connection from the J6 DC output to the 6430 as shown below. DO NOT daisy-chain the power connections. Note: The total power available for both the internal and external drives is 66 Vdc @ 4.6 A or approximately 300 W ±10%. If the two drives are running simultaneously and require more than 4.6 A, the voltage will drop. The power supply has a low voltage protection circuit that will fault the drive if the voltage is < 55 Vdc. Note: If the 6430 is powering additional 6410s with J6, a total of 1000 µf (maximum) 100 Vdc aluminum electrolytic capacitor, rated for 2A ripple current or greater @ 10 KHz and 105°C, must be installed at the 6410 (as close to the 6410 as possible) if the cable length is over 3 feet. DO NOT exceed 1000 µf total on J6 external connector. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 17 Installation 6410 6410 1 1 3 3 2 2 J6 - - - + + + J2 J2 6430 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Introduction The J12 signal interface accepts step, direction and enable signals from an indexer or other source and outputs an enabled signal which indicates the 6430 is applying current to the motor windings. J12 signal table Note: All inputs and outputs are optically isolated. Input/Output Pin Explanation STEP + J12-1 Input used to command motor rotation. See figure at the end of the table for circuit and timing information. DIR + J12-2 Input that determines the direction of motor rotation. If standard motor wiring is followed, the motor will turn clockwise if the opto current is zero. The sense of the DIR + input can be reversed by reversing the connection of either (but not both) motor phase connectors (i.e. switching A & A OR B & B). Refer to the figure at the end of the table for timing and circuit information. ENABLE + J12-3 Input used to enable or disable the 6430’s power stage. With the J6 5-6 jumper out (factory default) the power stage is enabled if the opto current is zero and disabled if the opto is driven. Inserting the jumper reverses this functionality. See figure at the end of the table for circuit information. There is a delay of approximately 500 µs after enabling the drive and the power stage becoming active. Enabled Collector J12-4 Output. Collector of transistor that is on when the 6430’s power stage is active. See figure at the end of the table for circuit information. J12-5 Not used. STEP - J12-6 Input used to command motor rotation. See figure at the end of the table for circuit and timing information. 2 - 18 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

rotation. If standard motor wiring is followed, the motor will turn clockwise if the opto current is zero. The sense of the DIR + input can be reversed by reversing the connection of either (but not both) motor phase connectors (i.e. switching A & A OR B & B). Refer to the figure at the end of the table for timing and circuit information. ENABLE - J12-8 Input used to enable or disable the 6430’s power stage. With the J6 5-6 jumper out (factory default) the power stage is enabled if the opto current is zero and disabled if the opto is driven. Inserting the jumper reverses this functionality. See figure at the end of the table for circuit information. There is a delay of approximately 500 µs after enabling the drive and the power stage becoming active. Enabled Emitter J12-9 Output. Emitter of transistor that is on when the 6430’s power stage is active. See figure at the end of the table for timing and circuit information. Typical interface The figure on the following page shows a typical interface between the user’s electronics and the 6430. The TTL gates should have totem pole outputs and be capable of sinking at least 10.0 mA at 0.4 volts. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 19 Installation Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

6430 Installation and Hardware Reference Manual - Rev 1 TLP 2601 ENABLE ENABLE 3 8 DIR DIR STEP STEP 1 6 2 7 (COLLECTOR) 4 (EMITTER) 9 TTL TTL TTL USER'S CONTROL ELECTRONICS +5 Vdc STEPPER DRIVE MOTION OCCURS ON THIS EDGE SETUP TIME STEP INPUT DIRECTION INPUT DIRECTION DATA 6430 ENABLED ENABLED J12 50 S MIN µ OVER THIS INTERVAL MUST BE STABLE 2.21K 464 1K TLP 621 TLP 621 1K TLP 621 5Vdc DRIVER_ENABLED STEP FILTER ENABLED) 250 NS MIN (1 S MIN WITH µ Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

