404 westridge dr. - mouser electronics404 westridge dr. • watsonville, ca 95076 831/761-6555 •...

404 Westridge Dr. • Watsonville, CA 95076831/761-6555 • 800/525-1609 • FAX 831/761-6544

www.appliedmotionproducts.com

1

INTRODUCTION

PPLIED MOTION PRODUCTS, founded in 1978 specializes in high-precision, costeffective, motors and motion control products. We offer a full complement of stepand BLDC motors, motion control electronics and gearheads to serve a diverseindustrial and OEM customer base.

Applied’s standard “off-the-shelf” products most often can provide the solu-tion to your motor, motion control and gearing requirements. However, if yourapplication is unusual and/or demanding we will engineer a design to optimize yourproduct’s performance. Many times this results in increasing our customer’sproductivity and product reliability while reducing costs.

We believe the key to a successful business relationship is our commitmentto fully understanding the customer’s product and the operating environment inwhich it must function. This is achieved by working closely with both thecustomer’s engineering and manufacturing groups. In many cases we participatefrom initial concept to finished product providing needed motor and controlexpertise. Our engineering experience allows us to offer customers a valuableservice in the design of their products and selection of a motion control solution.

Applied Motion’s products are available nationwide through a professionalnetwork of highly trained sales representatives and local distributors. Productliterature, samples, technical assistance and off the shelf product delivery can beprovided by contacting your nearest sales representative or distributor. Please callApplied Motion Products at (800) 525-1609 or FAX (831) 761-6544 for the locationand phone number of the sales office nearest you or visit our website at:www.appliedmotionproducts.com

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STEPPER SYSTEMS pages 16 – 67Selection Guide ........................................................................... 17PDO 2035 ............................................................................ 18 – 26PDO 3540 ............................................................................ 28 – 36Si3540 ................................................................................. 38 – 46PDO 5580 ............................................................................ 48 – 56Si5580 ................................................................................. 58 – 66

SYSTEM SOFTWARE pages 6 – 15Introduction ................................................................................... 6Si Programming Screens .............................................................. 9Si Software Specifications .......................................................... 10Si Main Screen Features .............................................................. 11Si Program Instructions .............................................................. 12X Programming ........................................................................... 14X Drive Instructions .................................................................... 15

STEPPER DRIVES pages 68 – 103Introduction ................................................................................. 69Selection Guide ........................................................................... 70Drive Summary ........................................................................... 711030 .................................................................................... 72 – 731240i ................................................................................... 74 – 752035 .................................................................................... 76 – 772035 O ................................................................................. 78 – 792035XD ............................................................................... 80 – 813535 .................................................................................... 82 – 833535 O ................................................................................. 84 – 853540M ................................................................................. 86 – 873540MO .............................................................................. 88 – 893540i ................................................................................... 90 – 915560 .................................................................................... 92 – 937080 .................................................................................... 94 – 977080i ................................................................................. 98 – 1011035D.............................................................................. 102 – 103

STEPPER MOTORS pages 105 – 134Standard Design Features ......................................................... 106Step Tables & Wiring Diagrams ...................................... 107 – 109Holding Torque Measurement ................................................... 110Rating Conversion ..................................................................... 110Size HT11 ....................................................................... 111 & 126Size 14 ............................................................................ 112 & 126Size 17 ............................................................................ 113 & 127Size HT17 ............................................................. 114 – 115 & 128Size 23 .................................................................. 116 – 117 & 129Size HT23 ............................................................. 118 – 119 & 130Size 34 .................................................................. 120 – 121 & 131Size HT34 ................................................... 122 – 123 & 132 – 133Size 42 ....................................................................................... 124



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sALPHA SERVO MOTORS pages 181 – 203Part Numbering System ............................................................ 18328 mm Motors ................................................................ 184 – 18540 mm Motors ................................................................ 186 – 18960 mm Motors ................................................................ 190 – 19180 mm Motors ................................................................ 192 – 19340 mm Motors w/Optional Gearhead .............................. 194 – 197

Standard ................................................................... 194 – 195Metric ....................................................................... 196 – 197

60 mm Motors w/Optional Gearhead .............................. 198 – 199Standard ............................................................................. 198Metric ................................................................................. 199

80 mm Motors w/Optional Gearhead .............................. 200 – 201Standard ............................................................................. 200Metric ................................................................................. 201

Motor Connectors ..................................................................... 202Recommended Cables & Drawings ........................................... 203

OPEN FRAME SERVO AMPLIFIERSpages 157 – 179

BL7080x .......................................................................... 158 – 166Technical Specifications ..................................................... 159Technical Drawings ............................................................ 160Recommended Motors ............................................ 161 – 163Torque Curves .......................................................... 164 – 165Extension Cable Drawings .................................................. 166

BL7080i ........................................................................... 168 – 176Technical Specifications ..................................................... 169Technical Drawings ............................................................ 170Recommended Motors ............................................ 171 – 173Torque Curves .......................................................... 174 – 175Extension Cable Drawings .................................................. 176

Regeneration Clamp ........................................................ 178 – 179

SERVO SYSTEMS pages 135 – 155BLSi7080 ......................................................................... 136 – 145

Technical Specifications ..................................................... 137Technical Drawings ............................................................ 138Connectors ......................................................................... 139Recommended Motors ............................................ 140 – 142Torque Curves .................................................................... 143Extension Cable Drawings .................................................. 144Ordering Information ......................................................... 145

BLX7080.......................................................................... 146 – 155Technical Specifications ..................................................... 147Technical Drawings ............................................................ 148Connectors ......................................................................... 149Recommended Motors ............................................ 150 – 152Torque Curves .................................................................... 153Extension Cable Drawings .................................................. 154Ordering Information ......................................................... 155



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MOTOR CONTROLS pages 205 – 216Si-1 ................................................................................. 206 – 207Si-100 .............................................................................. 208 – 211

Technical Specifications ..................................................... 209Technical Drawings ............................................................ 210Connectors & Switches ...................................................... 211

SiNet™ Hub ..................................................................... 212 – 213SiNet™ Hub 444 .............................................................. 214 – 215MMI ........................................................................................... 216

POWER SUPPLIES pages 217 – 220PS430 ........................................................................................ 218PS1050 ...................................................................................... 219PS1070 ...................................................................................... 220

GLOSSARY pages 222 – 227

CONVERSION TABLES page 228Tabl

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SOFTWARE

6

Softw

are

Sect

ion Applied Motion Products produces three classes of step and servo drives with integrated

motion controller. Each class is available as a complete motion System or componentlevel open frame unit. A System includes drive/controller/power supply in a packaged

unit, matched motor, software and, for servos, cables. Open frame component drives consistof an integrated drive/controller and software. Matching motors and power supplies for openframe units are offered separately.

Drives with Integrated Motion Controller Classifications:• Drives with Si™ programming• Drives with X configurator• Drives with on board oscillator

Si™ Drives

Si™ controls provide two unique modes of operation, Si™ (simple indexing) and SCL (Si™Command Language). Both operating modes are supported by the standard Si™ product andare user selectable. Si™ and SCL were designed for very different control environments.

Intended for use in stand alone applications Si™ provides quick, out of the box use with anextremely friendly, point and click graphical interface that does not require any softwareprogramming experience.

SCL is used where a PC or PLC will supply motion instructions in real time (host mode). SCL isbest suited for experienced software developers.

Si™ Drives in Si™ Mode

Si™ (Simple Indexer) mode is used in applications requiring stand-alone operation in eithersingle or multi-axes environments. Programs are constructed then stored in the drive and canbe executed upon power up or upon a trigger signal. Programming is accomplished throughthe use of graphical motion commands selected in a point and click manner. Once aninstruction is selected, a “fill-in the blanks” format is used to input motor and motionparameters.

Constructing a Si™ program requires no prior programming experience nor does it requirelearning a programming language. Si™, based upon user input, generates the actual motionprogram, thereby eliminating syntax errors. Once completed, programs are easily stored,edited and recalled.

An optional operator interface (MMI) provides an easy to use, inexpensive method forinputting machine operating instructions like input of variables or, for more advancedoperations, functions like selecting a program branch and decision making. Si™ also providesthe capability to control digital inputs and outputs as well as their associated logic. Si™ easilyinterfaces with devices like PLCs in applications where additional I/O and/or different types ofcontrol are required. Si™ can be implemented by a wide variety of users with varying degreesof experience and in numerous applications. Si™ has found success in all types of applicationsfrom simple linear actuator movements to complete machine control requiring operator



SOFTWARE

7

inputs. Si™ software is available on both stepper and servo drives. Our servo version includesQuick Tuner™ software, which simplifies tuning and set-up, with features like a built insampling oscilloscope.

Multiple axis stand-alone applications are handled in Si™ by either the SiNet™ Hub or SiNet™Hub 444.

• The SiNet™ Hub provides the ability to control up to 8 Si™ drives, either stepper orservo from a single hub. Programs are constructed then stored in the SiNet™ Hub andcan be executed upon power up or upon a trigger signal. Not only can you coordinate upto eight motors, the hub also has access to all inputs and outputs of all the drivesconnected to it, providing your program with a potential of up to 64 inputs and 24outputs. You can also use an Applied Motion MMI with the hub, thus allowing themachine operator to enter specific motion parameters. The SiNet™ Hub can commandmotion to occur independently or simultaneously in absolute, incremental or “sensorseeking” modes. SiNet™ Hub programs can access up to 50 MMI variables.

• The SiNet™ Hub 444 controls up to four Si™ drives, either stepper or servo from asingle hub. It also includes four programmable inputs and four programmable outputs,in addition to the I/O of the drives. Programs are constructed then stored in the SiNet™Hub 444 and can be executed upon power up or upon a trigger signal. You can also usean Applied Motion MMI with the hub, thus allowing the machine operator to enterspecific motion parameters. The SiNet™ Hub 444 can command motion to occurindependently or simultaneously in absolute, incremental or “sensor seeking” modes.SiNet™ Hub 444 programs can access up to 50 MMI variables.

Si™ Drives in SCL Mode

SCL mode (Si™ Control Language) is used for applications requiring control of motion on areal time basis from a host PC or PLC. SCL allows the host computer to direct the drive toperform a variety of motion and I/O tasks while retrieving system status information. SCLrequires a high level of software programming experience and the ability to construct aprogram using ASCII characters over a serial port. SCL is a versatile and powerful tool for anexperienced system developer. The drive is connected directly to a PC or PLC’s serial port forsingle axis applications. In the SCL mode, as in Si™ mode, the user can address their multi-axis applications with either the SiNet™ Hub or SiNet™ Hub 444, up to 8 drives can beconnected to a host’s serial port through one Hub.

In SCL mode, the Hub functions as a router relaying SCL commands to the appropriate driveor drives. This permits real time control from a host PC or PLC for up to 8 axes from a singleserial port. You can also use an Applied Motion MMI, which allows the machine operator toenter specific motion commands. Both Hub products can move motors independently orsimultaneously in absolute, incremental or “sensor seeking” modes. All Hub programs canaccess up to 50 MMI variables.



SOFTWARE

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X Drives

X drives can be selected to operate in the following modes:• Step and direction/pulse input, receiving pulses from a separate stand alone controller or

master encoder.• Oscillator/velocity drive, using an on board pulse generator• Indexing drive, in conjunction with the eXposition configuration software

The eXposition configuration software is used to program the drive’s six digital inputs. Eachinput can be configured to perform one of four functions: Move, Pulse or Quadrature, Move toSensor or Run/Stop.

Indexing ability of the X drives provides a level of functionality that was previously limited tofull scale controllers. For a number of applications, in industries like packaging, materialhandling and labeling, the X drive will provide all the position control needed. All X drives comewith eXposition configuration software. Servo X drives also come with our Quick Tuner™ servotuning software.

O Drives

O drives, which are designated by an “O” in a part number, include an on-board pulsegenerator (oscillator). The oscillator makes these drives capable of “on/off” motion initiated byexternal trigger and can be used for velocity control or “basic” position control (based on on/off time intervals). On board potentiometers control accel/decel ramps. The O drives providefor motor control where the most basic motion function is required.

Summary of Drives by Control Type

Si™ TypeStepper DrivesPackaged Open FrameSi3540 1240iSi5580 3540i

7080iServo DrivesPackaged Open FrameBLSi7080 BL7080i

X TypeStepper DrivesPackaged Open Frame

2035XDServo DrivesPackaged Open FrameBLX7080 BL7080X

O TypeStepper DrivesPackaged Open FramePDO2035 2035OPDO3540 3535OPDO5580 3540MO



SOFTWARE

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Si Programming Screens



SOFTWARE

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Si P

rogr

amm

ing INDEXER PROGRAMMING:

Programmable by RS-232 connection toIBM compatible PC running Windows 95,98, 2000, NT, XP or ME. Programming soft-ware and cable included. Programming isvery easy to learn and requires no previousprogramming experience.

Programs can be up to 100 lines long.Instructions are powerful, so 100 lines canprovide the user with a sophisticated pro-gram. For example, in one program line themotor can be moved until a sensor changesstate, then fed a precise distance to a stop,delayed and returned to the starting point.Distances, delays, feed and return speeds,acceleration and deceleration parameters areall included in the single program line. Thesame move can take 10 program lines ormore on other indexers.

There are a total of 20 different instruc-tions, including input/output, branches,loops and motion commands. These in-structions can be combined to make anearly infinite variety of programs, meetingthe demands of a wide range of applications.

As you compose your program, you cantest it by downloading to a drive and execut-ing. A sophisticated control panel allows youto observe the status input and output ter-

Si Software Specifications

minals in real time, highlights the instructionthat’s executing, and allows you to pauseand single step the program.

You can even emulate the optional ManMachine Interface on-screen. This allowsyou to try out the MMI before buying one,and eliminates the need to swap cables be-tween the PC and MMI while you’re testingyour program.

You can also write programs without adrive connected to your PC and save themto your hard disk.

Once programmed, the cable can be re-moved and the indexer-drive will run standalone. Programs and parameters are storedinternally in nonvolatile memory. Uponpower up, the drive automatically senses theconnection to the Windows programmingsoftware. If no connection is detected, theprogram is automatically executed startingon line 1.

All Si products support an optionalNEMA 4X operator interface (MMI) that al-lows the operator to enter variables such asspeeds, distances and repeat counts. TheMMI attaches to the RS-232 programmingport, leaving all inputs and outputs free.

Typical Dialog Box(for MMI prompt instructions)

Main Programming Screen



SOFTWARE

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Features of the Main Programming Screen

Features of the Program Control Panel

Microstep resolution2000-50800 steps/rev

Motor Current& Idle Current

Jog Input Settings(speed, accel rate)

Jog inputs can be assigned to other uses

CommunicationPort Setting

Limit Switch Options: normally open, normally closed, or not used & available for other uses

user defined units(inches, mm, degrees, etc)

Program WindowIndexer-Drive Type

Button to accesssupport information

Indexer-DriveFirmware Level

Indexer-Drive Control Buttons

Virtual MMI

Program Control

Status of Inputs

Status of Outputs



SOFTWARE

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Feed to LengthA point to point move. Parameters are dis-tance, direction, speed, accel and decel.Can also change speeds at a specified dis-tance within the move.

Feed & ReturnA point to point move that returns to thestarting point after specified delay. Param-eters include distance, feed speed, returnspeed, direction, accel, decel, and return de-lay time.

Feed to PositionA move to an absolute position. Parametersare position, speed, accel and decel.

Feed & Set OutputA point to point move. An output terminalcan be turned on or off during the move, orcan be turned on, off or pulsed at the end ofthe move.

Feed to SensorMoves the motor until an input (to which asensor is connected) changes state, thenstops at a specified distance beyond thesensor. Useful for applications like dispens-ing labels or moving objects on a conveyer.A safety distance can be given; if the motormoves beyond that distance without reach-ing the sensor, the motor stops and the pro-gram branches to a specified line.

Feed to Sensor & ReturnSame as Feed to Sensor, but returns to theoriginal starting point. Additional parametersare return speed and return delay time.

Set Abs PositionAssign a value, such as 0 inches, or 10 mm,to the present motor position.

Save Abs PositionStores the present absolute position to anMMI variable so that it can be “learned”and returned to later by a feed to positioninstruction.

Si Program Instructions



SOFTWARE

13

Seek HomePositions the motor at a home sensor (wiredto one of the general purpose inputs)“bouncing off” the limits if necessary.

Wait TimeDelays a specified amount of time. Range is.01 to 300 seconds. Adding a loop aroundthis instruction can extend the delay time toas much as 18 hours.

Wait InputPauses the program until an input, or set ofinputs, reaches a given condition. The joginputs are functional during this instruction.The Wait Input instruction can also display aprompt on the optional MMI and pause untilthe operator presses the ENTER key.

Hand WheelAllows the operator to precisely position themotor and load using an optional CNC handwheel.

MMI PromptDisplays a prompt on the optional man-ma-chine interface (MMI) panel and accepts aparameter from the operator. This param-eter is saved in nonvolatile memory and canbe used as a move speed, move distance orrepeat loop count. Speeds and distancescan be entered in user defined units such asinches or gallons. The MMI Prompt instruc-tion also allows the operator to choose asub program from a menu of up to 8 subprograms.

Go ToForces program to jump to a specific in-struction. At the least, you’ll need one ofthese at the end of your program to returnexecution to the beginning.

If InputCauses the program to branch to a givenline number if an input, or set of inputs,meets a specified condition. The If Input in-struction can also display a prompt on theoptional MMI and branch if the operatorpresses the YES key.

Set OutputSet a given output to a high or low voltagestate, or can emit a high or low pulse of 2 to500 milliseconds. This instruction is usefulfor triggering other motor controllers, relaysor cut-off knives. It can also be used to sig-nal events to another indexer or PLC.

CommentAllows the user to document the program byadding comments. Comments stay with theprogram even when downloaded to the drive.

RepeatThe beginning of a loop. Repeat a block ofinstructions a fixed number of times (up to65,535 times). Loops can be extended bynesting loops around each other (two nestedloops allow you to repeat the instructionswithin them more than 4 billion times).

End RepeatMarks the end of a repeat loop. The pro-gramming software matches these up foryou automatically. You don’t have to specifya line number. Connections are showngraphically on the screen.

Reset Repeat LoopResets a repeat loop counter to 0. Usefulfor resetting a loop that has been prema-turely terminated by an If Input instruction.

Change CurrentAllows the program to turn off the motorcurrent, resume the previous current level,or change the current setting anytime.

Si Program Instructions



SOFTWARE

14

X Pr

ogra

mm

ing The X Drive technology is a cross between a step and direction

drive, oscillator/velocity control drive and an indexing drive.The X drives have four digital inputs and one analog input. A

separate function can be assigned to each input by our easy-to-useWindows-based set up software. Input functions include step pulse,direction signal, run/stop (jogging) and triggering of point-to-pointand sensor-seeking moves. Speed and acceleration are independentlyprogrammable for each input. The speed can even be set according tothe voltage on the analog input. In pulse mode, a scaling feature al-lows the resolution of the command pulses to differ from the actualencoder resolution. You might, for example, want to command thedrive at 3600 steps/rev even though the encoder provides 8000counts/rev.

The X drives also have a single output that can provide an in posi-tion or in motion signal to other devices.



SOFTWARE

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X Drive Program Instructions

The Feed to Sensor function moves the motoruntil a sensor detects an object. Its great fordispensing labels and moving objects into po-sition on a conveyor. The Feed to Sensor dia-log includes adjustable speed, acceleration,distance beyond sensor and direction. You canalso decide the trigger and sensor conditions.

The Pulse function lets you control the XDrive from a pulse source, such as a PLC,motion controller, or master encoder. Youchoose the step resolution and the direction.Direction can be clockwise, counter-clock-wise or an external signal applied to the DIRinput. Input signals can be Pulse & Direction,CW Pulse/CCW Pulse or AB quadrature.

The Run/Stop function allows you to com-mand a motor to start and stop with a digitalsignal. The X Drive can be configured forone preset speed, or up to 8 speeds selectedby the digital inputs. The speed can even bedetermined, on the fly, by the voltage on theanalog input. Anytime you start, stop orchange speeds, the X Drive smoothly rampsup or down according to the acceleration rateyou’ve chosen. A Run/Stop move can alsorun for a preset amount of time, then stop.

The main screen lets you assign a functionto each input. You then proceed to an indi-vidual dialog for each function. That wayyou focus on only the parameters that arerelevant to your application.

For a Feed to Length (point to point) move,you can set the distance, direction, speedand acceleration. Built-in analytical toolsprovide you with information such as howlong a move takes and what the velocity pro-file looks like. You also specify how themove is triggered.



STEPPERSYSTEMS

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PACKAGED STEPPER SYSTEMS SELECTION GUIDE

FEATURES PDO2035 PDO3540 Si3540 PDO5580 Si5580

Motor Current (A/phase) 0.125–2.0 0.2–3.5 0.4–3.5 0.5–5.5 0.5–5.5

Input Voltage 110/220 AC 110/220 AC 110/220 AC 110/220 AC 110/220 AC

Steps/revolution 200–400 200–50,800 2,000–50,800 200–50,800 2,000–50,800

Maximum Output Power (W) 70 140 140 440 440

Overall Size (inches) 1.75 x 4.00 x 6.80 2.25 x 7.80 x 5.40 2.25 x 7.80 x 5.40 3.00 x 5.30 x 8.00 3.00 x 5.30 x 8.00

Typical NEMA Motor Size 11, 14, 17, 23 11, 14, 17, 23 11, 14, 17, 23 23, 34 23, 34

Built-in Power Supply • • • • •

Screw Terminal Connectors • • • • •

Pluggable Connectors • • • • •

Built-in Oscillator • • •

Oscillator Speed Range 10–12,000 Hz 0–25 rps N/A 0–25 rps N/A

Analog Input/Remote Speed Pot • • •

Bipolar Chopper (20–30 kHz) • • • • •

Idle Current Reduction • • • • •

Short Circuit Protection • •

Thermal Protection • • • • •

Fault Indicator (LED) • •

Fault Output (Signal) • •

Made in USA • • • • •

CE & TUV • • • •

Integral Indexer • •

Programmable Inputs/Outputs 8/3 8/3

Enable Input • • •

Catalog Page # 18 28 38 48 58

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STEPPERSYSTEMS

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PDO

2035

Ste

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illat

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PDO 2035 Packaged Pulse and Direction Step Motor Drivewith Digital Oscillator

Features

• AC input 110V or 220V switch selectable,50-60 Hz

• DC bus voltage 28 VDC full load, 35 VDC nominal• Switch selectable motor current from 0.125–2.0

amps/phase• Full and half step switch selectable• Automatic 50% idle current reduction, defeatable• Optically isolated inputs/outputs

• Speed, Direction, Enable: optically isolated,5–24 V logic

• Tach output isolated: Darlington phototransistorOne pulse per motor step

• Internal Pot• Speed 10–1,200 steps/sec/sec or 100–12,000

(switch selectable)• Accel/decel 750–200K steps/sec/sec

• External Speed Pot terminal type, 1k–10k ohms• 70 watts of usable power• Pluggable screw terminal connectors• Dual H-bridge, pulse width modulated amplifier

switching at 20–30 KHz• Ideal for 4, 6 or 8 leaded step motors NEMA sizes

11, 14, 17 and 23

Description

The PDO2035 is stepper drive packaged in a rug-ged steel case painted black with white epoxy silkscreen. Integral heat sink, mounting brackets,switch covers and connectors are included witheach drive. The drive has been matched with ninerecommended NEMA 11, 14, 17 & 23 motors in or-der to create a complete stepper motion solution.

The PDO2035 provides the user with two modes ofoperation to choose from, Pulse & Direction or Os-cillator. The specific operation mode desired is se-lected during set up via DIP switch. DIP switchesare also provided for setting the drive’s step reso-lution as well as the motor current.

Pulse & Direction Mode allows the PDO2035 to re-ceive step pulses from an indexer such as the Ap-plied Motion’s Si-100 or Si-1 or from a PLC or anyother external controller.

Oscillator Mode can control speed by an onboard

potentiometer and/or by an external analog volt-age. STEP input starts and stops the motor. DIR in-put controls direction of rotation.

The PDO2035 also provides a Tach Output and En-able Input.

A Tach Out signal is provided for measuring themotor speed. It generates 1 pulse per motor step.

ENABLE allows the user to turn off the current witha signal. The logic circuitry continues to operate,the drive “remembers” the step position even whenthe amplifier is disabled.

Factory set to operate at 110 volt input; thePDO2035 can be reset by the user to operate at 220volt input by a simple switch selection.

Pluggable screw terminal blocks are provided forthe motor, AC input as well as a 4 and 5 positionsignal input/output. Mating connectors are pro-vided with the drive.



STEPPERSYSTEMS

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POWER AMPLIFIER:

AMPLIFIER TYPE ....................................... Bipolar Darlington dual H-Bridge.CURRENT CONTROL .................................. Recirculating, pulse width modulated, switching at 20–30 KHz.OUTPUT CURRENT .................................... 0.125–2.0 amps, dip switch selectable.DC BUS VOLTAGE ...................................... 35 VDC.AC INPUT VOLTAGE ................................... 110 or 220 VAC (switch selectable) 50/60 Hz.MAXIMUM OUTPUT POWER ..................... 70 Watts.IDLE CURRENT REDUCTION...................... Automatic 50% idle current reduction, defeatable.MOTOR RESOLUTION ................................ Full or half step switch selectableSTATUS LED’S ............................................ AC power (red).

CONTROLLER SECTION:

DIGITAL OSCILLATOR ................................ Precise speed control with automatic ramps between speeds. Theaccel/decel rates are set by an on board potentiometer, and are ad-justable from 10 to 12,000 steps/sec/sec.

SPEED SETTINGS AND RANGE .................. On-Board: Speed potentiometer. High speed: 100–12,000 steps/sec/sec. Low speed: 10–1,200 steps/sec/sec.External: External potentiometer capable.

MODES OF OPERATION ............................. Two modes dip switch selectable:Pulse and Direction: works with pulse and direction controllersOscillator: on-board potentiometers and/or an external 0–5 V ana-log voltage, control speed.

STEP AND DIRECTION INPUTS ................. Optically isolated: 5–24 VDC. Steps requires a 10 microsecondminimum pulse width. The direction signal setup time is 50 micro-second minimum.

SYSTEM SPECIFICATIONS:

OVERALL SIZE ........................................... 1.75˝ x 4.00˝ x 6.80˝.CHASSIS MATERIAL .................................. Aluminum, black anodized with integral heat sink.CASE .......................................................... Steel with black paint and white epoxy silk screen. Includes switch

covers.WEIGHT ...................................................... 3 lbs.AMBIENT TEMPERATURE .......................... 0˚ to 50˚C (32˚ to 122˚F).HUMIDITY .................................................. Maximum of 90% non-condensing.CONNECTORS ............................................ Screw terminal connectors for input power and motor, and input/

output signals.MOTORS .................................................... Can drive 4, 6 or 8 lead motors, NEMA sizes 11– 23.

PDO 2035 Technical Specifications



STEPPERSYSTEMS

20

connectorenable, direction, step

dip switchesfull/half stepcurrent setting

power LED

motor connector

AC power connector

PDO 2035 Connectors and Switches

INPUTS (4 pin)

position no.1 en2 dir3 com4 step

MOTOR

position no.1 B–2 B+3 A–4 B+

AC POWER

position no.1 G2 N3 L

connectorexterior speed

trimpotsspeed, accel, decel

dip switchesoscillator set up

INPUTS (5 pin)

position no.1 tach–2 tach+3 wpr4 ccw5 cw



STEPPERSYSTEMS

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A+A–B+B–

step

direction

110/220

enable

tachout

OpticalIsolators

external speed pot

common

StepSequencer

Oscillator

current setting

full step/half step

step

dir

acceldecel

speed adj

tomotor

PowerSupplyVAC

Amplifier

oscoptions

1

12

3

23

45

PDO 2035 Technical Drawings

BLOCK DIAGRAM

MECHANICAL OUTLINE

DIREN

COMSTEP

TACH+TACH-

WPRCCW

CW

12

3

12

34

5

PDO 2035Step Motor Driver

POWER

HALFSTEP

B–B+

A–A+

GND

N

L

HILOBYPASS

INTEXT FULLSTEP

SPEED

DECEL

ACCEL

MO

TOR

AC

PO

WER

1000500250125

CURR

ENT

(BAS

E =

125m

A)

6.80"

.245"

4.00"

.273"1.75"

.19"

6.00"



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NEMA 11, 14, 17 Motor Data

NEMA 11, 14, 17 Motor Dimensions

RECOMMENDED MOTORS FOR PDO 2035

FEATURES 11 11 14 17 17 17

Motor P/N: 11012 11013 14842 17068 17071 17075

Motor Current amps 1.00 1.00 1.00 1.34 1.70 1.70

Resistance Ohms 1.40 2.00 4.30 2.10 1.70 1.70

Holding Torque oz-in 7.4 15.3 26 31.4 51 62.6

Rotor Inertia oz-in2 0.044 0.098 0.109 0.19 0.29 0.37

Bearings

Thrust Load (lbs) 3.0 3.0 3.0 3.0 3.0 3.0

Radial Load (lbs) 5.0 5.0 5.0 5.0 5.0 5.0

Radial Play inch/lbs .001 max .001 max .0004 max .0008 max .0008 max .0008 max@ 1 lb @ 1 lb @ 1 lb @ 1 lb @ 1 lb @ 1 lb

End Play inch/lbs .003 max .003 max .0004 max .003 max .003 max .003 max@ 2 lbs @ 2 lbs @ 2 lbs @ 2.2 lbs @ 2.2 lbs @ 2.2 lbs

Weight lbs. 0.26 0.39 0.47 0.44 0.57 0.73

Motor current, resistance and torque ratings are with parallel connection

NEMA 17Model L17068 1.30˝17071 1.54˝17075 1.85˝

12" min 4 X #4 – 40.17 DEEP

2 X 1.220

2 X 1.65Ø.866 +.000

–.001

L.59 .080

.59 ± .01

Ø.1968

.79±.02

+.0000–.0004

FLAT.177±.006

.177±.006FLAT

TYP

NEMA 14Model L14842 1.57˝

12" min

2 X 1.024

2 X 1.38

2 X #4 – 40

Ø.866+.000–.001

L

.059

Ø.1968 +.0000–.0004

.559 ± .014

.39

2 X .25

TYP

4 X M2.6 X .45.118 MIN

7.9" MIN

2 X .906 ± .018

Ø.866+0–.001

L

.06 ± .008

Ø.1968.02 X 45˚

+0–.0005

.787 ± .02

.394 ± .04 2 X 1.10 ± .012

NEMA 11Model L11012 1.32˝11013 1.87˝



STEPPERSYSTEMS

23

Torque CurvesPDO 2035 with NEMA 11, 14, 17 Step Motors

17075 MOTORMotor Connection: ParallelDrive Setting: Full, Half Step • 1.7 A/Phase

DynamicTorque(oz-in)

rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

FullHalf



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

FullHalf



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

FullHalf

11012 MOTORMotor Connection: 4 Lead BipolarDrive Setting: Full, Half Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5

10

FullHalf

11013 MOTORMotor Connection: 4 Lead BipolarDrive Setting: Full, Half Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

15

FullHalf



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

FullHalf



STEPPERSYSTEMS

24

NEMA 23 Motor Data

NEMA 23 Motor Dimensions

FEATURES RECOMMENDED MOTORS FOR PDO 2035

Motor P/N: 23394 23397 23400

Motor Current amps 2.83 2.83 2.83

Resistance Ohms 0.07 0.90 1.10

Holding Torque oz-in 77 177 264

Rotor Inertia oz-in2 0.66 1.64 2.62

Bearings

Thrust Load (lbs) 25 25 25

Radial Load (lbs) 15 15 15

Radial Play inch/lbs .001 max .001 max .001 max@ 1 lb @ 1 lb @ 1 lb

End Play inch/lbs .003 max .003 max .003 max@ 2.2 lbs @ 2.2 lbs @ 2.2 lbs

Weight lbs. 1.00 1.54 2.20


Model L23393 1.54˝23396 2.13˝23399 2.99˝

18.00 MIN

2 X 1.856

2 X 0.928

0.228 ± 0.006FLAT

Ø1.50 ± 0.0014 X Ø0.205 ± 0.01

2 X 2.22

+0.000–0.001

.59± 0.01

L .197.063 ± 0.008

.591 ± 0.01

Ø.250

0.630 ± .039 .787 ± .020

.228 ±.006FLAT

2 X 1.11

MOUNTINGEND

TYP



STEPPERSYSTEMS

25

Torque CurvesPDO 2035 with NEMA 23 Step Motors



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

FullHalf



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

100

FullHalf



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

FullHalf



STEPPERSYSTEMS

26

PDO

2035

Ord

erin

g In

form

atio

n

DRIVE ONLY ORDERING

Drive Type Description

PDO 2035 Packaged 2.0 amps, 35 VDC, 110/220 VAC input.Pulse & direction/oscillator drive.

System Ordering Example: PDO 2035 - 17068

COMPLETE SYSTEM ORDERING

Drive Type Motor System Number Step Motor Description

PDO 2035 11012 NEMA 11 high torque one stack

11013 NEMA 11 high torque two stack

14842 NEMA 14 two stack

17068 NEMA 17 high torque one stack


17075 NEMA 17 high torque three stack






STEPPERSYSTEMS

27



STEPPERSYSTEMS

28

PDO

3540

Ste

pper

Driv

e w

ith D

igita

l Osc

illat

or

PDO 3540 Packaged Pulse and Direction Step Motor Drivewih Digital OscillatorFeatures

• AC input 110V or 220V switch selectable, 50-60 Hz• DC bus voltage 35 VDC full load, 40 VDC nominal• Switch selectable motor current from 0.4–3.5

amps/phase• Microstepping:

• Pulse and Direction mode: switch selectable 200to 50,800 steps/rev

• Oscillator/Joystick mode: 12,800 steps/rev• Switch selectable idle current reduction, 0 or 50%• Optically isolated inputs/outputs

• Speed, Enable: optically isolated, differential 5 –24 V logic

• Step, Direction: optically isolated, differential 5 –12 V logic

• Wiper: 0–5 VDC analog signal• Tach output: isolated phototransistor. Tach out-

put is 100 pulses per motor revolution, 50%duty cycle.

• Internal Pot:• Low speed 0–5 rps• High speed 0–25 rps• Accel/decel 1–250 rev/sec/sec

• External Speed, Pot or Joystick 3 terminal type, 1k–10k ohms

• Self test, switch selectable• 140 watts of usable power• Screw terminal connectors• Dual, MOSFET H-bridge, 3 state, pulse width modu-

lated amplifier switching at 20–30 KHz• Ideal for 4, 6 or 8 leaded step motors NEMA sizes

11, 14, 17 and 23• CE and TUV compliant

Description

The PDO 3540 is a stepper drive packaged in a ruggedsteel case painted black with white epoxy silkscreen.Integral heat sink, mounting brackets, switch coversand connectors are included with each drive. Thedrive has been matched with twelve recommendedNEMA 11, 14, 17 & 23 motors in order to create acomplete stepper motion solution.

The PDO 3540 provides the user with four modes ofoperation to choose from, Self test, Pulse & Direction,Joystick or Oscillator. The specific operation mode de-sired is selected during set up via DIP switch. DIPswitches are also provided for setting the drive’s stepresolution as well as the motor current.

Self Test Mode is used for troubleshooting. If you areunsure about the motor or signal connections to thedrive you can use the self-test.

Pulse & Direction Mode allows the PDO 3540 to re-ceive step pulses from an indexer such as the AppliedMotion’s Si-100 or Si-1 or from a PLC or any otherexternal controller.

Joystick Mode allows speed and direction to be deter-mined by an external analog voltage. STEP and DIRinputs can be used for limit switches. SPEED inputselects speed range. LO SPEED and HI SPEED potsadjust the 2 speed ranges.

Oscillator Mode can control speed by onboard poten-tiometers and/or by an external analog voltage. STEPinput starts and stops the motor. DIR input controlsdirection of rotation. SPEED input selects the speedrange.

The PDO 3540 also provides a Tach Output and En-able Input.

A Tach Out signal is provided for measuring the mo-tor speed. It generates 100 pulses per revolution. Ifconnected to a frequency counter, speed reads out inrevs/second with two decimal places.

ENABLE allows the user to turn off the current to themotor by setting this signal to logic 0. The logic circuitrycontinues to operate, the drive “remembers” the stepposition even when the amplifier is disabled.

Factory set to operate at 110-volt input; the PDO 3540can be reset by the user to operate at 220-volt inputby a simple switch selection.

Pluggable screw terminal blocks are provided for themotor, AC input and 8-position signal input/output.Mating connectors are provided with the drive.

The PDO 3540 is both CE and TUV compliant.



STEPPERSYSTEMS

29

POWER AMPLIFIER:

AMPLIFIER TYPE ....................................... MOSFET, dual H-Bridge.CURRENT CONTROL .................................. 3 state, pulse width modulated, switching at 20–30 KHz.OUTPUT CURRENT .................................... 0.4–3.5 amps, dip switch selectable in 0.1 increments.POWER SUPPLY ........................................ Linear, toroidal transformer based for high reliability and low

noise. 110 or 220 VAC input, switch selectable. 50/60 Hz.DC BUS VOLTAGE ...................................... DC voltage at nominal line voltage: 35 VDC full load, 40 VDC no

load.AC INPUT VOLTAGE ................................... 110 or 220 VAC (switch selectable) 50/60 Hz.MAXIMUM OUTPUT POWER ..................... 140 Watts.IDLE CURRENT REDUCTION...................... 0% or 50% dip switch selectable.MOTOR RESOLUTION ................................ 16 resolutions. 200, 400, 1000, 2000, 5000, 10000, 12800,

18000, 20000, 21600, 25000, 25400, 25600, 36000, 50000,50800.

CONTROLLER SECTION:

MODE OF OPERATION ............................... Self Test: Used for trouble shooting to test motor and/or signalconnections.Pulse & Direction: Allows amplifier to receive step pulses from acontroller such as Applied’s Si-100 or Si-1, or any other pulsesource PLC or controller.Joystick: allows speed and direction to be determined by an exter-nal analog voltage. Step and Dir inputs can be used for limitswitches. Speed input selects speed range. LO SPEED and HISPEED pots adjust the 2 speed ranges.Digital Oscillator: allows for precise speed control with automaticramps between speeds. Accel/Decel rates are set by on board po-tentiometer and/or external analog voltage.

STEP AND DIRECTION INPUT .................... Optically isolated: 5-12 VDCSPEED RANGE ........................................... LO speed range: 0-5 rev/sec.

HIGH speed range: 0-25 rev/secAccel/decel range: 1-250 rev/sec/sec

TACH OUPUT .............................................. Optically isolated phototransistor. 30 VDC, 20mA max.


OVERALL SIZE ........................................... 2.25˝ x 7.8˝ x 5.40˝.CHASSIS MATERIAL .................................. Aluminum, black anodized with integral heat sink.CASE .......................................................... Steel with black paint and white epoxy silk screen. Includes switch

covers.WEIGHT ...................................................... 5 lbs.AMBIENT TEMPERATURE .......................... 0˚ to 50˚C (32˚ to 122˚F).HUMIDITY .................................................. Maximum of 90% non-condensing.CONNECTORS ............................................ Screw terminal connectors for input power and motor, and input/

output signals.MOTORS .................................................... Can drive 4, 6 or 8 lead motors, NEMA sizes 11– 23.AGENCY APPROVAL .................................. CE & TUV.




STEPPERSYSTEMS

30

BLOCK DIAGRAM

PDO 3540 Technical Drawingsm

otor phase Am

otor phase B

EXTSPEEDINPUT

current0.4 to 3.5A/phase

ext speedjoystick

50% idle

accelLOspeed

HIspeed

MicrostepSequencer

Digital Oscillator&

Joystick Interface

110 or220 VAC

InternalPowerSupply

power LED

MOSFET3 StatePWM Power

Amplifier

DIRECTION

HI/LO SPEEDENABLE

TACH

STEP

OpticalIsolation

fuse

steps/revosc bypass

self test

MECHANICAL OUTLINE

7.80"

2.25"1.125" 0.750" 0.750"

5.00"5.40"

0.200" (x6)

0.200"(x6)

12

34

56

12

34

56

78

MOT

OR

A+A-B+B-PD

O 35

40St

ep M

otor

Driv

er

50% IDLE

JOYSTICK

OSC BYPASS

STEPS/REV

SELF TEST

ACCEL

EXT SPEED

0.10.20.40.81.6CU

RREN

T

HIGH SPEED

LOW SPEED

(BAS

E =

0.4

A)

POWER

DIR+DIR–

STEP+STEP–

EN+EN–

SPEED+SPEED-TACH+TACH–

CWWPRCCW

AC P

OWER



STEPPERSYSTEMS

31

connectorinput/output

dip switchescurrent/resolution/joystick/external speed

power LEDpotentiometersoscillator speed, accel & decel

motor connector

AC power connector


INPUTS (13 pin)

position no.1 dir+2 dir–3 step+4 step–5 en+6 en–7 speed+8 speed–9 tach+10 tach–11 cw12 wpr13 ccw

MOTOR


AC POWER




STEPPERSYSTEMS

32



RECOMMENDED MOTORS FOR PDO 3540

FEATURES 11 11 14 17 17 17

Motor P/N: 11012 11013 14842 17068 17071 17075


Resistance Ohms 1.40 2.00 4.30 2.10 1.70 1.70



Bearings

Thrust Load (lbs) 3.0 3.0 3.0 3.0 3.0 3.0

Radial Load (lbs) 5.0 5.0 5.0 5.0 5.0 5.0



Weight lbs. 0.26 0.39 0.47 0.44 0.57 0.73


NEMA 17Model L17068 1.30˝17071 1.54˝17075 1.85˝

12" min 4 X #4 – 40.17 DEEP

2 X 1.220

2 X 1.65Ø.866 +.000

–.001

L.59 .080

.59 ± .01

Ø.1968

.79±.02

+.0000–.0004

FLAT.177±.006

.177±.006FLAT

TYP


12" min

2 X 1.024

2 X 1.38

2 X #4 – 40

Ø.866+.000–.001

L

.059

Ø.1968 +.0000–.0004

.559 ± .014

.39

2 X .25

TYP

4 X M2.6 X .45.118 MIN

7.9" MIN

2 X .906 ± .018

Ø.866+0–.001

L

.06 ± .008

Ø.1968.02 X 45˚

+0–.0005

.787 ± .02

.394 ± .04 2 X 1.10 ± .012

NEMA 11Model L11012 1.32˝11013 1.87˝



STEPPERSYSTEMS

33

Torque CurvesPDO 3540 with NEMA 11, 14, 17 Step Motors

14842 MOTORMotor Connection: ParallelDrive Setting: Full, 1/10th Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

Full1/10th

11012 MOTORMotor Connection: 4 Lead BipolarDrive Setting: Full, 1/10th Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

2

4

6

8

10

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

15

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

Full1/10th



STEPPERSYSTEMS

34

NEMA 23 Motor Data



Motor P/N: 23122 23123 23124 23394 23397 23400


Resistance Ohms 1.24 1.18 0.82 .070 0.90 1.10

Holding Torque oz-in 98 158 225 77 177 264


Bearings

Thrust Load (lbs) 25 25 25 25 25 25

Radial Load (lbs) 15 15 15 15 15 15



Weight lbs. 1.17 2.00 2.80 1.00 1.54 2.20


Model L23394 1.54˝23397 2.13˝23400 2.99˝

Model L23122 2.00˝23123 3.00˝23124 4.00˝

.75.81 ± .03

L.190

.060

18" min

2 x Ø.2500 +.0000–.0005

Ø1.5 ± .002

2 X 2.222 X 1.856

4 X Ø.205 ± .01

MOUNTINGEND

18.00 MIN

2 X 1.856

2 X 0.928

0.228 ± 0.006FLAT

Ø1.50 ± 0.0014 X Ø0.205 ± 0.01

2 X 2.22

+0.000–0.001

.59± 0.01

L .197.063 ± 0.008

.591 ± 0.01

Ø.250

0.630 ± .039 .787 ± .020

.228 ±.006FLAT

2 X 1.11

MOUNTINGEND

TYP



STEPPERSYSTEMS

35




rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

250

Full1/10th



STEPPERSYSTEMS

36

DRIVE ONLY ORDERING


PDO 3540 Packaged 3.5 amps, 40 VDC, 110/220 VAC input.Microstepping pulse & direction/oscillator drive.