to the 6430 drive. However, a resistor must be put in series with the command inputs as shown below. Values for several common supply voltages are given in the following table. If the drives have open collector outputs, pull up resistors (R3) should be added as shown. A typical value of R3 is 2.7K. Opto Supply to 6430 R1 R2 +12 Vdc 1 Kohm 1.5 K +15 Vdc 1.5 Kohm 2.2 K +30 Vdc 3.3 Kohms 6.8 K Mating connector The J12 signal interface connector is 9 contact female D connector. The mating cable connector is an ITT Cannon DE-9P with ITT Cannon DE110963 Hood and D20419 Clamp Kit. 6430 Installation and Hardware Reference Manual - Rev 1 2 - 21 Installation TLP 2601 ENABLE ENABLE 3 8 DIR DIR STEP STEP 1 6 2 7 R3 R3 R3 USER'S CONTROL ELECTRONICS STEPPER DRIVE 6430 J12 2.21K R1 R2 R2 464 1K TLP 621 TLP 621 1K OPTO SUPPLY Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

In this chapter This chapter explains how to power up the 6430 drive after installation. Topics covered are: • Setting up functions using switch S1 and Jumper J6 • AC Switch (SW1) Settings • Testing the installation This section is intended to familiarize the 6430 user with the hardware adjustments and settings required to power up and operate the 6430 drive. Introduction The 6430 drive is a two board assembly incorporating a Drive and a Power Board set. Drive The drive board has an eight position DIP switch ( S1) and a group of four jumpers (J6) controlling drive current, digital electronic damping, idle current reduction and binary or decimal step size. Power The power board has an AC switch (SW1) to select 120 or 240 Vac operation. Warning Connecting 240 (230) Vac with switch in 120 (115) Vac position will permanently damage the drive. 6430 Installation and Hardware Reference Manual - Rev 1 Powering Up 115 230 AC switch (SW1) Jumper J6 Switch S1 DRIVE board POWER board Transformer 6430 1 7 J6 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Introduction DIP switch S1 and Jumper J6 set the following: • Step size • Motor current level • Digital electronic damping ON/OFF • Idle current reduction • Enable sense • Step filter response time Location of S1 3 - 2 6430 Installation and Hardware Reference Manual - Rev 1 OPEN SWI POSITION 4 CLOSED OPEN DIGITAL ELECTRONIC DAMPING DISABLED ENABLED SW1 POSITION 1 2 3 STEP SIZE CLOSED CLOSED CLOSED CLOSED OPEN OPEN OPEN OPEN CLOSED CLOSED OPEN OPEN CLOSED CLOSED OPEN OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN DEC JMPR IN DEC JMPR OUT FULL HALF 1/5 1/10 1/25 1/50 1/125 1/250 HALF 1/4 1/8 1/16 1/32 1/64 1/128 1/256 IN: OPTO ON TO ENABLE OUT: OPTO OFF TO ENABLE ENABLE SENSE JUMPER IDLE T JUMPER SELECT IDLE CURRENT REDUCTION TIME SEE TABLE BELOW DEC JUMPER (SEE SW1 TABLE BELOW) IN: SELECT DECIMAL STEP SIZES OUT: SELECT BINARY STEP SIZES STEP BW JUMPER IN: 500 KHz MAX STEP RATE OUT: 2 MHz MAX STEP RATE JUMPERS 1-2, 3-4, & 7-8 INSTALLED AT FACTORY OPEN IDLE-T JUMPER SW1 POSITION 5 IDLE CURRENT REDUCTION IN IN OUT OUT CLOSED OPEN CLOSED OPEN DISABLED 0.1 SEC DELAY 0.05 SEC DELAY 1.0 SEC DELAY PC CARD EDGE S1 J6 7 1 MOTOR CURRENT AMPS RMS SW1 POSITION 6 7 8 CLOSED CLOSED CLOSED CLOSED OPEN OPEN OPEN OPEN CLOSED CLOSED OPEN OPEN CLOSED CLOSED OPEN OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN CLOSED OPEN 5.0 4.375 3.750 3.125 2.5 1.875 1.25 0.625 1 2 3 4 5 6 7 8 S1 SIDE VIEW FACTORY DEFAULT POSITIONS SHOWN FACTORY DEFAULTS: 5.0 AMPS RMS STEPSIZE 1/25 500 KHz MAX STEP RATE IDLE CURRENT REDUCTION ENABLED (0.1 SEC) DIGITAL ELECTRONIC DAMPING CONTROL ENABLED DRIVER ENABLED UNLESS ENABLE OPTO DRIVEN Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Definition The step size sets the amount of rotation per input step. Fifteen step sizes are available using Jumper J6 position 3-4 and DIP switch S1 positions 1-3 as shown. For all Pacific Scientific stepper motors and all 1.8° step motors, step size can be converted to steps per rotation using the following table: Decimal Binary Full 200 Half 400 Half 400 1/4 800 1/5 1,000 1/8 1,600 1/10 2,000 1/16 3,200 1/25 5,000 1/32 6,400 1/50 10,000 1/64 12,800 1/125 25,000 1/128 25,600 1/250 50,000 1/256 51,200 Benefits Selecting a microstep size of 1/5 or smaller results in: • higher resolution • smoother low speed operation • ability to operate in low-speed resonance regions 6430 Installation and Hardware Reference Manual - Rev 1 Powering Up Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Definition Mid-speed instability and the resulting loss of torque occurs in any step motor/drive system due to the motor back EMF modulating the motor winding currents at certain speeds. Mid-speed instability can be explained as a region of potential instability that occurs as a result of the electronic, magnetic, and mechanical characteristics of any stepping motor system. The circuitry used to control this phenomenon does so by advancing or delaying the switching of the output current with respect to the incoming pulse train. This should be taken into account if the user is attempting to employ pulse placement techniques. Enable the digital electronic damping function by placing DIP switch S1 position 4 in the open position as shown. This is the default position and should be used for most applications if your application is affected by loss of torque at mid-range speeds. If pulse placement techniques are being used, disable the digital electronic damping function by placing DIP switch S1 position 4 in the open position. Benefit This feature controls torque loss at mid-range speeds. When enabled, the motor maintains torque at mid-range operation, provided the torque load does not exceed motor torque ratings. 