Si3540 Packaged 3.5 amps, 40 VDC, 110/220 VAC input.Microstepping fully programmable drive/indexer with Si™ software.


PDO

3540

Ord

erin

g In

form

atio

n




Si3540 11013 NEMA 11 high torque two stack





23122 NEMA 23 one stack


23124 NEMA 23 three stack






STEPPERSYSTEMS

37



STEPPERSYSTEMS

38

Si35

40 P

rogr

amm

able

Ste

p M

otor

Driv

e

Features

• Si™, Si Command Language (SCL) or SiNet Hub pro-gramming languages included with drive

• AC input 110 V or 220 V switch selectable, 50-60 Hz• DC bus voltage 35 VDC full load, 40 VDC nominal• Software selectable motor current from 0.2 – 3.5

amps/phase• Software selectable motor resolution from 2,000 to

50,800 steps per revolution• Software selectable idle current reduction 0, 25%,

50% or 100%• Eight optically isolated programmable inputs 5 – 24

VDC. 2,200 ohms internal resistance. Can be config-ured for sinking (NPN) or sourcing (PNP) signals.

• Three optically isolated programmable outputs 12 –24 VDC, 100mA maximum

• RS-232 for PC/MMI communications• 140 watts of usable power• Screw terminal connectors• Dual, MOSFET H-bridge, 3 state, pulse width modu-

lated amplifier switching at 20 – 30 KHz• Ideal for 4, 6 or 8 leaded step motors NEMA sizes 11,

14, 17 and 23• Optional Man Machine Interface (MMI) allows ma-

chine operator to enter specific motion parameters• CE and TUV compliant

Description

The Si3540 is a programmable stepper drive/indexerpackaged in a rugged steel case painted black with whiteepoxy silkscreen. Integral heat sink, mounting brackets,switch covers and connectors are included with eachSi3540. The drive/indexer has been matched with twelverecommended NEMA 11, 14, 17 & 23 motors and comes

with all operating software necessary to create a com-plete stepper motion solution.

The Si3540 includes Applied Motion Products’, Win-dows based, Si™ software language for quick set upand ease of use. The Si™ is ideal for stand-alone opera-tion. For more experienced users, with software devel-opment expertise, the Si3540 also comes withApplied’s Si™ Command Language (SCL) program-ming instruction set. SCL allows for control of the Si™drive from a host PC or PLC thus permitting the user toperform a variety of motion, I/O tasks and system sta-tus retrieval via the host.

Multiple axis applications are handled by our SiNet™Hub Programmer, which gives you the ability to controlup to 8 Si™ drives, either stepper or servo on the samehub. Not only can you coordinate up to eight motors, thehub also has access to the inputs and outputs of all thedrives, providing your program with up to 64 inputs and24 outputs. You can also use Applied’s MMI to interfacethe drives with the machine operator.

Factory set to operate at 110-volt input; the Si3540 canbe set by the user to operate at 220-volt input by asimple switch selection.

Pluggable screw terminal blocks are provided for the I/O, motor and AC power input. Mating connectors, pro-gramming cable with computer interface connector aswell as all operating software are provided with each Si™drive.

The Si3540 is both CE and TUV compliant.

Si3540 Programmable Step Motor Drive



STEPPERSYSTEMS

39

POWER AMPLIFIER:AMPLIFIER TYPE .............................................. MOSFET, dual H-Bridge.CURRENT CONTROL ......................................... 3 state, pulse width modulated, switching at 20–30 KHz.OUTPUT CURRENT ........................................... 0.2–3.5 amps, software selectable.POWER SUPPLY ............................................... Linear, toroidal transformer based for high reliability and low noise. 110

or 220 VAC input, switch selectable. 50/60 Hz.DC BUS VOLTAGE ............................................. DC voltage at nominal line voltage: 35 VDC full load, 40 VDC no load.AC INPUT VOLTAGE .......................................... 110 or 220 VAC (switch selectable) 50/60 Hz.MAXIMUM OUTPUT POWER ............................ 140 watts.IDLE CURRENT REDUCTION ............................ 0%, 25%, 50%, or 100% software selectable.MOTOR RESOLUTION ....................................... 13 resolutions. Steps per revolution with 1.8° motor: 2000, 5000,

10000, 12800, 18000, 20000, 21600, 25000, 25400, 25600, 36000,50000, 50800, software selectable.

STATUS LED'S .................................................. AC power (red).

CONTROLLER (INDEXER) SECTION Si3540:SERIAL COMMUNICATION ............................... RS-232 programming port.MOTION UPDATE .............................................. 12800 Hz.INPUTS ............................................................. 8 user programmable inputs. Can be used for triggering, sensing, hom-

ing, branching, jogging or limits. 5-24 VDC optically isolated.OUTPUTS .......................................................... 3 general purpose, optically isolated 12–24 VDC outputs for interfacing

to other equipment. Open collector and emitter. 100 mA max.PARAMETER RANGES ...................................... Distance: 1 to 16,000,000 steps. Speed: .025 to 50 revolutions per sec-

ond (in any microstep resolution). Acceleration: 1 to 3,000 rev/sec/sec.Deceleration: 1 to 3,000 rev/sec/sec (set independently from accelera-tion). Time Delays: 0.01 to 300 seconds. Output Pulse Widths: 2 to 500milliseconds. Iterations per repeat loop: 1 to 65,535.

OPTIONAL OPERATOR INTERFACE (MMI) ....... NEMA 4/12 rated (splash proof & dust proof). 4 x 20 characters liquidcrystal display (LCD), standard or backlit. 20 key membrane keypad.Overall size: 4.9 x 4.9 x 1.42 inches.

SYSTEM SPECIFICATIONS:OVERALL SIZE .................................................. 2.25 x 7.8 x 5.40 inches.CHASSIS MATERIAL ......................................... Aluminum, black anodized with integral heat sink.WEIGHT ............................................................. 4 lbs.AMBIENT TEMPERATURE ................................. 0˚ to 50˚C (32˚ to 122˚F).HUMIDITY ......................................................... Maximum of 90% non-condensing.CONNECTORS ................................................... Screw terminal connectors for input power and motor, and I/O signals.MOTORS ........................................................... Can drive 4, 6 or 8 lead motors, NEMA sizes 11, 14, 17 & 23.CASE ................................................................. Steel with black paint and white epoxy silk screen. Includes switch covers.AGENCY APPROVAL ......................................... CE & TUV.

Si3540 Technical Specifications



STEPPERSYSTEMS

40



Amplifier

motor phase A

motor phase B

110 or220 VAC

INPUT1INPUT2INPUT3INPUT4

CW JOG/IN5CCW JOG/IN6

to PC/MMI

CW LIMITCCW LIMIT

OUT1OUT2OUT3

RS232Optical

Isolation

Si™Microstepping

IndexerSequencer

eeprom

OpticalIsolation

OpticalIsolation

InternalPowerSupply

power LEDfuse

7.80"

2.25"1.125" 0.750" 0.750"

5.00"5.40"

0.200" (x6)

0.200"(x6)

POWER

MOT

ORAC

POW

ER

A+A-B+B-

G

L

N

PC /

MM

IINPUT 1INPUT 2INPUT 3INPUT 4

IN 5 / JOG CWIN 6 / JOG CCW

IN / JOG COMIN / JOG COM

CCW -CCW +

CW +CW -

OUT 1 +OUT 1 -OUT 2 +OUT 2 -OUT 3 +OUT 3 -

LIM

ITS

Si35

40Pr

ogra

mm

able

Ste

p M

otor

Driv

er

BLOCK DIAGRAM

MECHANICAL OUTLINE



STEPPERSYSTEMS

41

Si3540 Connectors and Switches

inputs connector

inputs/limits connector

outputs connector

power LED

AC power connector

motor connector

I/O

position no.1 in/jog com2 in/jog com3 input 14 input 25 input 36 input 47 in 5/jog cw8 in 6/jog ccw9 cw+10 cw–11 ccw+12 ccw–13 out 1+14 out 1–15 out 2+16 out 2–17 out 3+18 out 3–

AC POWER


MOTOR


LIMITS

RS232 connectorpc

mmi



STEPPERSYSTEMS

42



RECOMMENDED MOTORS FOR Si3540

FEATURES 11 11 14 17 17 17

Motor P/N: 11012 11013 14842 17068 17071 17075


Resistance Ohms 1.40 2.00 4.30 2.10 1.70 1.70



Bearings

Thrust Load (lbs) 3.0 3.0 3.0 3.0 3.0 3.0

Radial Load (lbs) 5.0 5.0 5.0 5.0 5.0 5.0

Radial Play inch/lbs .001 .001 .0004 max .0008 max .0008 max .0008 max@ 1 lb @ 1 lb @ 1 lb @ 1 lb @ 1 lb @ 1 lb

End Play inch/lbs .003 max .003 max .0004 max .003 max .003 max .003 max@ 2 lbs. @ 2 lbs @ 2 lbs @ 2.2 lbs @ 2.2 lbs @ 2.2 lbs

Weight lbs. 0.26 0.39 0.47 0.44 0.57 0.73


NEMA 17Model L17068 1.30˝17071 1.54˝17075 1.85˝

12" min 4 X #4 – 40.17 DEEP

2 X 1.220

2 X 1.65Ø.866 +.000

–.001

L.59 .080

.59 ± .01

Ø.1968

.79±.02

+.0000–.0004

FLAT.177±.006

.177±.006FLAT

TYP


12" min

2 X 1.024

2 X 1.38

2 X #4 – 40

Ø.866+.000–.001

L

.059

Ø.1968 +.0000–.0004

.559 ± .014

.39

2 X .25

TYP

4 X M2.6 X .45.118 MIN

7.9" MIN

2 X .906 ± .018

Ø.866+0–.001

L

.06 ± .008

Ø.1968.02 X 45˚

+0–.0005

.787 ± .02

.394 ± .04 2 X 1.10 ± .012

NEMA 11Model L11012 1.32˝11013 1.87˝



STEPPERSYSTEMS

43

Torque CurvesSi3540 with NEMA 11, 14, 17 Step Motors



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

2

4

6

8

10

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

15

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

Full1/10th



STEPPERSYSTEMS

44

NEMA 23 Motor Data

FEATURES RECOMMENDED MOTORS FOR Si3540

Motor P/N: 23122 23123 23124 23394 23397 23400


Resistance Ohms 1.24 1.18 0.82 .070 0.90 1.10



Bearings

Thrust Load (lbs) 25 25 25 25 25 25

Radial Load (lbs) 15 15 15 15 15 15



Weight lbs. 1.17 2.00 2.80 1.00 1.54 2.20



Model L23394 1.54˝23397 2.13˝23400 2.99˝

Model L23122 2.00˝23123 3.00˝23124 4.00˝

.75.81 ± .03

L.190

.060

18" min

2 x Ø.2500 +.0000–.0005

Ø1.5 ± .002

2 X 2.222 X 1.856

4 X Ø.205 ± .01

MOUNTINGEND

18.00 MIN

2 X 1.856

2 X 0.928

0.228 ± 0.006FLAT

Ø1.50 ± 0.0014 X Ø0.205 ± 0.01

2 X 2.22

+0.000–0.001

.59± 0.01

L .197.063 ± 0.008

.591 ± 0.01

Ø.250

0.630 ± .039 .787 ± .020

.228 ±.006FLAT

2 X 1.11

MOUNTINGEND

TYP



STEPPERSYSTEMS

45

Torque CurvesSi3540 with NEMA 23 Step Motors



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

250

Full1/10th



STEPPERSYSTEMS

46

DRIVE ONLY ORDERING




System Ordering Example: Si3540 - 23122

Si35

40 O

rder

ing

Info

rmat

ion




Si3540 11013 NEMA 11 high torque two stack











OPTIONAL ACCESSORIES

Type Description

MMI-01 Standard man-machine interface.

MMI-02 Man-machine interface with backlit display.



STEPPERSYSTEMS

47



STEPPERSYSTEMS

48

PDO

5580

Ste

pper

Driv

e w

ith D

igita

l Osc

illat

or

PDO 5580 Packaged Pulse and Direction Step Motor Drivewih Digital Oscillator

Features• AC input 110V or 220V switch selectable, 50-60 Hz• DC bus voltage 75 VDC full load, 80 VDC nominal• Switch selectable motor current from 0.5–5.5 amps/

phase• Microstepping:

• Pulse and Direction mode: switch selectable 200 to50,800 steps/rev

• Oscillator/Joystick mode: 12,800 steps/rev• Switch selectable idle current reduction, 0 or 50%• Optically isolated inputs/outputs

• Speed, Enable: optically isolated, differential 5–24 Vlogic

• Step, Direction: optically isolated, differential5–12 V logic

• Wiper: 0–5VDC analog signal• Tach & Fault output: isolated phototransistor.

Output is 100 pulses per motor revolution, 50%duty cycle.

• Internal Pot:• Low speed 0–5 rps• High speed 0–25 rps• Accel/decel 1–250 rev/sec/sec

• External Speed, Pot or Joystick 3 terminal type, 1k–10k ohms

• Self test, switch selectable• 440 watts of usable power• Overtemp, overcurrent and surge protection• Screw terminal connectors• Dual, MOSFET H-bridge, 3 state, pulse width modu-

lated amplifier switching at 20–30 KHz• Ideal for 4, 6 or 8 leaded step motors NEMA sizes 23

or 34• CE and TUV compliant

Description

The PDO5580 is stepper drive packaged in a ruggedsteel case painted black with white epoxy silkscreen. In-tegral heat sink, mounting brackets, switch covers andconnectors are included with each drive. The drive hasbeen matched with twelve recommended NEMA 23 and34 motors in order to create a complete stepper motionsolution.

The PDO5580 provides the user with four modes of op-eration to choose from, Self test, Pulse & Direction, Joy-stick or Oscillator. The specific operation mode desiredis selected during set up via DIP switch. DIP switchs arealso provided for setting the drive’s step resolution aswell as the motor current.

Self Test Mode is used for troubleshooting. If you areunsure about the motor or signal connections to thedrive you can use the self-test.

Pulse & Direction Mode allows the PDO5580 to receivestep pulses from an indexer such as the AppliedMotion’s Si-100 or Si-1, or from a PLC or any other ex-ternal controller.

Joystick Mode allows speed and direction to be deter-mined by an external analog voltage. STEP and DIR in-puts can be used for limit switches. SPEED input selectsspeed range. LO SPEED and HI SPEED pots adjust the 2speed ranges.

Oscillator Mode can control speed by onboard potenti-ometers and/or by an external analog voltage. STEP in-put starts and stops the motor. DIR input controls direc-tion of rotation. SPEED input selects the speed range.

The PDO5580 also provides a Tach Output and EnableInput.

A Tach Out signal is provided for measuring the motorspeed. It generates 100 pulses per revolution. If con-nected to a frequency counter, speed reads out in revs/second with two decimal places.

ENABLE allows the user to turn off the current to themotor by setting this signal to logic 0. The logic circuitrycontinues to operate, the drive “remembers” the stepposition even when the amplifier is disabled.

Factory set to operate at 110-volt input; the PDO5580can be reset by the user to operate at 220-volt input by asimple switch selection.

Pluggable screw terminal blocks are provided for themotor, AC input and 8-position signal input/output. Mat-ing connectors are provided with the drive.

The PDO5580 is both CE and TUV compliant.



STEPPERSYSTEMS

49

POWER AMPLIFIER:

AMPLIFIER TYPE ....................................... MOSFET, dual H-Bridge, all parts rated for 100 volts.CURRENT CONTROL .................................. 3 state, pulse width modulated, switching at 20–30 KHz.OUTPUT CURRENT .................................... 0.5 to 5.5 amps/phase output current, switch selectable in 0.2

increments.POWER SUPPLY ........................................ Linear, toroidal transformer for high reliability and low noise. 110

or 220 VAC input, switch selectable. 50–60 Hz.DC BUS VOLTAGE ...................................... DC voltage at nominal line voltage: 75 VDC full load, 90 VDC no

load.AC INPUT VOLTAGE ................................... 110 or 220 VAC (switch selectable) 50–60 Hz.MAXIMUM OUTPUT POWER ..................... 440 Watts.PROTECTION CIRCUITS ............................. Short circuit and over temperature.IDLE CURRENT REDUCTION...................... 0% or 50% dip switch selectable.MOTOR RESOLUTION ................................ Oscillator/joystick modes: 1/64 step (12,800 s/r) with 1.8˚ motor.

Pulse & direction mode: 16 switch selectable resolutions: 200,400, 1000, 2000, 5000, 10000, 12800, 18000, 20000, 21600,2500, 25400, 25600, 36000, 50000, 50800 steps/rev.

CONTROLLER SECTION:

MODE OF OPERATION ............................... Self Test: Used for trouble shooting to test motor and/or signalconnections.Pulse & Direction: Allows amplifier to receive step pulses from acontroller such as Applied’s Si-100 or Si-1, or any other pulsesource PLC or controller.Joystick: allows speed and direction to be determined by an exter-nal analog voltage. Step and Dir inputs can be used for limitswitches. Speed input selects speed range. LO SPEED and HISPEED pots adjust the 2 speed ranges.Digital Oscillator: allows for precise speed control with automaticramps between speeds. Accel/Decel rates are set by on board po-tentiometer and/or external analog voltage.

STEP AND DIRECTION INPUT .................... Optically isolated: 5-12 VDCSPEED RANGE ........................................... LO speed range: 0-5 rev/sec.

HIGH speed range: 0-25 rev/secAccel/decel range: 1-250 rev/sec/sec

TACH OUPUT .............................................. Optically isolated phototransistor. 30 VDC, 20mA max.


OVERALL SIZE ........................................... 3 x 5.3 x 8 inches. See mechanical outline.CHASSIS MATERIAL .................................. Aluminum, black anodized with integral heat sink.WEIGHT ...................................................... 7.8 lbs.AMBIENT TEMPERATURE .......................... 0˚ to 70˚C.HUMIDITY .................................................. Maximum of 90% non-condensing.CONNECTORS ............................................ Screw terminal connectors for input power and motor, and I/O sig-

nals.MOTORS .................................................... Can drive 4, 6 or 8 lead motors, NEMA sizes 23 & 34.CASE .......................................................... Steel with black paint and white epoxy silk screen. Integral heat

sink, mounting brackets & switch covers included.AGENCY APPROVAL .................................. CE & TUV.