3 - 4 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Definition The Idle Current Reduction (ICR) function reduces the phase current at times when no motion is commanded. Motor current is reduced when no step commands are received for a given time. This time can be set to 0.05 seconds, 0.1 seconds or 1.0 second. Current to both motor windings is reduced by one-half. The ICR function can be enabled/disabled and the time delay between the last step command and current reduction can be set to 50 ms, 0.1 seconds, or 1.0 second using DIP switch S1 position 5 and Jumper J6 position 7-8. With the jumper installed (factory default), ICR is disabled when DIP Switch S1 position 5 is in the closed position and enabled with a delay of 0.1 second (current is reduced by 50% when no step command is received for 0.1 second when the switch is open. With the jumper removed, ICR is enabled and the delay can be set to 0.05 second or 1.0 second by placing DIP Switch S1 position 5 in the closed or open position respectively. Note: When ICR is active, both the holding torque generated by the motor and the motor stiffness around the holding position are reduced by approximately 50%. Benefits The ICR function: • Reduces motor and drive heating during stand-by operation 6430 Installation and Hardware Reference Manual - Rev 1 Powering Up Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Motor current can be set using DIP Switch S1 positions 6, 7, and 8 as shown. Current should be compatible with motor current ratings. 3.1.5 Enable Sense Control The polarity of the enable input can be changed using Jumper J6 position 5-6. With the jumper removed (factory default), the drive is enabled when the enable input is not driven and disabled when driven (current flows in enable opto). This allows the 6430 to be used with no connection to the enable input. With the J6 5-6 jumper installed, the enable input must be driven (current in opto) for the 6430 power stage to be enabled. 3.1.6 Step Bandwidth Adjustment A digital filter can be enabled which reduces susceptibility to noise on the step input at the expense of a lower limit on maximum step frequency. With Jumper J6 positions 1-2 installed (factory default) the filter is enabled and step pulses must have a minimum width of one microsecond. Pulses less than 0.5 microseconds in width will be rejected. With the filter disabled, Jumper J6 position 1-2 removed, step pulses must be a minimum of 0.25 microseconds wide. Therefore, the maximum step frequency is 500 KHz with the filter enabled and 2 MHz with the filter disabled. 3 - 6 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Introduction The AC Switch (SW1) on the 6430 power board allows the user to select 120 OR 240 Vac. Warning! Connecting 240 (230) Vac with switch in 120 (115) Vac position will permanently damage the drive. Location of AC Switch Note: The AC Switch is preset at the factory in the 230 Vac position. 6430 Installation and Hardware Reference Manual - Rev 1 Powering Up 115 230 AC switch (SW1) Jumper J6 Switch S1 Drive board Power board Transformer 1 7 J6 Remove screws four places Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Background The following procedure verifies that the 6430 is installed properly and that it was not damaged during shipment. Procedure After installing the 6430 as described in Chapter 2, test your installation as follows. Warning Perform this initial power up with the motor shaft disconnected from the load. Improper wiring or undiscovered shipping damage could result in undesired motor motion. Be prepared to remove power if excessive motion occurs. Connections test 1. Check all wiring and mounting to verify correct installation. 2. With the power Off, check that S1 is set as follows (factory default settings): These settings reflect the following: - Step size of 1/25 - Digital electronic damping enabled - Idle current reduction enabled - 5 A rms motor current Warning If the motor is rated at less than 5 A rms winding current, set positions 6, 7, & 8 accordingly. 3 - 8 6430 Installation and Hardware Reference Manual - Rev 1 1 2 3 4 5 6 7 8 O N Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