STEPPERSYSTEMS

50

PDO 5580 Technical Drawings

MECHANICAL OUTLINE

BLOCK DIAGRAM

PD0 5580Step Motor Driver

50% IDLE

JOYSTICKEXT SPEED

0.20.40.81.62.0

CURRENT

HIGH SPEED

LOW SPEEDSTEPS/REV

ACCEL

SELF TESTOSC BYPASS

(BASE = 0.5 A)

SHORT

TEMPPOWER

DIR+DIR–

STEP+STEP–

EN+EN–

FAULT+FAULT–

SPEED+SPEED-TACH+TACH–

CWWPRCCW

B–B+A–A+

MOTOR

N

G

L

AC P

OWER

90V pk

65

78

43

21

65

43

21

3.07 "

8.00 "

1.25 "

5.45 "

5.30 "

2.02 "

0.25"

0.06"

2.15"

3.00 "

8.97 " 9.25 "

motor phase A

motor phase B

EXTSPEEDINPUT

current0.5 to5.5A/phase

ext speedjoystick

50% idle

accelLOspeed

HIspeed

MicrostepSequencer

Digital Oscillator&

Joystick Interface

110 or220 VAC

InternalPowerSupply

power LED


Amplifier

DIRECTION

HI/LO SPEEDENABLE

TACH

STEP

OpticalIsolation

fuse

steps/rev

osc bypassself test

FaultMonitor

overtemp LEDovercurrent LED

OpticalIsolation

FAULT OUT



STEPPERSYSTEMS

51

ı/o connectordirection/step/enable/fault

status LEDspower/overtemp fault/motor short

switchesmotor current/idle current/external pot/joystick mode

motor connector

AC power connector


INPUTS

position no.1 speed+2 speed–3 tach+4 tach–5 cw+6 wpr–7 ccw+

MOTOR


AC POWER


switchessteps per rev/osc mode/self test

ı/o connectorspeed/tach out/ external pot/joystick/0–5 V analog speed

potentiometersaccel/decel rate

low speed/high speed

INPUTS

position no.1 dir+2 dir–3 step+4 step–5 en+6 en–7 fault+8 fault–



STEPPERSYSTEMS

52

NEMA 23 Motor Data



Motor P/N: 23122 23123 23124 23395 23398 23401


Resistance Ohms 1.24 1.18 0.82 0.32 0.38 0.50



Bearings

Thrust Load (lbs) 25 25 25 25 25 25

Radial Load (lbs) 15 15 15 15 15 15



Weight lbs. 1.17 2.00 2.80 1.00 1.54 2.20


Model L23395 1.54˝23398 2.13˝23401 2.99˝

Model L23122 2.00˝23123 3.00˝23124 4.00˝

.75.81 ± .03

L.190

.060

18" min

2 x Ø.2500 +.0000–.0005

Ø1.5 ± .002

2 X 2.222 X 1.856

4 X Ø.205 ± .01

MOUNTINGEND

18.00 MIN

2 X 1.856

2 X 0.928

0.228 ± 0.006FLAT

Ø1.50 ± 0.0014 X Ø0.205 ± 0.01

2 X 2.22

+0.000–0.001

.59± 0.01

L .197.063 ± 0.008

.591 ± 0.01

Ø.250

0.630 ± .039 .787 ± .020

.228 ±.006FLAT

2 X 1.11

MOUNTINGEND

TYP



STEPPERSYSTEMS

53




rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

250

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

Full1/10th



STEPPERSYSTEMS

54

NEMA 34 Motor Data



Motor P/N: 34348 34349 34350 34474 34476 34478


Resistance Ohms 0.30 0.25 0.20 0.24 0.33 0.49



Bearings

Thrust Load (lbs) 50 50 50 35 35 35

Radial Load (lbs) 25 25 25 30 30 30


End Play inch/lbs .001 max .001 max .001 max .003 max .003 max .003 max@ 15 lbs @ 15 lbs @ 15 lbs @ 1 lbs @ 1 lbs @ 1 lbs

Weight lbs. 3.00 5.40 7.70 3.86 6.18 8.66


Model L34474 2.60˝34476 3.78˝34478 4.96˝

Model L34348 2.50˝34349 3.70˝34350 5.10˝

2 X 2.74±.011.34±.04

.98±.01FLAT

1.46±.04

.98±.01FLAT

18MIN

.2–.4

4 X .45

3.38

L MAX

.39.08

2 X Ø.5+.0000–.0005

FLATS

4 X Ø.26 THRU

Ø2.875±0.001

2 X 1.370

+.000–.006

18" min

2 X 3.26MAX

Ø2.875± .002

4 X Ø.216± .01

2 X 2.74

L

1.19 ± .04.19

.0631.19 ± .03

Ø 3.38MAX

Ø.3750+.0000–.0005TYP



STEPPERSYSTEMS

55




rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

100

200

300

400

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

100

200

300

400

500

Full1/10th



rev/sec0 5 10 15 20 25 30 35 4050

100

150

200

250

300

350

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

130

260

390

520

650

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

1000

Full1/10th



STEPPERSYSTEMS

56

DRIVE ONLY ORDERING





PDO

5580

Ord

erin

g In

form

atio

nCOMPLETE SYSTEM ORDERING


PDO 5580 23122 NEMA 23 one stack

Si5580 23123 NEMA 23 two stack













STEPPERSYSTEMS

57



STEPPERSYSTEMS

58

Si55

80 P

rogr

amm

able

Ste

p M

otor

Driv

e

Si5580 Programmable Step Motor Drive

Features

• Si™, Si Command Language (SCL) or SiNet Hub pro-gramming languages included with drive

• AC input 110V or 220V switch selectable, 50-60 Hz• DC bus voltage 75 VDC full load, 80 VDC nominal• Software selectable motor current from 0.5 – 5.5

amps/phase• Software selectable motor resolution from 2,000 to

50,800 steps per revolution• Software selectable idle current reduction 0, 25%,

50% or 100%• Eight optically isolated programmable inputs 5 – 24

VDC. 2,200 ohms internal resistance. Can be config-ured for sinking (NPN) or sourcing (PNP) signals.

• Three optically isolated programmable outputs 12 –24 VDC, 100mA maximum

• One optically isolated output 5 VDC dedicated to faultout

• RS-232 for PC/MMI communications• Over current and over temperature protection• 440 watts of usable power• Screw terminal connectors• Dual, MOSFET H-bridge, 3 state, pulse width modu-

lated amplifier switching at 20 – 30 KHz• Ideal for 4, 6 or 8 leaded step motors NEMA sizes 23

& 34• Optional Man Machine Interface (MMI) allows ma-

chine operator to enter specific motion parameters• CE and TUV compliant

Description

The Si5580 is a programmable stepper drive/indexerpackaged in a rugged steel case painted black with whiteepoxy silkscreen. Integral heat sink, mounting brackets,switch covers and connectors are included with eachSi5580. The drive/indexer has been matched with twelverecommended NEMA 23 & 34 motors and comes with alloperating software necessary to create a complete step-per motion solution.

The Si5580 includes Applied Motion Products’,Microsoft Windows based, Si™ software language forquick set up and ease of use. The Si™ is ideal for stand-alone operation. For more experienced users, with soft-ware development expertise, the Si5580 also comes withApplied’s Si Command Language (SCL) programminginstruction set. SCL allows for control of the Si™ drivefrom a host PC or PLC thus permitting the user to per-form a variety of motion, I/O tasks and system status re-trieval via the host.

Multiple axis applications are handled by our SiNet™ HubProgrammer, which gives you the ability to control up to 8Si™ drives, either stepper or servo on the same hub. Notonly can you coordinate up to eight motors, the hub alsohas access to the inputs and outputs of all the drives, pro-viding your program with up to 64 inputs and 24 outputs.You can also use Applied’s MMI which allows the machineoperator to enter specific motion commands.

Factory set to operate at 110-volt input; the Si5580 can beset by the user to operate at 220-volt input by a simplyswitch selection.

Pluggable screw terminal blocks are provided for theI/O, motor and AC power inputs. Mating connectors,programming cable with computer interface connectoras well as all operating software are provided with eachSi™ drive.

The Si5580 is both CE and TUV compliant.



STEPPERSYSTEMS

59

POWER AMPLIFIER (MOTOR DRIVE):AMPLIFIER TYPE .............................................. MOSFET, dual H-Bridge.CURRENT CONTROL ......................................... 3 state, pulse width modulated, switching at 20–30 KHz.OUTPUT CURRENT ........................................... 0.5–5.5 amps, software selectable.POWER SUPPLY ............................................... Linear, toroidal transformer based for high reliability and low noise. 110

or 220 VAC input, switch selectable. 50/60 Hz.DC BUS VOLTAGE ............................................. DC voltage at nominal line voltage: 75 VDC full load, 90 VDC no load.AC INPUT VOLTAGE .......................................... 110 or 220 VAC (switch selectable) 50/60 Hz.MAXIMUM OUTPUT POWER ............................ 440 watts.IDLE CURRENT REDUCTION ............................ 0%, 25%, 50%, or 100% software selectable.MOTOR RESOLUTION ....................................... 13 resolutions. Steps per revolution with 1.8° motor: 2000, 5000,

10000, 12800, 18000, 20000, 21600, 25000, 25400, 25600, 36000,50000, 50800, software selectable.

STATUS LED'S .................................................. AC power (red)Over Temperature (yellow)Over Current (yellow)

CONTROLLER (INDEXER) SECTION:SERIAL COMMUNICATION ............................... RS-232 programming port.INPUTS ............................................................. 8 user programmable inputs. Can be used for triggering, sensing, hom-

ing, branching, jogging or limits, optically isolated 5-24 VDC.OUTPUTS .......................................................... 3 general purpose, optically isolated 12–24 VDC outputs for interfacing

to other equipment. Open collector and emitter. 100 mA max.PARAMETER RANGES ...................................... Distance: 1 to 16,000,000 steps. Speed: .025 to 50 revolutions per sec-

ond (in any microstep resolution). Acceleration: 1 to 3,000 rev/sec/sec.Deceleration: 1 to 3,000 rev/sec/sec (set independently from accelera-tion). Time Delays: 0.01 to 300 seconds. Output Pulse Widths: 2 to 500milliseconds. Iterations per repeat loop: 1 to 65,535.

OPTIONAL OPERATOR INTERFACE (MMI) ....... NEMA 4/12 rated (splash proof & dust proof). 4 x 20 characters liquidcrystal display (LCD)standard or backlit. 20 key membrane keypad. Over-all size: 4.9 x 4.9 x 1.42 inches.


OVERALL SIZE .................................................. 3.0 x 5.3 x 8.0 inches.CHASSIS MATERIAL ......................................... Aluminum, black anodized with integral heat sink.WEIGHT ............................................................. 7.8 lbs.AMBIENT TEMPERATURE ................................. 0˚ to 50˚C (32˚ to 122˚F).HUMIDITY ......................................................... Maximum of 90% non-condensing.CONNECTORS ................................................... Screw terminal connectors for input power and motor, and I/O signals.MOTORS ........................................................... Can drive 4, 6 or 8 lead motors, NEMA sizes 11, 14, 17, 23 & 34.CASE ................................................................. Steel with black paint and white epoxy silk screen. Includes switch covers.AGENCY APPROVAL ......................................... CE & TUV.




STEPPERSYSTEMS

60


BLOCK DIAGRAM

MECHANICAL OUTLINE

motor phase A

motor phase B

110 or 220 VAC



to PC/MMI

CW LIMITCCW LIMIT

FAULT OUT

OUT1OUT2OUT3Fault

Monitor



Amplifier

fuse

OpticalIsolation

RS232 OpticalIsolation

OpticalIsoation

Si™Microstepping

IndexerSequencer

eeprom

OpticalIsolation

InternalPowerSupply

8.97 " 8.00 "

3.07 "

3.00 "

1.25 "

9.25 "

5.45 "

5.30 "

2.02 "

0.25"

0.06"

2.15"

Si5580Step Motor Driver

POWER

TEMP

SHORT

B–B+A–A+

MOTOR

N

G

L

AC P

OWER

PC/M

MI

LIM

ITS

STOP

IN 1IN 2IN 3IN 4JOG CWJOG CCWIN/JOG COMIN/JOG COM

CW+CW-CCW+CCW-OUT 1+OUT 1-OUT 2+OUT 2-OUT 3+OUT 3-FAULT+FAULT-

90V pk



STEPPERSYSTEMS

61

Si5580 Connectors and Switches

I/O

position no.1 in 12 in 23 in 34 in 45 jog cw6 jog ccw7 in/jog com8 in /jog ccw9 cw+10 cw–11 ccw+12 ccw–13 out 1+14 out 1–15 out 2+16 out 2–17 out 3+18 out 3–19 fault+20 fault–

AC POWER


MOTOR


LIMITS

LEDspowerovertempovercurrent

RS232 connectorpcmmi

motor connector

AC power connector

input connector

input/limits connector

output connector



STEPPERSYSTEMS

62

NEMA 23 Motor Data


Motor P/N: 23122 23123 23124 23395 23398 23401


Resistance Ohms 1.24 1.18 0.82 0.32 0.38 0.50



Bearings

Thrust Load (lbs) 25 25 25 25 25 25

Radial Load (lbs) 15 15 15 15 15 15



Weight lbs. 1.17 2.00 2.80 1.00 1.54 2.20



Model L23395 1.54˝23398 2.13˝23401 2.99˝

Model L23122 2.00˝23123 3.00˝23124 4.00˝

.75.81 ± .03

L.190

.060

18" min

2 x Ø.2500 +.0000–.0005

Ø1.5 ± .002

2 X 2.222 X 1.856

4 X Ø.205 ± .01

MOUNTINGEND

18.00 MIN

2 X 1.856

2 X 0.928

0.228 ± 0.006FLAT

Ø1.50 ± 0.0014 X Ø0.205 ± 0.01

2 X 2.22

+0.000–0.001

.59± 0.01

L .197.063 ± 0.008

.591 ± 0.01

Ø.250

0.630 ± .039 .787 ± .020

.228 ±.006FLAT

2 X 1.11

MOUNTINGEND

TYP



STEPPERSYSTEMS

63




rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

250

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

Full1/10th



STEPPERSYSTEMS

64

NEMA 34 Motor Data


Model L34474 2.60˝34476 3.78˝34478 4.96˝

Model L34348 2.50˝34349 3.70˝34350 5.10˝

18" min

2 X 3.26MAX

Ø2.875± .002

4 X Ø.216± .01

2 X 2.74

L

1.19 ± .04.19

.0631.19 ± .03

Ø 3.38MAX

Ø.3750+.0000–.0005TYP


Motor P/N: 34348 34349 34350 34474 34476 34478


Resistance Ohms 0.30 0.25 0.20 0.24 1.50 0.49



Bearings

Thrust Load (lbs) 50 50 50 35 35 35

Radial Load (lbs) 25 25 25 30 30 30


End Play inch/lbs .001 max .001 max .001 max .003 max .003 max .003 max@ 15 lbs @ 15 lbs @ 15 lbs @ 1 lbs @ 1 lbs @ 1 lbs

Weight lbs. 3.00 5.40 7.70 3.86 6.18 8.66


2 X 2.74±.01MOTOR TO BE SUPPLIEDWITH 1/8 X .843 LG KEY

Ø.37501.25±.02

.875±.01

18MIN

.2–.4

1.12±0.4

3.38±.02

L MAX

.330.062

Ø.5000+.0000–.0005

.125+.000–.002

.555+.000–.017

4 X Ø.218 THRU

Ø2.875±.002

2 X 1.370 +.0000–.0005



STEPPERSYSTEMS

65




rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

100

200

300

400

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

100

200

300

400

500

Full1/10th



rev/sec0 5 10 15 20 25 30 35 4050

100

150

200

250

300

350

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

130

260

390

520

650

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

1000

Full1/10th



STEPPERSYSTEMS

66

DRIVE ONLY ORDERING




System Ordering Example: Si5580 - 23122

Si55

80 O

rder

ing

Info

rmat

ion



PDO 5580 23122 NEMA 23 one stack

Si5580 23123 NEMA 23 two stack












Type Description





STEPPERSYSTEMS

67



68

STEPPERDRIVES

Open

Fra

me

Driv

es



69

STEPPERDRIVES

STEP MOTORS require electronic circuits to provide them with appropriate amounts ofpower and to accept and/or generate motion command signals. Circuits that provideonly power to the motor are called drives. Circuits capable of generating high-level

motion profile command signals are called indexers. Circuits that accept lower level run/stopsignals, and generate acceleration/deceleration signals are know as a drive with oscillator.Power and lower level command signal circuits can be combined into a single unit most oftenreferred to as a drive with oscillator and with higher-level command abilities as drive/indexer.

Applied Motion offers compact open frame step motor drives, open frame drives with on boarddigital oscillators as well as open frame drives with indexer featuring our Si™ programming. Allopen frame drives require a DC power source. Applied Motion also offers matching powerssupplies for all its open frame drives. Please see the power supply section of this catalog fortechnical specifications.

Full and half step drives include:1030, drive only2035, drive only2035 O, drive with oscillator3535, drive only3535 O, drive with oscillator1035D, dual motor drive only

Microstepping drives include;1240i, drive with indexer and Si programming2035XD, drive with programmable oscillator3540M, drive only3540MO, drive with oscillator3540i, drive with indexer and Si programming5560, drive only7080, drive only7080i, drive with indexer and Si programming

Each drive has been matched with appropriate sized NEMA step motors in order to providemaximum performance of both motor and drive. You can find a listing of recommendedmotors on each catalog drive specification page.

All of Applied’s open frame units are designed and manufactured at our facilities in California.All drives are thoroughly tested for function, mechanical/electrical specifications, performanceranges and are extensively burned-in under load before being approved for shipment.

Please refer to the selection guides on the next few pages for help in choosing an appropriateproduct for your application. Detailed specifications for each open frame drive can be found inthis section of the catalog. If you require assistance in your selection or additional technicaldata please contact us 800-525-1609 or go to our web site at:www.appliedmotionproducts.com.



70

STEPPERDRIVES

PULSE & DIRECTION DRIVES ONLY

PartNumber

MotorCurrentRange(amps)

PowerSupplyVoltageRange

StepResolutionper Rev. Construction Type

1030 0 - 1.0 12 - 30 VDC 200 - 800 Open frame

1035D 0 - 1.0 12 - 35 VDC 200/400 Plastic case

2035 0.125 - 2.0 12 - 35 VDC 200/400 Open frame

2035XD 0.1 - 2.0 12 - 35 VDC 200–50,800 Open frame

3535 0.4 - 3.5 12 - 35 VDC 200/400 Open frame

3540M 0.4 - 3.5 12 - 42 VDC 400 - 12,800 Open frame

5560 1.0 - 5.5 24 - 60 VDC 200 - 12,800 Open frame

7080 0.8 - 7.0 24 - 80 VDC 200 - 50,800 Open frame

DRIVES WITH BUILT-IN OSCILLATOR

PartNumber




2035-O 0.125 - 2.0 12 - 35 VDC 200/400 Open frame

2035XD 0.1 - 2.0 12 - 35 VDC 200–50,800 Open frame

3535-O 0.4 - 3.5 12 - 35 VDC 200/400 Open frame

3540MO 0.4 - 3.5 12 - 42 VDC 12,800 Open frame

DRIVES WITH BUILT-IN INDEXER

PartNumber




1240i 0.2 - 1.2 12 - 42 VDC 2,000 - 50,800 Open frame

3540i 0.2 - 3.5 12 - 42 VDC 2,000 - 50,800 Open frame

7080i 0.8 - 7.0 24 - 80 VDC 2,000 - 50,800 Open frameOpen

Fra

me

Driv

es S

elec

tion

Guid

e



71

STEPPERDRIVES

Open

Fra

me

Driv

es S

umm

ary

OPEN FRAME DRIVES SUMMARYFE

ATUR

ES10

3010

35D

2035

2035

O35

3535

35 O

2035

XD35

40M

3540

MO

5560

7080

1240

i35

40i

7080

i

Mot

or C

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nt (

A/ph

ase)

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00.

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imum

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ower

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3570

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212

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140

140

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ize

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53

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102

7678

8284

8086

8892

9474

9098

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& H

ALF

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ROST

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NGM

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STEP

PING

STEP

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VES

DRIV

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IVE/

Si™

INDE

XER



72

STEPPERDRIVES

1030

Ste

p M

otor

Driv

e

Features

• DC bus voltage 12-30 VDC motor supply (includ-ing ripple)

• Factory settings• Motor current at 1.0 per phase• 800 steps per revolution• Idle current configured at 60%.• Optically isolated inputs, 5 – 12V

• 30 watts of usable power• AMP MTA-100 vertical latching headers• MOSFET, dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,

switching at 20 – 30 KHz.• Drives 4, 6 or 8 lead size 11, 14, 17, 23 step

motors• CE compliant• The following factory settings can be changed for

volume orders:• Motor current• Set resolution• Idle current reduction• Horizontal header can replace vertical headers

Description

The 1030 step motor driver is a full, half or one-quarter step per phase sequencer with MOSFETthree state switching amplifiers and optoisolatedcircuits. The drive also includes an automatic fea-ture to lower motor current anytime the motor isleft at rest for more than one second.

The amplifier regulates motor current by choppingat a constant, inaudible frequency. The 1030’s mo-tor current, step resolution and idle current reduc-tion are all factory configured. Standard configura-tions for each are stated in the features sectionabove.

Recommended motors for the 1030 drive:

Size 11 Size 14 Size 17 Size 23———— ———— ———— ————HT11-012 5014-842 HT17-068 HT23-393HT11-013 HT17-071 HT23-396

HT17-075 HT23-399

Note:Mating connectors are only supplied withsample orders. See the 1030 user’s manual formating connector part numbers.