3. Check that Jumper J6 is set as follows: These settings reflect the following: - Idle Current Reduction Enabled (0.1 second delay) - 6430 enabled without enable input driven - Decimal step size selected - Step input filter enabled 4. Switch On 120 OR 240 Vac power, as selected by position of AC Switch. Warning! Connecting 240 (230) Vac with switch in 120 (115) Vac position will permanently damage the drive. Signals test 1. Verify that the motor has holding torque by attempting to rotate the motor shaft. The energized motor shaft is either immovable or is resistant to rotation. 2. Input a step command and verify that the motor moves. 3. Reverse the polarity of the DIRECTION signal and step the motor. The direction of rotation should change. Getting help If you need further assistance with your installation, please contact your local distributor. 6430 Installation and Hardware Reference Manual - Rev 1 Powering Up J6 1 7 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

This chapter covers maintenance and troubleshooting of the 6430 unit. 4.1 Maintaining the 6430 Drive Introduction The 6430 drives are designed for minimum maintenance. The following cleaning procedure, performed as needed, will minimize problems due to dust and dirt build-up. Procedure Remove superficial dust and dirt from the unit using clean, dry, low-pressure air. 4.2 Troubleshooting the 6430 Drive Introduction The 6430 has an “enabled” output which is on when the drive is enabled and off when the drive is disabled or faulted due to any of the following: • Output overcurrent (line-to-line or line-to-neutral short) • Bus overvoltage • Low voltage supply out of tolerance. Procedure Use the troubleshooting tables and the simple circuit shown on the following pages to diagnose and correct most problems. If you are unable to achieve satisfactory operation, contact your local Pacific Scientific Distributor or the Applications Engineering Department. 6430 Installation and Hardware Reference Manual - Rev 1 4 - 1 Powering Up Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Corrective action table Use the following table to troubleshoot the 6430’s power supply. SYMPTOM POSSIBLE CAUSE ACTION Motor does not turn LEDs ON (green and/or red) 120/240 Vac switch in 240 position, input from 120 Vac Turn power off, correct switch position. AC Input line low Increase Input AC to spec. Dead short or overload across external 66 Vdc output connector (J6). Remove short or reduce load. Over temperature Check ambient temperature or internal fan malfunction/blockage. Bad load connection Check load connection. Check J6 Vdc output with a voltmeter and ensure output voltage is 66V ±3%. 1. If output voltage > 70 Vdc and < 78 Vdc add a load and ensure Vdc is ≈ 66Vdc. 2. If output voltage > 78 Vdc, return 6430 to factory for service. Drive board fault See Section 4.2.2 4 - 2 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

turn, LEDs OFF Check AC input Use proper input. 240 Vac applied and switch in 120 Vac position. Return to factory for service. Motor runs for a while and stops, both LEDs come on Over temperature. Reduce load. Check for excessive ambient temperature. Check for internal fan malfunction/blockage. Motor turns on and off on its own and red LED keeps flashing OR Motor stops after running once. 120 Vac applied and switch in 240 Vac position Correct switch position. Over load. Reduce load. AC input line low. Check input AC line voltage for low line. Drive Board Fault. See Section 4.2.2 Internal failure. Return to factory for service. 6430 Installation and Hardware Reference Manual - Rev 1 4 - 3 Powering Up Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Corrective action table Use the following table to troubleshoot the drive board: SYMPTOM CORRECTIVE ACTION Motor produces no torque, Meter reads high. Note: See figure on next page. Ensure that the J6 5-6 jumper is out, or if in, that the enable input opto is driven with at least 3 mA. Disconnect the AC power. Disconnect motor cable and cycle the J1 power supply Off and On. If the meter reads low, check motor cable and motor for shorts across the windings or between the windings and the motor case. Motor produces no torque, meter reads low. Note: See figure on next page. Verify that DIP Switch S1 position 6, 7, and 8 (current select) are set correctly. Re-check that the motor cable is wired correctly and properly plugged into the drive. Motor produces torque but does not turn. Make sure that the STEP input is switching and meets specified electrical and timing requirements. Motor rotates in the wrong direction Check polarity of the DIRECTION input. Also, check that the DIRECTION input satisfies the specified electrical and timing requirements. Reverse the A and A motor phases. Motor does not reach expected position Check that the step size setting of the drive is the same as the step size setting of the indexer. Verify that the motor does not stall. If it does: 1. Use a finer step size to avoid low-speed resonance problems. 2. Enable Digital Electronic Damping control. (S1 position 4 OFF). Check that the STEP and DIRECTION Inputs satisfy all electrical and timing requirements. 4 - 4 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

simply replace it with another and apply power. 6430 Installation and Hardware Reference Manual - Rev 1 4 - 5 Powering Up 6430 4.7 K J12-4 J12-9 Meter + Meter - User Power Supply 5 Vdc @ 1 mA Note: High = 5 Vdc Low = 1 Vdc < Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