1030 Step Motor DriveFull, Half & Eighth Stepping1.0 amp, 30 VDC

STEP+STEP–

DIR+DIR–

680

680

Input Circuit

0.770" MAX

0.062"

2.00"

2.25"

1.60"

0.80" 0.70"

0.125" pin 1motor connector

pin 1logic & power connector

with vertical headers

.300"with horizontal headers



73

STEPPERDRIVES

1030 Torque Curves

HT11-012 MOTORMotor Connection: 4 Lead BipolarDrive Setting: Full Resolution • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

2

4

6

8

10

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

15

24 V12 V

5014-842 MOTORMotor Connection: ParallelDrive Setting: Full Resolution • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

24 V12 V

HT17-068 MOTORMotor Connection: ParallelDrive Setting: Full Resolution • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

24 V12 V



74

STEPPERDRIVES

2.70

3.70

0.150

3.00

4.00

4x Ø.156

.70max

.062

Features

• Programmable for stand alone operation with AppliedMotion’s easy to use Si Programmer™ Windows soft-ware (software and programming cable included)

• Can be operated in real time from a host PC or PLC us-ing Applied Motion’s Si Command Language™ (SCL)

• Can be networked with all other Si™ products via Ap-plied Motion’s SiNet™ Hub

• DC bus voltage 12-42 VDC motor supply (includingripple)

• Software selectable motor current from 0.2 - 1.2amps/phase

• Software selectable Step resolutions from 2,000 to50,800 steps per revolution

• Software selectable idle current reduction 0%, 25%,50% or 100%

• 8 user programmable inputs• 3 optically isolated 5–24 VDC outputs• Communication via RS232 or optional RS485• 48 watts of usable power• Screw terminal connector blocks for power, motor and

I/O. RJ11 for RS232 port• MOSFET, dual H-Bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,

switching at 20–30 kHz• Optional operator terminal (MMI) either standard or

backlit• Drives 4, 6 or 8 lead size 11, 14, 17 or 23 step motors• CE compliant

Description

The 1240i is a programmable step motor driver suitedfor a wide range of motion control applications. It in-cludes a sophisticated controller integrated with a 48-watt microstepping amplifier.

The 1240i includes Applied Motion’s easy to use Si Pro-grammer™ Windows software for the rapid developmentof stand-alone motion control programs. The 1240i canalso be commanded in real time from a host PC or PLC,using the Si Command Language™.

For multi-axis applications, up to eight Applied MotionSi™ drives (stepper or Servo) can be networked using asingle SiNet™ Hub.

The 1240i includes 8 optically isolated programmable in-puts for triggering, branching, position sensing and endof travel detection. 3 optically isolated programmableoutputs can send signals to other electronic devices andactivate relays.12

40i P

rogr

amm

able

Ste

p M

otor

Driv

e1240i Programmable Step Motor DriveMicrostepping1.2 amps, 40 VDC

Recommended motors for the 1240i drive:


HT17-075 HT23-399

MECHANICAL OUTLINE

BLOCK DIAGRAM

3 StatePWM Power

Amplifier

motor phase A

motor phase B

12 - 42 VDC



to PC/MMI

CW LIMITCCW LIMIT

OUT1OUT2OUT3

RS232 OpticalIsolation

OpticalIsoation

Si™Microstepping

IndexerSequencer

eeprom

OpticalIsolation

InternalPowerSupply



75

STEPPERDRIVES

1240i Torque Curves

HT11-012 MOTORMotor Connection: 4 Lead BipolarDrive Setting: 1/10th Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

2

4

6

8

24 V



rev/sec0 5 10 15 20 25 30 35 400

2

4

6

8

10

24 V

5014-842 MOTORMotor Connection: ParallelDrive Setting: 1/10th Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

42 V24 V

HT17-068 MOTORMotor Connection: ParallelDrive Setting: 1/10th Step • 1.2 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

100

120

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

42 V24 V



76

STEPPERDRIVES

2035 Step Motor DriveFull & Half Stepping2.0 amps, 35 VDC

Features


• Switch selectable motor current from 0.125–2.0amps/phase

• Switch selectable full or half step• Switch selectable idle current reduction, 0 or

50%• Optically isolated 5–24 VDC inputs for step, di-

rection and enable• Enable input to turn off current to the motor• 70 watts of usable power• Screw terminal connectors• Dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,

switching at 20–30 KHz• Drives 4, 6 or 8 lead size 11, 14, 17 or 23 step

motors• CE compliant

Description

The 2035 step motor driver is a full or half drive, stepphase sequencer with three state switching amplifi-ers and optoisolated circuits. The drive also includesan automatic feature to lower motor current by 50%anytime the motor is left at rest for more than onesecond. This feature can be disabled.

The amplifier regulates motor current by choppingat a constant, inaudible frequency. Phase current isselected from 16 levels by a DIP switch. Full or halfresolution is switch selectable.



HT17-075 HT23-400

2035

Ste

p M

otor

Driv

e

MECHANICAL OUTLINE

2.50"

3.75"

0.125"

3.00"0.25"

4.00"

0.15"

4x Ø.125

3.70"

1.50"

0.25"

.875"

2x Ø.125

BLOCK DIAGRAM

OpticalIsolator

step

direction

com

enable

StepSequencer

current setting

50% idle

full step/half step

54

32

step

12-35 VDC

dir

A+A–B+B–

tomotor

OpticalIsolator 1

Amplifier

Optical Isolator



77

STEPPERDRIVES

2035 Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

8

16

24

32

40

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

100

120

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

35 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

35 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

35 V24 V



78

STEPPERDRIVES

2035 O Step Motor Drive with OscillatorFull & Half Stepping2.0 amps, 35 VDC

Features



• Switch selectable full or half step• Switch selectable idle current reduction, 0 or 50%• Optically isolated 5–24 VDC inputs, step, direc-

tion and enable• Enable input to turn off current to the motor• On-board oscillator generates step pulses and

accel/decel ramps• On-board trimpot or external speed adjustment• Optically isolated 5–24 VDC Tach output for moni-

toring speed• 70 watts of usable power• Screw terminal connectors• Dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,



Description

The 2035O step motor driver is a full or half stepdrive, step phase sequencer with three stateswitching amplifiers and optoisolated circuits.This drive has a built in ramping pulse generator(oscillator) with adjustable speed, accelerationand deceleration. Oscillator speed range is 0–5,000 Hz. Speed can be set from on-board trimpotor external pot.

A jumper allows you to select the internal oscillator.In oscillator mode, the pulse input becomes a run/stop signal: when this signal is set high, the motoraccelerates to a preset speed and slews. Loweringthe input signal causes the drive to decelerate torest.

The amplifier regulates motor current by choppingat a constant, inaudible frequency. Phase current isselected from 16 levels by a DIP switch.

2035

O S

tep

Mot

or D

rive

with

Osc

illat

or

2.50"

3.75"

0.125"

3.00"0.25"

4.00"

0.15"

4x Ø.125

3.70"

1.50"

0.25"

.875"

2x Ø.125

MECHANICAL OUTLINE

BLOCK DIAGRAM

Amplifier

OpticalIsolator

step

direction

com

extspeed

pot

enable

StepSequencer

Oscillator

STEP/SLEW JUMPER

current setting

50% idle

full step/half step

step

dir

acceldecel

speed adj

A+A–B+B–

tomotor

OpticalIsolator

12-35 VDC

54

23

1

OpticalIsolator

Recommended motors for the 2035 O drive:


HT17-075 HT23-400



79

STEPPERDRIVES

2035 O Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

8

16

24

32

40

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

100

120

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

35 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

35 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

35 V24 V



80

STEPPERDRIVES

2035XD Step Motor Drive with Oscillator2 Axis Full, Half and MicrostepProgrammable Digital Oscillatoror Pulse Direction2.0 amps, 35 VDC

Features


• Software programmable motor current, 0.1–2.0amps/phase

• Software programmable step size, 200–50800steps/rev

• Automatic idle current reduction• Four optically isolated digital inputs: step/run 1,

step/run 2, direction 1, direction 2• Two analog inputs, 10 bit resolution, 0 - 5VDC• On-board oscillator generates step pulses and

accel/decel ramps• Fixed speed or proportional to analog input• Optically isolated 5–24 VDC Tach output for

monitoring speed• 70 watts of usable power per axis• Screw terminal connectors• Dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,


motors

Description

The 2035XD step motor driver is a two axis, soft-ware configured step/direction or oscillator drive.Drives can be quickly and precisely configured us-ing our eXposition™ software and a Windows PC.

When configured for pulse/direction mode, the twodrives can be commanded by the step and directionsignals available from many PLCs and step motorindexers.

In oscillator mode, the two drives generate theirown acceleration and deceleration profiles and arecommanded by digital run/stop signals. These sig-nals can be supplied by PLCs, mechanicalswitches, single board computers or other motioncontrol devices. Speeds may be fixed or can be set“on the fly” by 0 to 5 volt analog signals.

2035

XD D

ual S

tep

Mot

or D

rive

with

Osc

illat

or

MECHANICAL OUTLINE

BLOCK DIAGRAM

Recommended motors for the 2035XD drive:


HT17-075 HT23-400

2.50"

3.75"

0.125"

3.00"0.25"

4.00"

0.15"

4x Ø.125

3.70"

1.50"

0.25"

.875"

2x Ø.125

PWM Power

Amplifier

10 - 35 VDC

STEP/RUN1STEP/RUN2

DIR1DIR2

PC

OUT

RS232

2 Axis

Controller

eeprom

OpticalIsolation

+5V OUTANALOG1 INANALOG2 IN

GND

Filter

InternalLogic

Supply

motor

PWM Power

Amplifiermotor



81

STEPPERDRIVES

2035XD Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

5

10

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

100

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

35 V24 V



82

STEPPERDRIVES

3535 Step Motor DriveFull & Half Stepping3.5 amps, 35 VDC

Features



• Switch selectable full or half step• Automatic 50% idle current reduction• Optically isolated 5 VDC inputs for step, direction

and enable• Enable input to turn off current to the motor• 122 watts of usable power• Screw terminal connectors• MOSFET, dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,



Description

The 3535 step motor driver is a full or half drive,step phase sequencer with MOSFET three stateswitching amplifiers and optoisolated circuits. Thedrive also includes an automatic feature to lowermotor current by 50% anytime the motor is left atrest for more than one second.

The amplifier regulates motor current by choppingat a constant, inaudible frequency. Phase current isselected from 32 levels by a DIP switch. Full or halfresolution is DIP switch selected.



HT17-075 HT23-400

3535

Ste

p M

otor

Driv

e

2.50"

3.75"

0.125"

3.00"0.25"

4.00"

0.15"

4x Ø.125

3.70"

1.50"

0.25"

.875"

2x Ø.125

MECHANICAL OUTLINE

12-35 VDC

Amplifier

step

direction

+5 StepSequencer

current setting

full step/half step

65

43

step

dir

A+A–B+B–

tomotor

2

enable

OpticalIsolator

OpticalIsolator

1

OpticalIsolator

BLOCK DIAGRAM



83

STEPPERDRIVES

3535 Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

5

10

35 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

35 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

35 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

35 V24 V



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30

60

90

120

150

35 V24 V



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35 V24 V



84

STEPPERDRIVES

3535 O Step Motor Drive with OscillatorFull & Half Step3.5 amps, 35 VDC

Features



• Switch selectable full or half step• Automatic 50% idle current reduction• Optically isolated 5 VDC inputs, step, direction

and enable• Enable input to turn off current to the motor.• On-board oscillator generates step pulses and

accel/decel ramps• On-board trimpot or external speed adjustment• 122 watts of usable power• Screw terminal connectors• MOSFET, dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,

switching at 20–30 KHz.• Drives 4, 6 or 8 lead size 11, 14, 17 or 23 step


Description

The 3535O step motor driver is a full or half stepdrive, step phase sequencer with MOSFET threestate switching amplifiers and optoisolated circuits.This drive has a built in ramping pulse generator(oscillator) with adjustable speed, acceleration anddeceleration. Oscillator speed range is 400–5,000Hz. Speed can be set from on-board trimpot or ex-ternal pot.

A jumper allows you to select the internal oscillator.In oscillator mode, the pulse input becomes a run/stop signal: when this signal is set high, the motoraccelerates to a preset speed and slews. Loweringthe input signal causes the drive to decelerate torest.

The amplifier regulates motor current by choppingat a constant, inaudible frequency. Phase current isselected from 32 levels by a DIP switch.

3535

O S

tep

Mot

or D

rive

with

Osc

illat

or

2.50"

3.75"

0.125"

3.00"0.25"

4.00"

0.15"

4x Ø.125

3.70"

1.50"

0.25"

.875"

2x Ø.125

MECHANICAL OUTLINE

Amplifier

step

direction

+5

extspeed

pot

1

StepSequencer

Oscillator

STEP/SLEW JUMPER

current setting

full step/half step

step

dir

acceldecel

speed adj

A+A–B+B–

tomotor

enable

OpticalIsolator

OpticalIsolator 12-35 VDC

OpticalIsolator

65

43

2

BLOCK DIAGRAM

Recommended motors for the 3535 O drive:


HT17-075 HT23-400



85

STEPPERDRIVES

3535 O Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

5

10

35 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

35 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

35 V24 V



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5

10

15

20

25

30

35 V24 V



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10

20

30

40

50

60

35 V24 V



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10

20

30

40

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60

35 V24 V



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20

30

40

50

60

35 V24 V



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35 V24 V



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100

150

200

250

35 V24 V



86

STEPPERDRIVES

MECHANICAL OUTLINE

BLOCK DIAGRAM

MOSFETAmplifier

step

direction

+5 MicrostepSequencer


stepresolution1/2, 1/5,

1/10 or 1/64

50% idlecurrent

reductionon/off

dir

A+A–B+B–

tomotor

enable OpticalIsolator

self teston/off

step

12-42 VDC

OpticalIsolator

OpticalIsolator

4.00"3.75"

2.50"0.125"

3.00"0.25" 0.15"

4 x Ø.125

3.70"

1.50"

0.25"

.875"

2x Ø.125

3540

M S

tep

Mot

or D

rive

Features


• Switch selectable currents from 0.4–3.5 amps/phase motor current

• Switch selectable Step resolutions: 400, 1000,2000, 12800 steps/rev. Other resolutions areavailable upon request

• Switch selectable idle current reduction, 0 or 50%• Optically isolated 5 VDC inputs for step, direction

and enable• Enable input to turn off current to the motor• Self test, switch selectable• 140 watts of usable power• Screw terminal connectors. Pin headers available

upon request• MOSFET, dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,

switching at 20–30 KHz.• Drives 4, 6 or 8 lead size 11, 14, 17, 23 or 34 step


Description

The 3540M step motor driver is a microsteppingdrive from 400 to 12,800 steps per revolution, withcustom resolutions available upon request, stepphase sequencer with MOSFET three state switch-ing amplifiers and optoisolated circuits. The drivealso includes an automatic feature to lower motorcurrent by 50% anytime the motor is left at rest formore than one second. This feature can be dis-abled. Additional there is a switch selectable self-test which rotates the motor 1/2 revolution in eachdirection at 100 steps/second.

The amplifier regulates motor current by chopping ata constant, inaudible frequency. Phase current is se-lected from 32 levels by a DIP switch. Microsteppingresolution is also selected by DIP switch.

Recommended motors for the 3540M drive:


HT17-075 HT23-400

3540M Step Motor DriveMicrostepping3.5 amps, 40 VDC

Size 34————5034-348



87

STEPPERDRIVES

3540M Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

24 V



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

42 V24 V

HT17-071 MOTORMotor Connection: ParallelDrive Setting: 1/10th Resolution • 1.7 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

40 V24 V



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10

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30

40

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60

42 V24 V



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30

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42 V24 V



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120

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42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

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60

80

100

120

42 V24 V



88

STEPPERDRIVES

MECHANICAL OUTLINE

BLOCK DIAGRAM

4.00"3.75"

2.50"0.125"

3.00"0.25" 0.15"

4 x Ø.125

3.70"

1.50"

0.25"

.875"

2x Ø.125

run

direction

common

extspeed

12-42 VDC

hi/lo speed


ext speedjoystick

A+A–B+B–

tomotor

enabletach out+tach out-

50% idleaccelLO

speedHI

speed

MicrostepSequencer

MOSFETAmplifier

OpticalIsolation

Digital Oscillator&

Joystick Interface

3540

MO

Step

Mot

or w

ith O

scill

ator

Features



• Microstepping at 12,800 steps/rev• Switch selectable idle current reduction, 0 or 50%• Optically isolated 5–12 VDC inputs

• Run, directs drive to run or stop• Direction, sets direction of rotation• Speed, selects high speed (25rps) or low

speed (5rps) range• Enable, removes all motor current when active• Wiper, 0–5V analog for external speed signal,

pot or joystick• Output, Tach: 5–24V optically isolated, 100

pulses per revolution• Internal Pot, accel/decel (1–250 rev/sec/sec, Low

speed (0–5 rps), High speed (0–25 rps)• External Speed, Pot or Joystick 3 terminal type,

1k–10k ohms• 140 watts of usable power• Screw terminal connectors• MOSFET, dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,

switching at 20–30 KHz• Drives 4, 6 or 8 lead size 11, 14, 17, 23 or 34 step


Description

The 3540MO step motor driver is a microsteppingdrive at 12,800 steps per revolution, step phase se-quencer with MOSFET three state switching ampli-fiers and optoisolated circuits. This drive includes 5optically isolated inputs, external speed control,tach output, and internal pots for accel/decel ratealong with high/low speed range selection.

The amplifier regulates motor current by chopping ata constant, inaudible frequency. Phase current is se-lected from 32 levels by a DIP switch. Microsteppingresolution is also selected by DIP switch.

3540MO Step Motor Drive with Digital OscillatorMicrostepping3.5 amps, 40 VDC

Recommended motors for the 3540MO drive:


HT17-075 HT23-400Size 34————5034-348



89

STEPPERDRIVES

3540MO Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

24 V



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

40 V24 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

42 V24 V



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10

20

30

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50

42 V24 V



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30

60

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120

42 V24 V



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50

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150

200

42 V24 V



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20

40

60

80

100

120

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

42 V24 V



90

STEPPERDRIVES

MECHANICAL OUTLINE

BLOCK DIAGRAM

MOSFETAmplifier

motor phase A

motor phase B

12 - 42 VDC



to PC/MMI

CW LIMITCCW LIMIT

OUT1OUT2OUT3

RS232Optical

Isolation

Si™Microstepping

IndexerSequencer

eeprom

OpticalIsolation

OpticalIsolation

InternalLogic

Supply

2.45"

4.70

0.150"

3.000.25

5.00

0.15

4.70

1.50

0.25

.875

6 x Ø.170

3540

i Pro

gram

mab

le S

tep

Mot

or D

rive

Features

• Programmable for stand alone operation with AppliedMotion’s easy to use Si Programmer™ Windows soft-ware (software and programming cable included)

• Can be operated in real time form a host PC or PLC usingApplied Motion’s Si Command Language™ (SCL).

• Can be networked with all other Si™ products via AppliedMotion’s SiNet™ Hub

• DC bus voltage 12-42 VDC motor supply (includingripple)

• Software selectable from 0.2–3.5 amps/phase motorcurrent

• Software selectable Step resolutions from 2,000 to50,800 steps per revolution

• Software selectable idle current reduction 0%, 25%,50% or 100%

• 8 user programmable inputs• 3 optically isolated 5–24 VDC outputs• Communication via RS232 or optional encoder/RS485

daughter board• 140 watts of usable power• Screw terminal connector blocks for power, motor and

I/O. RJ11 for RS232 port• MOSFET, dual H-Bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control, switching

at 20–30 kHz• Optional RS485 and encoder input board• Optional operator terminal (MMI) either standard or

backlit• Drives 4, 6 or 8 lead size 11, 14, 17, 23 or 34 step motors• CE and TUV compliant

Description

The 3540i is a programming step motor driver suitable fora wide range of motion control applications. It includes asophisticated controller integrated with a 140 watt micro-stepping amplifier.

The 3540i includes Applied Motion’s easy to use Si Pro-grammer™ Windows software for the rapid development ofstand-alone motion control programs. The 3540i can alsobe commanded in real time from a host PC or PLC, usingthe Si Command Language™ .

For multi-axis applications, up to eight Applied Motion Si™drives (stepper or Servo) can be networked using a singleSiNet™ Hub.

The 3540i includes 8 optically isolated programmable inputsfor triggering, branching, position sensing and end of traveldetection. 3 optically isolated programmable outputs cansend signals to other electronic devices and activate relays.

3540i Programmable Step Motor Indexer/DriveMicrostepping3.5 amps, 40 VDC



HT17-075 HT23-400Size 34————5034-348



91

STEPPERDRIVES

3540i Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

24 V



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

24 V



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5

10

15

20

25

42 V24 V



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10

20

30

40

40 V24 V



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20

30

40

50

60

42 V24 V



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10

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30

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50

42 V24 V



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30

60

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120

42 V24 V



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50

100

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200

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

100

120

42 V24 V



92

STEPPERDRIVES

Features



• Switch selectable idle current reduction, 0% or50%

• Switch selectable Step resolutions from 200 to12,800 steps/rev.

• Optically isolated 5 VDC inputs for step, directionand enable

• Enable input to turn off current to the motor• 330 watts of usable power• Thermal, overvoltage and overcurrent protection• Screw terminal connectors for power and motor• MOSFET, dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,

switching at 20–30 KHz• Drives 4, 6 or 8 lead size 11, 14, 17, 23, or 34

step motors

Description

The 5560 step motor driver is a microstepping drivefrom 200 to 12,800 steps per revolution, step phasesequencer with MOSFET three state switching am-plifiers and optoisolated circuits. The drive also in-cludes an automatic feature to lower motor currentby 50% anytime the motor is left at rest for morethan one second. This feature can be disabled.

The amplifier regulates motor current by choppingat a constant, inaudible frequency. Phase current isselected from 16 levels by a DIP switch.Microstepping resolution is also selected by DIPswitch.


Size 17 Size 23 Size 34———— ———— ————HT17-071 HT23-395 HT34-474HT17-075 HT23-398 HT34-476

HT23-401 HT34-478

5560 Step Motor DriveMicrostepping5.5 amps, 60 VDC

5560

Ste

p M

otor

Driv

e

MECHANICAL OUTLINE

2.45"

5.70"

0.150"

3.00"0.25"

6.00"

0.15"

5.70"

2.00"

.720"

1.345"

6x Ø.170

BLOCK DIAGRAM

fault

motor phase A

motor phase B

24-60VDC

5A fuse

OvervoltageMonitor

stepdirectionenable

+5

currentselector

PWM PowerAmplifier

PWM Clock20 kHz

PWM PowerAmplifier

VoltageRegulator

VoltageRegulator

OpticalIsolation

MicrostepSequencer

resolutionselector

FaultMonitor

overcurrentovertemp

98

76

1

idlereducer

54

32



93

STEPPERDRIVES

5560 Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60 V48 V



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20

30

40

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60

60 V48 V



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60 V48 V



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60 V48 V



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60 V48 V



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50100150200250300350

60 V48 V



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300

400

500

600

60 V48 V



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200

400

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800

1000

60 V48 V



94

STEPPERDRIVES

2.45"

5.70"

0.150"

3.00"0.25"

6.00"

0.15"

5.70"

2.00"

.720"

1.345"

6x Ø.170

motor phase A

motor phase B

24-80VDC

6.3A fuse

stepdirectionenable

powerlight

overcurrentlight

overtemplight

fault output

OpticalIsolation

FaultMonitor

PWM Clock25 kHz

PWM PowerAmplifier

PWM PowerAmplifier

VoltageRegulator

idlecurrent

reduction

currentselector

MicrostepSequencer

resolutionselector

Self Test

1

23

45

67

43

21

Features



• Switch selectable Step resolutions from 200 to50,800 steps/rev

• Switch selectable idle current reduction, 0% or50%

• Optically isolated 5–24 VDC inputs for step, di-rection and enable

• Enable input to turn off current to the motor• 560 watts of usable power• Short circuit and thermal protection• Screw terminal connectors for power and motor• MOSFET, dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control,

switching at 20–30 KHz• Drives 4, 6 or 8 lead size 11, 14, 17, 23, or 34

step motors• CE compliant

Description

The 7080 step motor driver is a microstepping drivefrom 200 to 50,800 steps per revolution, step phasesequencer with MOSFET three state switching am-plifiers and optoisolated circuits. The drive also in-cludes an automatic feature to lower motor currentby 50% anytime the motor is left at rest for morethan one second. This feature can be disabled.

The amplifier regulates motor current by choppingat a constant, inaudible frequency. Phase current isselected by a DIP switch. Microstepping resolutionis also selected by DIP switch.


Size 17 Size 23 Size 34———— ———— ————HT17-068 HT23-395 HT34-474HT17-071 HT23-398 HT34-476HT17-075 HT23-401 HT34-478

7080 Step Motor DriveMicrostepping7.0 amps, 80 VDC

7080

Ste

p M

otor

Driv

e

MECHANICAL OUTLINE

BLOCK DIAGRAM



95

STEPPERDRIVES

7080 Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

80 V48 V

HT17-068 MOTOR Motor Connection: ParallelDrive Setting: Full Resolution • 1.375 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5101520253035

80 V48 V



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10

20

30

40

50

60

80 V48 V



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10

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30

40

50

60

80 V48 V



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10

20

30

40

50

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

80 V48 V



96

STEPPERDRIVES

7080 Torque Curves



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40

80

120

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200

80 V48 V



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50

100

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80 V48 V



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80 V48 V



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80 V48 V



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80 V48 V



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80 V48 V



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97

STEPPERDRIVES



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200

400

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1000

80 V48 V



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200

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800

1000

80 V48 V



98

STEPPERDRIVES

2.45"

5.70"

0.150"

3.00"0.25"

6.00"

0.15"

5.70"

2.00"

.720"

1.345"

6x Ø.170


motor phase A

motor phase B

24-80VDCfuse

INPUT1INPUT2INPUT3INPUT4CW JOG

CCW JOG

to PCor MMI

CW LIMITCCW LIMIT

FAULT OUT

OUT1OUT2OUT3

FaultMonitor


Amplifier

InternalVoltage

Regulatoreeprom

OpticalIsolation

Si™Microstepping

IndexerSequencer

RS232

OpticalIsolation

OpticalIsolation

Filters

Features• Programmable for stand alone operation with Applied

Motion’s easy to use Si Programmer™ Windows software(software and programming cable included)

• Can be operated in real time from a host PC or PLC using Ap-plied Motion’s Si Command Language™ (SCL)

• Can be networked with all other Si™ products via AppliedMotion’s SiNet™ Hub

• DC bus voltage 24-80 VDC motor supply (including ripple)• Software selectable from 0.8–7.0 amps/phase motor current• Software selectable Step resolutions from 2,000 to 50,800

steps per revolution• Software selectable idle current reduction 0%, 25%, 50%

or 100%• 8 user programmable inputs• 3 optically isolated 24 VDC outputs• Short circuit and over temperature protection• Communication via RS232• 560 watts of usable power• Screw terminal connector blocks for power and motor,

Wago cage clamp connector for I/O. RJ11 for RS232 port• MOSFET, dual H-bridge, inaudible PWM amplifier• 3 state, pulse width modulated current control, switching at

20–30 kHz• Optional operator terminal (MMI) either standard or backlit• Drives 4, 6 or 8 lead size 11, 14, 17, 23 and 34 step motors• CE compliant

DescriptionThe 7080i is a programming step motor driver suitable for a widerange of motion control applications. It includes a sophisticatedcontroller integrated with a 560-watt microstepping amplifier.

The 7080i includes Applied Motion’s easy to use Si Program-mer™ Windows software for the rapid development of standalone motion control programs. The 7080i can also be com-manded in real time from a host PC or PLC, using the Si Com-mand Language™.

For multi-axis applications, up to eight Applied Motion Si™drives (stepper or Servo) can be networked using a singleSiNet™ Hub.

The 7080i includes 8 programmable inputs for triggering,branching, position sensing and end of travel detection. 3 opti-cally isolated programmable outputs can send signals to otherelectronic devices and activate relays.

The 7080i is a PC board mounted on an aluminum angle heattransfer chassis. Drive dimensions are 2˝ by 3˝ by 6˝.


Size 17 Size 23 Size 34———— ———— ————HT17-068 HT23-395 HT34-474HT17-071 HT23-398 HT34-476HT17-075 HT23-401 HT34-478

7080i Programmable Step Motor Indexer/DriveMicrostepping7.0 amps, 80 VDC

7080

i Pro

gram

mab

le S

tep

Mot

or D

rive

MECHANICAL OUTLINE

BLOCK DIAGRAM



99

STEPPERDRIVES

7080i Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

80 V48 V



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5

10

15

20

80 V48 V



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5

10

15

20

25

30

80 V48 V



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80 V48 V



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10

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30

40

50

60

80 V48 V



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60

80 V48 V



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20

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50

80 V48 V



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60

80

80 V48 V



100

STEPPERDRIVES



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40

80

120

160

200

80 V48 V



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50

100

150

200

250

80 V48 V



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50

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250

300

80 V48 V



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250

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350

80 V48 V



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200

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600

800

80 V48 V



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100

200

300

400

500

600

80 V48 V



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30

60

90

120

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

80 V48 V

7080i Torque Curves



101

STEPPERDRIVES



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

1000

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

1000

80 V48 V



102

STEPPERDRIVES

Features

• Accepts 12 – 35 VDC power supply (includingripple)

• Adjustable motor current: 0 to 1.0 amps/phase.• Full or half step (jumper selectable), quarter

stepping available for OEM• Compact size (1.0 x 2.4 x 3.55 inches)• Mounts on DIN rail• Optically isolated 5 – 24V step and direction in-

puts can be configured for sinking or sourcinglogic

• Automatic idle current reduction.• Drives 4, 6 or 8 lead step motors, sizes 11 – 23• Compatible step motors available from stock• Lightweight, rugged molded case• Pluggable, screw terminal connectors• CE compliant

Description

The 1035D consists of two stepper drives that canoperate in full or half step mode. Each driver can beindividually controlled via its step and direction in-puts. Each driver includes an automatic feature tolower motor current anytime the motor is left atrest for more than one-half second.

The amplifiers regulate motor current by choppingat a constant, inaudible frequency. Phase currentfor each axis is independently adjustable by frontpanel potentiometers.

Recommended motors for the 1035D drive:


HT17-075 HT23-400

1035D Dual Step DriveFull & Half Stepping1.0 amps, 35 VDC

1035

D Du

al S

tep

Mot

or D

rive

MECHANICAL OUTLINE

3362

3362

0-1A

0-1A

A+A–B+B–

A+A–B+B–

STEPDIR

COMDIR

STEP

1035D

2.40" 1.00" 2.75"

3.55" 3.90"

axis

1ax

is 2

comdir

step

dirstep

current setting

A+A–B+B–

tomotor #2

12-35 VDC

current setting

full/half select

AmplifierStep

Sequencer

A+A–B+B–

tomotor #1Amplifier

StepSequencer

IdleCurrent

Reduction

OpticalIsolation

BLOCK DIAGRAM



103

STEPPERDRIVES

1035D Torque Curves



rev/sec0 5 10 15 20 25 30 35 400

2

4

6

8

10

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

15

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

24 V12 V



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

24 V12 V



STEP MOTORS

104

STEPPERDRIVES



STEP MOTORS

105

Step

Mot

ors



STEP MOTORS

106

Stan

dard

Des

ign

Feat

ures

SIZE 11 SIZE 14 SIZE 17 SIZE HT17 SIZE 23 SIZE HT23 SIZE 34 SIZE HT34

SHAFT RUN-OUT(inches) .0005 .0005 .0005 .0005 .001 .002 .002 .002

RADIAL PLAY(inch/Lbs.)

.001 max@ 1.1 Lb.

.0004 max@ 1 Lb.

.001 max@ 1 Lb.

.001 max@ 1 Lb.

.001 max@ 1 Lb.

.001 max@ 1.1 Lb.

.001 max@ 1 Lb.

.001 max@ 1 Lb.

END PLAY(inch/Lbs.)

.003max@ 2.2 Lbs.

.0004 max@ 2 Lbs.

.001 max@ 3 Lbs.

.003 max@ 2.2 Lbs.

.003 max@ 2.2 Lbs.

.003 max@ 2.2 Lbs.

.001 max@ 15 Lbs.

.003 max@ 2.2 Lbs.

PERPENDICULARITY .002 .003 .003 .003 .003 .003 .003 .003

CONCENTRICITY(inches) .002 .002 .002 .002 .002 .002 .002 .002

OPERATINGTEMPERATURE

RANGE-20°C to 50°C -20°C to 50°C -20°C to 50°C -20°C to 50°C -20°C to 50°C -20°C to 50°C -20°C to 50°C -20°C to 50°C

INSULATIONCLASS 130°C Class B 130°C Class B 130°C Class B 130°C Class B 130°C Class B 130°C Class B 130°C Class B 130°C Class B

LEAD WIREGAUGE 26 AWG 26 AWG 22 AWG 26 AWG 22 AWG 22 AWG 18 AWG 22 AWG

MAXIMUMRADIAL LOAD (lbs.) 5 5 5 5 15 15 25 25

MAXIMUMTHRUST LOAD (lbs.) 3 3 3 3 25 25 50 50

Mechanical, Electrical& Environmental Specifications

Design Tips• Series connect lead wires for best torque at low speeds.• Center tap to end or parallel connect lead wires for best torque at higher speeds.• Keep motor case temperature below 100˚ C. This can be achieved by lowering the motor

current or limiting the duty cycle.• Allow sufficient time to accelerate load.• Size motor with 100% safety factor for required torque @ speed.• Do not disassemble motors. A significant reduction in motor performance will result.• Do not machine shafts without consulting Applied Motion Products.• Do not disconnect motor from drive while in operation.• Do not use holding torque/detent torque of motor as fail safe brake.

Motion Installation Tips• Mount the motor securely against a surface with good thermal conductivity such as steel or

aluminum.• Properly align the motor with the load using a flexible coupling.• Protect the motor shaft from excessive thrust, overhung and shock loads.



STEP MOTORS

107

CW FACINGMOUNTING ENDSTEP TABLE

STEP RED BLUE YELLOW WHITE

0 + – + –

1 – + + –

2 – + – +

3 + – – +

4 + – + –

WIRING DIAGRAM

Red

Blue

4LEAD

MOTOR

Yellow

WhiteB–

B+

A–

A+

Step

Tabl

es &

Wiri

ng D

iagr

ams4 Lead Wire Configuration–Bipolar Drive



STEP MOTORS

108

CW FACINGMOUNTING END



STEP TABLE

STEP RED RED/WHT GRN GRN/WHT

0 ON OFF ON OFF

1 OFF ON ON OFF

2 OFF ON OFF ON

3 ON OFF OFF ON

4 ON OFF ON OFF

Connect center taps (white & black) to plus (+) voltage. UNIPOLAR DRIVE ONLY!

STEP TABLE

STEP RED BLACK GREEN WHITE

0 + – + –

1 – + + –

2 – + – +

3 + – – +

4 + – + –

STEP TABLE

STEP RED RED/WHT GREEN GRN/WHT

0 + – + –

1 – + + –

2 – + – +

3 + – – +

4 + – + –

* NC denotes lead wires are not connected and areindividually taped off.

Grn/Wht

Green

White6

LEADMOTOR

Red

Red/Wht

Black

WIRING DIAGRAM

Grn/Wht

Green

White

Red

Red/Wht

Black

*N/C

B–

A+

*N/C

A–

B+

6LEAD

MOTOR

WIRING DIAGRAM

WIRING DIAGRAM

Grn/Wht

Green

White

Red

Red/Wht

Black

B+

B–

A+

A–

*N/C

*N/C

6LEAD

MOTOR

6 Lead Wire Configuration–Unipolar Drive

6 Lead Wire Configuration–Bipolar Drive/Center Tap to End

6 Lead Wire Configuration–Bipolar Drive/End to End



STEP MOTORS

109

STEP TABLE

STEP ORANGE BLACK RED YELLOW

0 + – + –

1 – + + –

2 – + – +

3 + – – +

4 + – + –

STEP TABLE

STEP A+ A– B+ B–

0 + – + –

1 – + + –

2 – + – +

3 + – – +

4 + – + –

STEP TABLE

STEP ORANGE BLACK RED YELLOW

0 ON OFF ON OFF

1 OFF ON ON OFF

2 OFF ON OFF ON

3 ON OFF OFF ON

4 ON OFF ON OFF

Connect orange/white, black/white, red/white, and yellow/white to plus (+) voltage.UNIPOLAR DRIVE ONLY!

WIRING DIAGRAM

Orange

Blk/Wht

Org/Wht

Red YellowYel/Wht

Black

Red/WhtB–

B+

A–

A+

8LEAD

MOTOR

WIRING DIAGRAM

Orange

Blk/Wht

Org/Wht

Red

Yellow

Yel/Wht

Black

Red/Wht

B–

B+

A–

A+

8LEAD

MOTOR

WIRING DIAGRAM




8 Lead Wire Configuration–Unipolar Drive

8 Lead Wire Configuration–Bipolar Drive/Parallel Connected

8 Lead Wire Configuration–Bipolar Drive/Series Connected

Orange

Blk/Wht

Org/Wht

Red

Yellow

Yel/Wht

Black

Red/Wht

8LEAD

MOTOR



STEP MOTORS

110

Electrical and holding torque ratings shown in the catalog tables are based on the motorbeing connected using the following drive schemes:

Leads Drive Scheme Holding Torque

4 bipolar bipolar, 2 phase on

6 unipolar unipolar, 2 phase on

8 unipolar unipolar, 2 phase on

Step motors can be connected using a variety of drive schemes. To determine the rating of amotor using a drive scheme that is different than the standard rating method, multiply thestandard rated value by the number indicated in the chart that corresponds to the drivescheme desired.

Holding Torque Measurement

Rating Conversion

Desired Value

Known

Value

Bipolar BipolarDrive Unipolar series parallel

Scheme Rating multiplier multiplier multiplier

Unipolar volts 1 1.4 .7or

Bipolar amps 1 .7 1.4Center Tap

to End ohms 1 2 .5

mH 1 4 1

holding torque 1 1.4 1.4

Bipolar volts .7 1 .5series

amps 1.4 1 2

ohms .5 1 .25

mH .25 1 .25

holding torque .7 1 1

Bipolar volts 1.4 2 1parallel

amps .7 .5 1

ohms 2 4 1

mH 1 4 1

holding torque .7 1 1



STEP MOTORS

111

MOTOR CONNECTION Minimum1 = series Motor Holding Rotor Motor

2 = parallel Length Torque Step Inertia WeightPart # 3 = unipolar (inches) (oz-in) Leads Angle Volts Amps Ohms mH (oz-in2/G-CM2) (Lbs.)

HT11-012 2 1.32 7.0 4 1.8 1.4 1.0 1.4 1.4 .044/8 .26

HT11-013 2 1.87 15 4 1.8 2.0 1.0 2.0 2.6 .098/18 .39

OTHER LENGTHS AND WINDINGS AVAILABLE UPON REQUEST• Part numbers listed are for single shaft. To order double shaft add ‘D’ to the end.

Hybr

id S

tep

Mot

ors

SIZEHT11

4 X M2.6 X .45.118 MIN

7.9" MIN

2 X .906 ± .018

Ø.866+0–.001

L

.06 ± .008

Ø.1968.02 X 45˚

+0–.0005

.787 ± .02

.394 ± .04 2 X 1.10 ± .012

REDA+

A–BLUE

YELLOW WHITE

B+ B–

PMSTEP RED BLUE YELLOW WHITE

0 + – + –1 – + + –2 – + – +3 + – – +4 + – + –

Switching sequence for CW rotation facingmounting end.



STEP MOTORS

112

Hybr

id S

tep

Mot

ors



5014-820 2 1.00 8.0 4 1.8 3.2 .35 8.5 8.0 .051/9.3 .33

5014-842 2 1.57 26.0 4 1.8 4.8 1.0 4.3 5.5 .109/20 .47


12" min

2 X 1.024

2 X 1.38

2 X #4 – 40

Ø.866+.000–.001

L

.059

Ø.1968 +.0000–.0004

.559 ± .014

.39

2 X .25

TYP

SIZE14



STEP MOTORS

113

Hybr

id S

tep

Mot

ors



5017-006 1 1.34 21.2 6 1.8 5.7 .67 8.4 12.4 .104/19.0 .40

3 15.0 4.0 .95 4.2 3.1

5017-007 1 21.2 13.6 .28 48.0 64.0

3 15.0 9.6 .40 24.0 16.0

5017-008 1 14.1 17.0 .11 150.0 180.0

3 10.0 12.0 .16 75.0 45.0

5017-009 1 1.54 31.1 8.5 .57 15.0 26.0 .147/27.0 .52

3 22.0 6.0 .80 7.5 6.5

5017-010 1 31.1 17.0 .28 60.0 112.0

3 22.0 12.0 .40 30.0 28.0

5017-011 1 31.1 33.9 .14 240.0 420.0

3 22.0 24.0 .20 120.0 105.0

5017-012 1 1.85 42.4 5.7 .85 6.6 11.2 .191/35.0 .66

3 30.0 4.0 1.20 3.3 2.8

5017-013 1 42.4 8.5 .57 15.0 23.2

3 30.0 6.0 .80 7.5 5.8

5017-014 1 42.4 17.0 .28 60.0 104.0

3 30.0 12.0 .40 30.0 26.0


12 4 X #4 – 40.17 DEEP

2 X 1.220

2 X 1.65Ø.866 +.000

–.001

DIM L.39

.080

.94 ± .02

Ø.1968+.0000–.0004

SIZE17



STEP MOTORS

114



HT17-068 1 1.3 31.4 8 1.8 5.7 .67 8.4 11.2 .190/35.0 .44

2 31.4 2.8 1.34 2.1 2.8

3 22.2 4.0 0.95 4.2 2.8

HT17-069 1 31.4 13.6 0.28 48.0 60.0

2 31.4 6.8 0.57 12.0 15.0

3 22.2 9.6 0.40 24.0 15.0

HT17-070 1 31.4 17.5 0.22 80.0 88.0

2 31.4 8.8 0.44 20.0 22.0

3 22.2 12.4 0.31 40.0 22.0

HT17-071 1 1.54 51.0 5.7 0.85 6.6 14.4 .29/54.0 .57

2 51.0 2.8 1.70 1.7 3.6

3 36.1 4.0 1.20 3.3 3.6

HT17-072 1 51.0 9.0 0.57 16.0 30.4

2 51.0 4.5 1.13 4.0 7.6

3 36.1 6.4 0.80 8.0 7.6

Hybr

id S

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Mot

ors

SIZEHT17

OTHER LENGTHS AND WINDINGS AVAILABLE UPON REQUEST• Part numbers listed are for single shaft. To order double shaft add ‘D’ to the end.• All HT17 motors are optimized for microstepping.