defective If you cannot correct the drive problem, or if it is defective, return it to Pacific Scientific for repair or replacement. Return procedure 1. Call Pacific Scientific at (815) 226-3100 from 8am to 6pm Eastern Standard Time to get a Returned Materials Authorization Number (RMA#). Note: Do not attempt to return the 6430 or any other equipment without a valid RMA#. Returns received without a valid RMA# will not be accepted and will be returned to the sender. 2. Pack the drive in its original shipping carton. Pacific Scientific is not responsible or liable for damage resulting from improper packaging or shipment. 3. Ship the drive to: Pacific Scientific 110 Fordham Road Wilmington, MA 01887 Attn: Repair Department, RMA# _________ Note: Do not ship Pacific Scientific motors to the above address. The correct address for motors is: Pacific Scientific 4301 Kishwaukee Street Rockford, IL 61105 Attn: Stepper Repair Department, RMA# ________ Shipment of your drive or motor to Pacific Scientific constitutes authorization to repair the unit. Refer to Pacific Scientific’s repair policy for standard repair charges. Your repaired unit will be shipped via UPS Ground delivery. If another means of shipping is desired, please specify this at the time of receiving an RMA#. 4 - 6 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Electrical Input voltage 120/240 Vac (+10%, -15%) 60/50 Hz Rated drive current (motor phase current) Setting 5 A 5A ± 0.25A 4.375 4.375 ± 0.2A 3.75 3.75 ± 0.2 A 3.125 3.125 ± 0.15 A 2.5 2.5 ± 0.15 A 1.875 1.875 ± 0.125 1.25 1.25 ± 0.125 0.625 0.625 ± 0.1 A Fuse 5 A Slo-Blo 250 Vac Drive circuit Two-phase bipolar, chopper current regulated Chopper frequency 20 KHz, nominal 6430 Installation and Hardware Reference Manual - Rev 1 A - 1 Specifications Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Full (1/2) 200 (400) 1/2 (1/4) 400 (800) 1/5 (1/8) 1000 (1600) 1/10 (1/16) 2000 (3200) 1/25 (1/32) 5000 (6400) 1/50 (1/64) 10000 (12800) 1/125 (1/128) 25000 (25600) 1/250 (1/256) 50000 (51200) Signal input requirements (See circuit diagram, Section 2.5.4) Optically Isolated Inputs: Input Min Input Current - Opto ON Max Input Current Max Reverse Voltage (Input to J12-9) J12-1, J12-6 - Step 5.5 mA 10 mA 5 volts J12-2, J12-7 - Direction 3.0 mA 4.5 mA 5 volts J12-3, J12-7 - Enable 3.0 mA 4.5 mA 5 volts Signal output characteristics (See circuit diagram, Section 2.5.4) J12-4, J12-9 Enabled (Optically isolated NPN transistor with open collector and open emitter) Maximum low level voltage while sinking 2 mA: 0.5 volts A - 2 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

500 KHz with step filter enabled Step/Direction timing requirements The figure below show the required timing relationship between the STEP and DIRECTION inputs: Minimum ramp time for step rate (Accel/Decel) 50 milliseconds (This restriction only applies with digital electronic damping control enabled. Drive state generator transition delay relative to input step 1. With digital electronic damping control enabled, at pulse frequencies less than 500 full steps/sec, delay is less than 500 µsec. At frequencies greater than 500 full steps/sec, delay is less than 270° of the input pulse period. 2. With digital electronic damping control disabled, delay is less than 10 µsec at all step frequencies. 6430 Installation and Hardware Reference Manual - Rev 1 A - 3 Specifications MOTION OCCURS ON THIS EDGE SETUP TIME STEP INPUT DIR - INPUT DIRECTION DATA 50 S MIN µ OVER THIS INTERVAL MUST BE STABLE STEP FILTER ENABLED) 250 NS MIN (1 S MIN WITH µ Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Storage temperature -40°C to +70°C Humidity Range 10 to 90%, non-condensing Mechanical Dimensions Refer to Section 2.4 Weight 6.0 lb nominal Connectors AC Input Phoenix MSTBA 2,5/3-G connector. Mating connector: Phoenix MCI, 5/5-ST-3,81. Signal 9 contact female D connector, Mating connector: ITT Cannon DE-9P with ITT Cannon DE110963 Hood and D20419 Clamp Kit. Motor PCD ELVH0510 connector. Mating connector: PCD ELVP05100. 66 Vdc output PCD ELVH0310 connector. Mating connector: PCD ELVP03100. A - 4 6430 Installation and Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Background This appendix lists 6430 part numbers and gives information on ordering. 6430 part number table Part Pacific Scientific Order # Comment Stepper Drive 6430 Connector Kit CK6430 9-pin D connector 5-pin PCD 3-pin PCD 3-pin PCD Installation and Hardware Manual MA6430 Motor Cable SPC-xxx-6410 SPC-xxx-6410-KN* xxx represents length in feet; for example, SPC-005 is a cable 5 feet long. For lengths over 50 feet contact Pacific Scientific. The connectors are MS on the motor end and PCD on the drive end to connect to Pacific Scientific motors. *Note: Cables for K and N series stepper motors. 6430 Installation & Hardware Reference Manual - Rev 1 B - 1 Order Information Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Contact Pacific Scientific to order these parts. Call 815-226-3100 from 8am to 6pm Eastern Standard Time. Write Pacific Scientific 4301 Kishwaukee Street Rockford, IL 61105 Fax (815) 226-3048 B - 2 6430 Installation & Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