12" min 4 X #4 – 40.17 DEEP

2 X 1.220

2 X 1.65Ø.866 +.000

–.001

L.59 .080

.59 ± .01

Ø.1968

.79±.02

+.0000–.0004

FLAT.177±.006

.177±.006FLAT

TYP



STEP MOTORS

115

HT17-073 1 1.54 51.0 8 1.8 17.0 0.28 60.0 120.0 .29/54.0 .57

2 51.0 8.5 0.57 15.0 30.0

3 36.1 12.0 0.40 30.0 30.0

HT17-074 1 51.0 33.9 0.14 240.0 424.0

2 51.0 17.0 0.28 60.0 106.0

3 36.1 24.0 0.20 120.0 106.0

HT17-075 1 1.85 62.8 5.7 0.85 6.6 12.0 .37/68.0 .73

2 62.8 2.8 1.70 1.7 3.0

3 44.4 4.0 1.20 3.3 3.0

HT17-076 1 62.8 10.2 0.57 18.0 38.0

2 62.8 5.1 1.13 4.5 9.5

3 44.4 7.2 0.80 9.0 9.5

HT17-077 1 62.8 17.0 0.28 60.0 116.0

2 62.8 8.5 0.57 15.0 29.0

3 44.4 12.0 0.40 30.0 29.0




Hybr

id S

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Mot

ors

SIZEHT17

12" min 4 X #4 – 40.17 DEEP

2 X 1.220

2 X 1.65Ø.866 +.000

–.001

L.59 .080

.59 ± .01

Ø.1968

.79±.02

+.0000–.0004

FLAT.177±.006

.177±.006FLAT

TYP



STEP MOTORS

116



4023-839 1 1.5 49.5 6 1.8 8.5 0.71 12.0 20.0 .311/57 .80

3 35.0 6.0 1.00 6.0 5.0

5023-019 1 56.6 18.7 0.31 60.0 112.0

3 40.0 13.2 0.44 30.0 28.0

4023-819 1 2.0 74.9 7.2 0.71 10.2 40.0 .547/100 1.17

3 53.0 5.1 1.00 5.1 10.0

4023.820 1 74.9 1.8 2.76 0.7 1.4

3 53.0 1.3 3.90 0.33 0.35

4023-823 1 74.9 15.6 0.31 50.0 152.0

3 53.0 11.0 0.44 25.0 38.0

4023-998 1 74.9 33.9 0.21 160.0 328.0

3 53.0 24.0 0.30 80.0 82.0

5023-100 2 81.0 4 3.2 2.00 1.6 5.0

5023-122 1 96.6 8 4.9 0.99 5.0 17.2

2 96.6 2.5 1.98 1.3 4.3

3 69.0 3.5 1.40 2.5 4.3

5023-196 1 113.0 6 18.7 0.42 44.0 128.0

3 80.0 13.2 0.60 22.0 32.0

5023-094 1 2.25 117.0 8.5 0.85 10.0 23.0 .79/144 1.20

3 83.0 6.0 1.20 5.0 8.0

Hybr

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Mot

ors

SIZE23

OTHER LENGTHS AND WINDINGS AVAILABLE UPON REQUEST• Part numbers listed are for single shaft. To order double shaft add ‘D’ to the end.*Optimized for microstepping and use with 160 volt drives.

.75.81 ± .03

L.190

.060

18" min

2 x Ø.2500 +.0000–.0005

Ø1.5 ± .002

2 X 2.222 X 1.856

4 X Ø.205 ± .01

MOUNTINGEND

∗



STEP MOTORS

117

5023-499 2 2.25 110.0 4 1.8 3.3 2.00 1.7 5.0 .79/144 1.20

4023-828 1 3.0 141.0 6 2.7 3.32 0.8 2.0 1.28/234 2.00

3 100.0 1.9 4.70 0.4 0.5

4023-830 1 141.0 6.6 1.27 5.2 20.0

3 100.0 4.7 1.80 2.6 5.0

5023-024 1 141.1 7.6 1.06 7.2 27.9

3 100.0 5.4 1.50 3.6 6.9

5023-123 1 158.0 8 5.9 1.26 4.6 18.8 1.14/210

2 158.0 3.0 2.52 1.2 4.7

3 112.0 4.2 1.78 2.3 4.7

5023-149 1 3.25 198.0 5.1 1.41 3.6 16.0 1.19/219 2.12

2 198.0 2.5 2.83 0.9 4.0

3 140.0 3.6 2.00 1.8 4.0

4023-833 1 4.0 212.0 6 3.1 3.25 1.1 3.2 1.76/322 2.80

3 150.0 2.2 4.60 0.48 0.8

4023-835 1 212.0 4.8 2.05 2.30 9.2

3 150.0 3.4 2.90 1.16 2.3

5023-124 1 224.0 8 5.7 1.75 3.3 16.8 1.72/315

2 224.0 2.8 3.49 0.8 4.2

3 160.0 4.0 2.47 1.63 4.2

OTHER LENGTHS AND WINDINGS AVAILABLE UPON REQUEST• Part numbers listed are for single shaft. To order double shaft add ‘D’ to the end.*Optimized for microstepping and use with 160 volt drives.



Hybr

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Mot

ors

SIZE23

.75.81 ± .03

L.190

.060

18" min

2 x Ø.2500 +.0000–.0005

Ø1.5 ± .002

2 X 2.222 X 1.856

4 X Ø.205 ± .01

MOUNTINGEND

∗

∗



STEP MOTORS

118



HT23-393 1 1.54 76.6 8 1.8 7.4 0.71 10.4 21.6 0.66/120 1.0

2 76.6 3.7 1.41 2.6 5.4

3 54.2 5.2 1.00 5.2 5.4

HT23-394 1 76.6 4.0 1.41 2.8 5.6

2 76.6 2.0 2.83 0.7 1.4

3 54.2 2.8 2.00 1.4 1.4

HT23-395 1 76.6 2.7 2.12 1.3 2.4

2 76.6 1.3 4.24 0.3 0.6

3 54.2 1.9 3.00 0.6 0.6

HT23-396 1 2.13 177.0 10.2 0.71 14.4 44.0 1.64/300 1.54

2 177.0 5.1 1.41 3.6 11.0

3 125.0 7.2 1.00 7.2 11.0

HT23-397 1 177.0 5.1 1.41 3.6 10.0

2 177.0 2.5 2.83 0.9 2.5

3 125.0 3.6 2.00 1.8 2.5

Hybr

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Mot

ors

SIZEHT23


18.00 MIN

2 X 1.856

2 X 0.928

0.228 ± 0.006FLAT

Ø1.50 ± 0.0014 X Ø0.205 ± 0.01

2 X 2.22

+0.000–0.001

.59± 0.01

L .197.063 ± 0.008

.591 ± 0.01

Ø.250

0.630 ± .039 .787 ± .020

.228 ±.006FLAT

2 X 1.11

MOUNTINGEND

TYP



STEP MOTORS

119

Hybr

id S

tep

Mot

ors

SIZEHT23

HT23-398 1 2.13 177.0 8 1.8 3.3 2.12 1.5 4.8 1.64/300 1.54

2 177.0 1.6 4.24 0.4 1.2

3 125.0 2.3 3.00 0.8 1.2

HT23-399 1 2.99 264.0 11.6 0.71 16.4 56.0 2.62/480 2.20

2 264.0 5.8 1.41 4.1 14.0

3 187.0 8.2 1.00 8.2 14.0

HT23-400 1 264.0 6.4 1.41 4.5 14.4

2 264.0 3.2 2.83 1.1 3.6

3 187.0 4.5 2.00 2.3 3.6

HT23-401 1 264.0 4.2 2.12 2.0 6.4

2 264.0 2.1 4.24 0.5 1.6

3 187.0 3.0 3.00 1.0 1.6




18.00 MIN

2 X 1.856

2 X 0.928

0.228 ± 0.006FLAT

Ø1.50 ± 0.0014 X Ø0.205 ± 0.01

2 X 2.22

+0.000–0.001

.59± 0.01

L .197.063 ± 0.008

.591 ± 0.01

Ø.250

0.630 ± .039 .787 ± .020

.228 ±.006FLAT

2 X 1.11

MOUNTINGEND

TYP



STEP MOTORS

120



4034-322 1 2.5 212.0 6 1.8 8.2 1.13 7.2 46.0 3.66/670 3.00

3 150.0 5.8 1.60 3.6 11.5

4034-324 1 212.0 3.5 2.19 1.6 12.0

3 150.0 2.5 3.10 0.8 3.0

4034-326 1 212.0 2.5 3.32 0.8 5.0

3 150.0 1.8 4.70 0.4 1.3

5034-348 1 212.0 8 3.0 2.42 1.3 10.0

2 212.0 1.5 4.84 0.3 2.5

3 150.0 2.1 3.42 0.6 2.5

4034-329 1 3.7 424.0 6 4.2 2.83 1.5 12.0 6.72/1230 5.40

3 300.0 3.0 4.00 0.8 3.0

4034-331 1 424.0 3.5 3.25 1.1 11.0

3 300.0 2.5 4.60 0.6 2.8

5034-349 1 447.0 8 3.5 3.54 1.0 11.6

2 447.0 1.8 7.07 0.3 2.9

3 316.0 2.5 5.00 0.5 2.9

Hybr

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Mot

ors

SIZE34

OTHER LENGTHS AND WINDINGS AVAILABLE UPON REQUEST• Part numbers listed are for single shaft. To order double shaft add ‘D’ to the end.• All size 34 motors are optimized for microstepping.* Optimized for use with 160 volt drives.

∗

∗

18" min

2 X 3.26MAX

Ø2.875± .002

4 X Ø.216± .01

2 X 2.74

L

1.19 ± .04.19

.0631.19 ± .03

Ø 3.38MAX

Ø.3750+.0000–.0005TYP



STEP MOTORS

121

4034-334 1 5.1 636.0 6 1.8 6.1 2.47 2.4 28.0 10.2/1870 7.70

3 450.0 6 4.3 3.50 1.2 7.0

4034-336 1 636.0 6 3.7 3.89 1.0 10.0

3 450.0 6 2.6 5.50 0.5 2.5

4034-338 1 636.0 6 3.4 4.95 0.7 6.8

3 450.0 6 2.4 7.00 0.4 1.7

4034-339 1 636.0 6 2.1 7.78 0.3 2.8

3 450.0 6 1.5 11.00 0.1 0.7

5034-350 1 667.0 8 3.5 4.17 0.8 10.4

2 667.0 8 1.8 8.34 0.2 2.6

3 472.0 8 2.5 5.90 0.4 2.6

OTHER LENGTHS AND WINDINGS AVAILABLE UPON REQUEST• Part numbers listed are for single shaft. To order double shaft add ‘D’ to the end.• All size 34 motors are optimized for microstepping.* Optimized for use with 160 volt drives.



Hybr

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Mot

ors

SIZE34

∗

18" min

2 X 3.26MAX

Ø2.875± .002

4 X Ø.216± .01

2 X 2.74

L

1.19 ± .04.19

.0631.19 ± .03

Ø 3.38MAX

Ø.3750+.0000–.0005TYP



STEP MOTORS

122

2 X 2.74±.011.34±.04

.98±.01FLAT

1.46±.04

.98±.01FLAT

18MIN

.2–.4

4 X .45

3.38

L MAX

.39.08

2 X Ø.5+.0000–.0005

FLATS

4 X Ø.26 THRU

Ø2.875±0.001

2 X 1.370

+.000–.006



HT34-474 1 2.60 389 8 1.8 2.8 3.15 0.96 7.6 7.65/1400 4.00

2 389 1.4 6.3 0.24 1.9

3 278 2.0 4.5 0.48 1.9

HT34-476 1 3.78 855 3.92 3.15 1.32 12.0 14.8/2700 6.2

2 855 1.96 6.3 0.33 3.0

3 611 2.8 4.5 0.66 3.0

HT34-478 1 4.96 1284 5.3 2.8 1.94 22.0 27.9/4000 8.66

2 1284 2.7 5.6 0.49 5.5

3 917 3.8 4.0 0.97 5.5

Hybr

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Mot

ors

SIZEHT34

OTHER LENGTHS AND WINDINGS AVAILABLE UPON REQUEST• Part numbers listed are for single shaft. To order double shaft add ‘D’ to the end.• All HT34 motors are optimized for microstepping.* Optimized for use with 160 volt drives.

∗

∗

∗



STEP MOTORS

123

Hybr

id S

tep

Mot

ors

SIZEHT34

HT34-485 1 3.11 650 8 1.8 3.2 4.3 0.76 5.2 7.8/1400 6.18

2 650 1.6 8.6 0.19 1.3

3 455 2.24 6.0 0.38 1.3

HT34-486 1 4.63 1200 4.4 4.1 1.08 8.8 14.6/2680 8.4

2 1200 2.2 8.1 0.27 2.2

3 840 3.1 5.7 0.54 2.2

HT34-487 1 6.14 1845 4.8 4.5 1.08 9.6 21.9/4000 11.9

2 1845 2.4 9.0 0.27 2.4

3 1290 3.4 6.3 0.54 2.4



2 X 2.74±.01MOTOR TO BE SUPPLIEDWITH 1/8 X .843 LG KEY

Ø.37501.25±.02

.875±.01

18MIN

.2–.4

1.12±0.4

3.38±.02

L MAX

.330.062

Ø.5000+.0000–.0005

.125+.000–.002

.555+.000–.017

4 X Ø.218 THRU

Ø2.875±.002

2 X 1.370 +.0000–.0005


.875±.010

Ø.625+.0000–.0005

.1875+.000–.002

.705+.000–.017

Size HT34-487 Shaft Dimensions:



STEP MOTORS

124

MOTOR CONNECTION Minimum1 = series Motor Holding

TerminalRotor Motor

2 = parallel Length Torque Block Step Inertia WeightPart # 3 = unipolar (inches) (oz-in) Connections Angle Volts Amps Ohms mH (oz-in2/G-CM2) (Lbs.)

5042-022 1 7.7 1591.0 8 1.8 3.8 6.70 0.6 7.6 49.2/9000 18.3

2 1591.0 1.9 13.40 0.1 1.9

3 1125.0 2.7 9.50 0.28 1.9

5042-023 1 1591.0 6.6 3.32 2.0 35.2

2 1591.0 3.3 6.65 0.5 8.8

3 1125.0 4.7 4.70 1.00 8.8

OTHER LENGTHS AND WINDINGS AVAILABLE UPON REQUEST• Part numbers listed are for single shaft. To order double shaft add ‘D’ to the end.• All size 42 motors are optimized for microstepping and use with 160 volt drives.

2 X 4.20MAX

Ø2.186±.002

4 X Ø.28±.01

2 X 3.50Ø4.26 MAX

Ø.6248+.0000–.0006

Ø.5000+.0000–.0005

.062

1.25 ± .08

DIM L

.32

1⁄2 - 14 NPT 1.38 ± .05

SEE KEYWAY DETAIL

.063

0.1248+0.001/-0

.135+.005/-0

0.69

MOUNTINGSURFACE

Ø.509±.009

#404 WOODRUFF KEYWAYKEY SUPPLIED WITH MOTOR

SHAFT KEYWAY DETAIL

Hybr

id S

tep

Mot

ors

SIZE42 TERMINAL # WINDING WIRE COLOR

1 RED

2 BLUE

3 BLACK

4 WHITE

5 GREEN

6 YELLOW

7 BROWN

8 ORANGE

1

62

3

PM

4 5

8 7



STEP MOTORS

125



STEP MOTORS

126

Dyna

mic

Torq

ue D

ata

HT11-012 MOTORMotor Connection: 4 Lead BipolarDrive Setting: Full, 1/10th Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

2

4

6

8

10

Full1/10th

HT11-013 MOTORMotor Connection: 4 Lead BipolarDrive Setting: Full, 1/10th Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

3

6

9

12

15

Full1/10th

Size HT11 MotorTypical Speed/Torque Performance*

Size 14 MotorTypical Speed/Torque Performance*

5014-842 MOTORMotor Connection: ParallelDrive Setting: Full, 1/10th Step • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

Full1/10th

*Full steps/sec = Rev/sec x 200. Half steps/sec = Rev/sec x 400.



STEP MOTORS

127*Full steps/sec = Rev/sec x 200. Half steps/sec = Rev/sec x 400.*Full steps/sec = Rev/sec x 200. Half steps/sec = Rev/sec x 400.


5017-006 MOTORMotor Connection: Center Tap to EndDrive Setting: Half Step Resolution • 1.0 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

5

10

15

80 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

80 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

80 V



STEP MOTORS

128


*Full steps/rev = Rev/sec x 200.



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

5

10

15

20

25

30

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

5101520253035

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

80 V48 V



STEP MOTORS

129*Full steps/sec = Rev/sec x 200. Half steps/sec = Rev/sec x 400.




rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

25

50

75

100

80 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

80 V



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

80 V



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

80 V



rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

80 V



STEP MOTORS

130





rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

42 V24 V

HT23-394 MOTORMotor Connection: ParallelDrive Setting: Full, 1/10th Step • 2.8 A/Phase


rev/sec0 5 10 15 20 25 30 35 400

10

20

30

40

50

60

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

20

40

60

80

100

120

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

42 V24 V



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

250

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

250

Full1/10th



STEP MOTORS

131





rev/sec0 5 10 15 20 25 30 35 400

30

60

90

120

150

80 V



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

250

80 V



rev/sec0 5 10 15 20 25 30 35 400

50100150200250300350

80 V



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

100

200

300

400

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

100

200

300

400

500

Full1/10th



STEP MOTORS

132*Full steps/sec = Rev/sec x 200. Half steps/sec = Rev/sec x 400.

Size HT34 MotorTypical Speed/Torque Performance



rev/sec0 5 10 15 20 25 30 35 400

50

100

150

200

250

300

80 V48 V



rev/sec0 5 10 15 20 25 30 35 4050

100

150

200

250

300

350

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

100

200

300

400

500

600

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

1000

80 V48 V



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

1000

80 V48 V



STEP MOTORS

133



rev/sec0 5 10 15 20 25 30 35 400

100

200

300

400

500

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

1000

Full1/10th



rev/sec0 5 10 15 20 25 30 35 400

200

400

600

800

1000

1200

Full1/10th

Size HT34 MotorTypical Speed/Torque Performance


134



SERVOSYSTEMSSTEP MOTORS

135



SERVOSYSTEMS

Serv

o Sy

stem

s

136



SERVOSYSTEMS

BLSi

7080

Pro

gram

mab

le S

ervo

Am

plifi

er

BLSi7080 Programmable Servo Amplifier

Features:

• BLSi7080 can be programmed for stand-alone opera-tion with the easy to use Si™ Programmer Windowssoftware (software and programming cable included).

• BLSi7080 can be operated in real time from a host PCor PLC using the Si™ Command Language (SCL), viaRS-232.

• Direct 120/240 volt, 50/60 Hz AC input. No externalPower Supply needed.

• Continuous current of 7A, peak current to 14A.• Speeds to 6,000 rpm. Motor and load dependent.• 20 kHz precision PWM amplifier.• Pluggable screw terminal connectors for AC power,

motor phases, communications and I/O.• Pluggable, industry standard D connector for encoder

and commutation signals.• Optically isolated RS-232, RS-485 or RS-422 commu-

nications.• Optically isolated I/O.• Internal regeneration clamp circuit. No external com-

ponents needed.

Options:

• Five custom matched Applied Motion Alpha seriesbrushless servomotors.

• Standard or custom length extension cables.• Complete system configuration ordering.• SiNet™ Hub compatible for networking with all Ap-

plied Motion intelligent stepper and servo drives tocreate full machine control.

• Two custom configured operator interfaces are avail-able the MMI-01 and backlit MMI-02. MMI can beused to display messages or by the operator to entercommand data such as move speeds, distance or loopcounts.

Description:

The BLSi7080 programmable servo drive include a mo-tion controller, digital PID position loop, amplifier and80 volt power supply. These features make it suitable fora wide range of motion applications using either brushor brushless motors.

The BLSi7080 includes Applied Motion’s easy to useSi™ Programmer Windows software for the rapid devel-opment of stand-alone motion control programs. TheBLSi7080 can also be commanded in real time from ahost PC or PLC, using the Si™ Command Language(SCL).

For multi-axis applications, up to eight BLSi7080 drivescan be networked using the SiNet™ Hub. Up to 32 drivescan be connected using the built-in RS-485 interface.Networking also allows the BLSi7080 to be mixed withother Si™ drive models, stepper and servo.

The BLSi7080 includes 8 programmable inputs for trig-gering, branching, position sensing and end of travel de-tection. 3 programmable outputs can send signals toother electronic devices and activate relays.

Tuning the PID loop of either model is easy with ourQuick Tuner software, which features a built-in oscillo-scope. Software selection of encoder line count andcommutation sequence allows the motor to be config-ured without swapping wires.

137



SERVOSYSTEMS

POWER AMPLIFIER SECTION:

AMPLIFIER TYPE ................................................. 3 phase MOSFET.CURRENT CONTROL ............................................ 4 quadrant, pulse width modulated, switching at 20 kHz.AC INPUT ............................................................. 90 – 130 Volts @ 4 amps maximum or 180 – 260 Volts @ 2 amps maxi-

mum. Externally switch selectable. 50/60 Hz.OUTPUT CURRENT .............................................. 7.0 amps continuous. 14 amps peak current, 2 seconds max.INTERNAL DC BUS VOLTAGE .............................. 90 VDC NO LOAD, 70 VDC @ 7 amps maximum load (with AC input at

specified values).MAXIMUM CONTINUOUS OUTPUT POWER........ 400 Watts.PROTECTION CIRCUITS ...................................... Drive over temperature. Over-voltage resulting from motor regeneration.POSITION RESOLUTION ...................................... Set via software to match encoder resolutions from a minimum of 25 lines

to a maximum of 12,500 lines per revolution producing a minimum of 100counts to a maximum of 50,000 counts per revolution in quadrature.

MOTION UPDATE ................................................. 12,800 Hz.SERVO UPDATE ................................................... 4,266 Hz.ENCODER INPUTS ............................................... Differential 5 V, A & B quadrature.COMMUTATION INPUTS ...................................... 5 V TTL level, filtered.ENCODER POWER ............................................... 5 VDC, 200 mA (maximum) provided by drive.ENCODER RESOLUTION ...................................... 100 to 50,000 counts/rev (25 to 12,500 lines).