location, 3-7 setting, 3-7 Address , 4-6, B-2 Applications, 1-4 B Bipolar chopper drive, 1-2 C Cable J1, 2-7 J3, 2-8 Chopper frequency, A-1 Cleaning unit, 4-1 Components, system, 1-4, 2-3 Connections motor, 2-8 parallel, 2-12, 2-13, 2-14, 2-15 series, 2-12, 2-13, 2-14, 2-15 testing, 3-8 Connectors, A-4 J1, 2-6 J3, 2-10 J6, 2-16 J12, 2-21 Current, input, 2-6 output, 1-1 rating, A-1 D Damage, 2-1 Date code, 2-1 Defective unit, 4-6 Definition, general drive, 1-1 Digital electronic damping, 1-2, 3-4 benefits, 3-4 definition, 3-4 Dimensions, 2-4 DIRECTION input, 2-18, 4-4, A-2 Drive circuit, A-1 current/stepsize, see S1 switch features, 1-2 E Earth ground, safety, 2-2 Enabling the drive, 3-9 F Fuse selection, A-1 6430 Installation & Hardware Reference Manual - Rev 1 I - 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

H Help, getting, 3-9 Humidity, A-4 I ICR, see Idle current reduction Idle current reduction, 1-3, 3-5 benefits, 3-5 definition, 3-5 Input/Output connections diagram, 2-5 Inputs, 2-18 Inspecting, 2-1 Installation, 2-2, 2-4 Interface, high voltage, 2-21 typical, 2-20 J J1-Power, 2-6 cable, 2-6 diagram, 2-7 procedure, 2-7 J3-Motor, 2-8 cable, making your own, 2-9 connector, 2-10 diagram, 2-11 Pacific Scientific, cable, 2-8 procedure, 2-11 safety, 2-2 table, 2-10 J6-66 VDC Output, 2-16 cable, 2-16 connection diagram, 2-17 connector, 2-16 diagram, 2-16 J12-Signal interface, 2-18 connector, 2-21 diagram, 2-20 I/O table, 2-18 Jumpers, 1-3, 3-2 M Maintenance, 4-1 Manual, how to use, 1-4 Microstepping, 1-2, 3-3 I - 2 6430 Installation & Hardware Reference Manual - Rev 1 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

connector, 2-10 Flying Lead, 2-12 MS connectors, 2-14 Power Max, 2-15 Terminal Board, 2-13 Pacificc Scientific, cable, 2-8 selection, 2-3 Mounting, 2-3 dimensions, 2-4 guidelines, 2-3 Multi-axis, 2-17 N Noise pickup reduction, 2-6 O Optically isolated connections, A-2 safety, 2-2 Opto supply table, 2-21 Order information, B-1 Output - J6 - 66 VDC Output, 2-16 cable, 2-16 connection diagram, 2-17 connector, 2-16 diagram, 2-16 Overview, general, 1-1 P Packing list, 2-1 Parallel connection, 2-12 - 2-15 Phase A , A, 2-10 Phase B, B, 2-10 Power supply, 1-1 features, 1-2 Power-up, 3-1 Problems/Solutions, 4-2 R Ramp time, A-3 Repair procedure, 4-6 Return, procedure, 4-6 S S1 switch location, 3-2 setting, 3-2 digital electronic damping set up, 3-4 idle current reduction, setup, 3-5 step size set up, 3-3 Safety, 2-2 Series connection, 2-12 - 2-15 Shock hazard, reduction, 2-6 Short circuit protection, circuitry, 1-2 6430 Installation & Hardware Reference Manual - Rev 1 I - 3 Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

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