CONTROLLER SECTION:

SERIAL COMMUNICATION .................................. RS-232 programming port. Optically isolated.STATUS LED’S ..................................................... DC power (red), Overtemp (yellow). Regeneration Clamp (yellow)NETWORK COMMUNICATION ............................. RS-485 or RS-422 programming and SCL (SiNet Command Language) se-

rial port. Optically isolated. Up to 32 devices can be connected on amultidropped network.

INPUTS ................................................................ 8 user programmable inputs:2 dedicated, optically isolated limit switch inputs, 5 – 24 VDC. 4 generalpurpose, filtered inputs. The Feed to Sensor instruction can use these in-puts for sensing needs. The Wait Input instruction can wait for one of theinputs to see a given voltage state or signal edge. The If Input instructioncan branch based on the state of an input. 2 jog inputs (cw and ccw) thatcan also be used as general purpose inputs.

OUTPUTS ............................................................. 3 general purpose, optically isolated outputs for interfacing to other equip-ment. Can be opened, closed, or programmed to send a pulse by the SetOutput instruction.

PARAMETER RANGES ......................................... Distance: 1 to 16,000,000 encoder counts (CW or CCW), absolute position2 billion.Speed: .025 to 100 revolutions per second.Acceleration: 1 to 3,000 rev/sec/sec.Deceleration: 1 to 3,000 rev/sec/sec (set independently from acceleration).Time Delays: .01 to 300 seconds.Output Pulse Widths: 2 to 500 milliseconds.Iterations per loop: 1 to 65,535.

OPTIONAL OPERATOR INTERFACE (MMI) .......... NEMA 4X rated (splash proof & dust proof).4 x 20 characters liquid crystal display (LCD) standard or backlit.20 key membrane keypad.Overall size: 4.9 x 4.9 x 1.42 inches.Optional backlit display.


OVERALL SIZE ..................................................... 4˝ x 8˝ x 5.3˝.CHASSIS MATERIAL ............................................ Steel, painted black with white characters. Black anodized aluminum heat

sink.WEIGHT ................................................................ 11 Lbs.AMBIENT TEMPERATURE .................................... 0 to 40C (32 to 104F) normal operating.

0 to 70C (32 to 150F) maximum.HUMIDITY ............................................................ Maximum of 90% non-condensing.CONNECTORS ...................................................... Pluggable screw terminal connectors for input power, I/O signals, Commu-

nications and motor, DB-15 for encoder/Hall signals.RECOMMENDED MOTORS .................................. Can drive 30W to 400W BLDC motor.

BLSi7080 Technical Specifications

138



SERVOSYSTEMS

BLSi7080 Technical Drawings

9.25 " 8.97 "

1.25 "

4.12 "

8.00 "

4.00 " 5.45 "

5.30 "

2.02 "

0.25"

0.06"

2.15"

BLSi7080Programmable Servo Drive

POWERPC/MMI

G

L2/N

L1AC POWER

RX+RX–

TX–TX+

OUT3+OUT3–

JOG/IN COM

IN1

OUT2–OUT2+OUT1–OUT1+

CCW JOG/IN6

CW LIMIT+

CCW LIMIT+

CW JOG/IN5

IN4

IN3IN2

COM

COM

CW LIMIT–

CCW LIMIT–

TEMP

REGEN

PHASE APHASE BPHASE C

G

GND

RS-4

85/4

22M

OTOR

FEED

BACK

90V pk

MOT

OR

MECHANICAL OUTLINE

MOSFETPWM Power

Amplifier

120 - 240 VAC



PC/MMI

CW LIMITCCW LIMIT

OUT1OUT2OUT3

RS232

PIDServoLoop

Si™Programmable

Controller

eeprom

OpticalIsolation

InternalLogicSupply

motor

encoder

RS485/422

80 Volt DCPower Supply

RS485/422

OpticalIsolation

RegenerationClamp Circuit

BLOCK DIAGRAM

139



SERVOSYSTEMS

RS-232 connectorRS-485/422 connector

motor connector

motor encoder I/O connector

AC power connector

LEDs

I/O connectorinputs 1–4

I/O connectorjog cw & ccw

I/O connectoroutputs 1–3

BLSi7080 Connectors

I/O

position no.1 in 12 com3 in 24 in 35 com6 in 47 cw jog/in 58 jog/in com9 ccw jog/in 610 cw limit +11 cw limit –12 ccw limit +13 ccw limit –14 out 1+15 out 1–16 out 2+17 out 2–18 out 3+19 out 3– AC POWER

position no.1 L12 L2/N3 G

MOTOR

position no.1 GROUND2 PHASE C3 PHASE B4 PHASE A

COMMUNICATIONSposition no.

1 RS-2322 RS-485 GND3 RS-485 TX –4 RS-485 TX +5 RS-485 RX –6 RS-485 RX +

ENCODER I/ODB-15 CONNECTORposition no.

1 A+2 A–3 B+4 B–5 INDEX +6 INDEX –7 SHIELD8 NO CONNECTION9 +5 VDC10 GROUND11 HALL 112 HALL 213 HALL 314 NO CONNECTION15 NO CONNECTION

I/O connectorcw & ccw limits

140



SERVOSYSTEMS

METRIC

Mounting Flange inches (mm) ■ 1.10 (28 mm) ■ 1.57 (40 mm) ■ 2.36 (60 mm)

Part Number A0030-104-2-000 A0050-104-3-000 A0100-104-3-000 A0200-104-4-000 A0400-105-4-000

System P/N 2802 4002 4012 6001 6011

Voltage V 48 48 48 48 60

Output Power W 30 50 100 200 400

Maximum OperatingSpeed rpm 5,000 5,000 5,000 5,000 3,600

Continuous OperatingSpeed rpm 3,000

Continuous Stall Torque N.m.lb-in

0.0950.84

0.1591.41

0.3182.81

0.645.66

1.2711.24

Peak Torque(@ 3X rated current)

N.m.lb-in

0.2862.53

0.484.25

0.958.41

1.9116.9

3.8233.8

KT Torque Constant N.m./Alb-in/A

0.060.64

0.080.71

0.110.97

0.0950.84

0.191.68

KE Voltage Constant V/krpm 6.60 8.40 11.7 10.0 20.4

Winding Resistance Ohm 2.80 2.60 2.00 0.37 0.63

Winding Inductance mH 1.80 3.10 2.60 1.10 2.00

Continuous StallCurrent amps 1.5 2 3 6.7 6.5

Rotor Inertia g-cm2

oz-in-sec210

1.42 X 10-423

3.262 X 10-442

5.952 X 10-4200

2.832 X 10-3360

5.10 X 10-3

Maximum WindingTemp Class B (130˚C)

Friction Torque (max) N.m.lb-in

0.020.18

0.030.27

0.030.27

0.040.35

0.040.35

Weight (lbs) .077 0.88 1.10 2.42 3.52

Phases 3

Poles 8

Recommended Motors for BLSi7080

MOTOR TO ENCODER TOAMPLIFIER CABLES AMPLIFIER CABLESPART NUMBER LENGTH PART NUMBER LENGTH

BLMTR-CA-04 4 ft BLENC-CA-04 4 ftBLMTR-CA-10 10 ft BLENC-CA-10 10 ftBLMTR-CA-20 20 ft BLENC-CA-20 20 ftBLMTR-CA-XX custom length BLENC-CA-XX custom length

BLSi7080 Extension Cables

Note: All electrical specs are phase to phase.BLSi7080 amplifier uses 2X peak current limit.

141



SERVOSYSTEMS

Recommended 28 mm Alpha Motor for BLSi7080


305 +76–0

ENCODER CONNECTOR:HOUSING AMP #206036-3

PINS AMP #1-66103-7 (15 PCS)CABLE CLAMP AMP #206070-1

MOTOR CONNECTOR:HOUSING AMP #206153-1PINS AMP #1-66099-4 (4 PCS)CABLE CLAMP AMP #206062-3

Ø28

LABEL

L ± 1

A

POTTING

5.0

2.020 ± 1

0.080.05

AB

Ø6.000 –0.0120

Ø25.000 –0.0210

0.6 X 45˚

B

28

Ø38 REF

2 X Ø3.0 ONA Ø33 B.C.

(57)

DIMENSION “L”PART NUMBER L mm (inch)

A0030-104-2-000 87.0 (3.43)

305 +76–0

29.215.0




A

2.525 ± 1

5.0 0.080.05

Ø30.00 –0.021

AB

+0

0.75(.03) X 45˚

Ø8.000 –.009+0

B2 X Ø4.5 THRU

180˚ APARTON A Ø46 B.C.

40

LABEL

L ±1

10.0

22.1512.2


A0050-104-3-000 70.6 (2.78)

A0100-104-3-000 88.4 (3.48)

142



SERVOSYSTEMS


PIN AMP #1-66103-7 (15 PCS)CABLE CLAMP AMP #206070-1

MOTOR CONNECTOR:HOUSING AMP #206153-1PIN AMP #1-66099-4 (4 PCS)CABLE CLAMP AMP #206062-3

A

3.030 ± 1

6.00.080.05

AB

Ø14.0 –0.0110

0.75 X 45˚

Ø50.0 –0.025+0

305 +76–0

B 4 X Ø5.5 THRUON A Ø70 B.C.

60

L ± 1LABEL


A0200-104-4-000 93 (3.66)

A0400-105-4-000 121 (4.76)


143



SERVOSYSTEMS

BLSi7080 Torque Curveswith 28mm, 40 mm & 60 mm Alpha Brushless Servo Motors

0 1000 2000 3000 4000 50000

5

10

15

20

25

30

Peak Continuous

A0030-104-2-000, Alpha Motor

rpm

oz-in

BLSi7080 set at 1.7 amps (3.4 peak)

0 1000 2000 3000 4000 50000

10

20

30

40

50

Peak Continuous

A0050-104-3-000, Alpha Motor

rpm

oz-in


0 1000 2000 3000 4000 50000

20

40

60

80

100

Peak Continuous

A0100-104-3-000, Alpha Motor

rpm

oz-in


0 1000 2000 3000 4000 50000

40

80

120

160

200

Peak Continuous

A0200-104-4-000, Alpha Motor

rpm

oz-in


0 1000 2000 3000 4000 50000

60

120

180

240

300

360

Peak Continuous

A0400-105-4-000, Alpha Motor

rpm

oz-in


144



SERVOSYSTEMS

123

71114

15 16

106

(4) encoder B–(3) encoder B+(2) encoder A–(1) encoder A+

(9) +5 VDC(10) ground (+5 return)

(11) Hall 1(12) Hall 2

encoder index + (5)encoder index – (6)shield (7)no connection (8)

no connection (15)no connection (14)Hall 3 (13)

AM

P

“L” +3–0

ENCODER EXTENSION CABLE CONNECTOR:HOUSING AMP #206037-1

PINS AMP #1-66105-8 (15 PINS)CABLE CLAMP AMP #206070-1

APPLIED MOTIONP/N: BLENC-CA-XX

BELDON 9541 15 CONDUCTOR CABLE

1 2 3 4 5 6 7 8

9 10 11 12 13 14 15

DIMENSION “L” PART #

4 feet BLENC-CA-04

10 feet BLENC-CA-10

20 feet BLENC-CA-20

123

4

APPLIED MOTIONP/N: BLMTR-CA-XX

“L” + 3–0

4 x 1.5

3 x .2"STRIP &TIN DIP BELDON 9418 4 CONDUCTOR CABLE

MOTOR EXTENSION CABLE CONNECTOR:HOUSING AMP #206060-1



4 feet BLMTR-CA-04

10 feet BLMTR-CA-10

20 feet BLMTR-CA-20

BLSi7080 Motor Extension Cable DrawingsENCODER EXTENSION CABLE

MOTOR POWER EXTENSION CABLE

0° 60° 120° 180° 240° 300° 360° 0° 15° 30° 45° 60° 75° 90°

VAB VBC VCA

Hall 1+

D

MECHANICAL (SHAFT) ANGLEELEC. ANGLE

Mot

or B

ack

EMF

CCW (VIEWING SHAFT END)

Hall 2+

Hall 3+

MOTOR SHAFT CAN BE LOCKED AT “O°” BY APPLYING THERATED CURRENT + TO TERMINAL “B” AND – TO TERMINAL “A”.

ENCODER RESOLUTION 2,000 LINES/REV

Motor Phase Excitation Sequence

145



SERVOSYSTEMSCOMPLETE SYSTEM ORDERING

Drive Type Motor System Number Extension Cable System Number

BLSi7080 2802 04

BLx7080 4002 10

4012 20

6001

6011

PROGRAMMABLE DRIVE ORDERING


BLSi7080 Packaged 7.0 amp continuous, 80 VDC programmableservo drive with Si™ software.

BLx7080 Packaged 7.0 amp continuous, 80 VDC programmableor pulse & direction servo drive

INDIVIDUAL MOTOR ORDERING

Motor Part Number Description System Number

A0030-104-2-000 30 watt, 48 volt, 28 mm frame 2802





INDIVIDUAL EXTENSION MOTOR CABLE ORDERING

Motor Cable Length System Number

BLMTR-CA-04 4 feet 04



BLMTR-CA-XX Custom Length N/A

INDIVIDUAL EXTENSION ENCODER CABLE ORDERING

Encoder Cable Length System Number

BLENC-CA-04 4 feet 04



BLENC-CA-XX Custom Length N/A

System Ordering Example: BLSi7080-4002-10

BLSi

7080

Ord

erin

g In

form

atio

n


Type Description



146



SERVOSYSTEMS

BLx7

080

Serv

o Am

plifi

er

BLx7080 Servo Amplifier

Description

The BLx7080 programmable servo drives includea motion controller, digital PID position loop, am-plifier and 80 volt power supply. These featuresmakes it suitable for a wide range of motion appli-cations using either brush or brushless motors.

The BLx7080 accepts pulse and direction com-mands from any type of motion controller, and alsoincludes preset moves and jog capabilities. TheBLx has seven inputs and one output.

Tuning the PID loop is easy with our Quick Tunersoftware, which features a built-in oscilloscope.Software selection of encoder line count and com-mutation sequence allows the motor to be config-ured without swapping wires.

Features:

• BLx7080 can be used with any motion control-ler, PLC indexer or other controller that generatespulse and direction commands, or can be set toperform preset moves or jog functions.

• Direct 120/240 volt, 50/60 Hz AC input. No exter-nal Power Supply needed.

• Continuous current of 7A, peak current to 14A.• Speeds to 6,000 rpm. Motor and load dependent.• 20 kHz precision PWM amplifier.• Pluggable screw terminal connectors for AC

power, motor phases, communications and I/O.• Pluggable, industry standard D connector for en-

coder and commutation signals.• Optically isolated RS-232.• Optically isolated I/O.• Internal regeneration clamp circuit. No external

components needed.

Options

• Five custom matched Applied Motion Alpha se-ries brushless servomotors.

• Standard or custom length extension cables.• Complete system configuration ordering.

147



SERVOSYSTEMS

POWER AMPLIFIER:

AMPLIFIER TYPE .......................................... 3 phase MOSFET.CURRENT CONTROL ..................................... 4 quadrant, pulse width modulated, switching at 20 kHz.AC INPUT ...................................................... 120 Volts @ 4 amps maximum or 240 Volts @ 2 amps maximum. Ex-

ternally switch selectable. 50/60 Hz.OUTPUT CURRENT ....................................... 7.0 amps continuous. 14 amps peak current, 2 seconds max.INTERNAL DC BUS VOLTAGE........................ 90 VDC NO LOAD, 70 VDC @ 7 amps maximum load (with AC input at

specified values).MAXIMUM CONTINUOUS OUTPUT POWER . 400 Watts.PROTECTION CIRCUITS................................ Drive over temperature. Over-voltage resulting from motor regenera-

tion.POSITION RESOLUTION ............................... Electronic gearing feature allows any resolution from 200 to 65,535

steps per rev.MOTION UPDATE .......................................... 12,800 Hz.SERVO UPDATE ............................................ 4,266 Hz.ENABLE INPUT .............................................. Programmable inputs on the logic connector (IN1 – IN6) that can be

used to disable the drive. The current to the servomotor will be turnedoff. The BLx7080 operates normally without any connections to theenable circuit. Use this feature only to disable the amplifier.

ENCODER INPUTS ........................................ Differential 5 V, A & B quadrature.COMMUTATION INPUTS ............................... 5 V TTL level, filtered.ENCODER POWER ........................................ 5 VDC, 200 mA (maximum) provided by drive.ENCODER RESOLUTION ............................... 100 to 50,000 counts/rev (25 to 12,500 lines).

CONTROL SECTION:

SERIAL COMMUNICATION............................ RS-232 programming port. Optically isolated.STATUS LED’S ............................................... DC power (red), Overtemp (yellow). Regeneration Clamp (yellow)INPUTS.......................................................... 7 dedicated/user programmable inputs:

IN1/STEP & IN2/DIR: differential, high speed, optically isolated. 5V,440 ohm, 2 mHz max step rate, 1 msec direction set up and holdtime. These inputs also accept Encoder A & B quadrature or Step-up/Step-Down signals. IN3/SPEED & IN4/SENSOR: optically isolated, 5 –24V, 2,200 ohm. IN5 & IN6: optically isolated, 5 – 24V, 2,200 ohm,General purpose inputs.ANALOG1: 0 – 5V, 10 bit resolution. Maximum impedance of drivingsignal or potentiometer: 10k ohm.

OUTPUT ........................................................ 1 optically isolated (can source or sink current), 100 mA, 30V max.


OVERALL SIZE .............................................. 4˝ x 8˝ x 5.3˝.CHASSIS MATERIAL ..................................... Steel, painted black with white characters. Black anodized aluminum

heat sink.WEIGHT ......................................................... 11 Lbs.AMBIENT TEMPERATURE ............................. 0 to 40C (32 to 104F) normal operating.

0 to 70C (32 to 150F) maximum.HUMIDITY ..................................................... Maximum of 90% non-condensing.CONNECTORS ............................................... Pluggable screw terminal connectors for input power, I/O signals,

Communications and motor, DB-15 for encoder/Hall signals.RECOMMENDED MOTORS ........................... Can drive 30W to 400W BLDC motor.

BLX7080 Technical Specifications

148



SERVOSYSTEMS

MOSFETPWM Power

Amplifier

120 - 240 VAC

IN1/STEPIN2/DIR

IN3/SPEEDIN4/SENSOR

IN5IN6

OUT1

PC RS232

PIDServoLoop

eepromOpticalIsolation

InternalLogicSupply

motor

encoder

+5V OUTANALOG IN

GNDFilter

80 Volt DCPower Supply

RegenerationClamp Circuit

4.12 "

8.00 "

4.00 "

1.25 "

8.97 " 9.25 "

5.45 "

5.30 "

2.02 "

0.25"

0.06"

2.15"

POWERPC

G

L2/N

L1AC POWER

GND

COM

IN1/STEP

ANALOG IN+5V OUT

OUT1–OUT1+

IN6COM

IN5

IN4/SENSOR

IN3/SPEEDIN2/DIR

COM

COM

TEMP

REGEN

PHASE APHASE BPHASE C

G

MOT

ORFE

EDBA

CK

90V pk

MOT

OR

Optic

ally

Isol

ated

I/O

BLx7080 Technical Drawings

MECHANICAL OUTLINE

BLOCK DIAGRAM

149



SERVOSYSTEMS

BLx7080 Connectors

RS-232 connector

motor connectorto motor windings

motor encoder I/O connector

AC power connector

LEDspower

overtempregeneration

I/Oinputs, outputs

I/O

position no.1 in 1/step+2 in 1/step–3 in 2/dir+4 in 2/dir–5 in 3/speed6 com7 in 4/sensor8 in 59 com10 in 611 out 1+12 out 1–

AC POWER

position no.1 L12 L2/N3 GROUND

MOTOR

position no.1 GROUND2 PHASE C3 PHASE B4 PHASE A

COMMUNICATIONSposition no.

1 RS-232

MOTOR ENCODER I/Oposition no.

1 A+2 A–3 B+4 B–5 INDEX +6 INDEX –7 SHIELD8 NO CONNECTION9 +5 VDC10 GROUND11 HALL 112 HALL 213 HALL 314 NO CONNECTION15 NO CONNECTION

Analog I/O

ANALOG I/O

position no.1 +5 out2 analog in3 GROUND

150



SERVOSYSTEMS

METRIC



System P/N 2802 4002 4012 6001 6011

Voltage V 48 48 48 48 60

Output Power W 30 50 100 200 400

Maximum OperatingSpeed rpm 5,000 5,000 5,000 5,000 3,600



0.0950.84

0.1591.41

0.3182.81

0.645.66

1.2711.24


N.m.lb-in

0.2862.53

0.484.25

0.958.41

1.9116.9

3.8233.8


0.060.64

0.080.71

0.110.97

0.0950.84

0.191.68




Continuous StallCurrent amps 1.5 2 3 6.7 6.5

Rotor Inertia g-cm2

oz-in-sec210

1.42 X 10-423

3.262 X 10-442

5.952 X 10-4200

2.832 X 10-3360

5.10 X 10-3

Maximum WindingTemp Class B (130˚C)


0.020.18

0.030.27

0.030.27

0.040.35

0.040.35

Weight (lbs) .077 0.88 1.10 2.42 3.52

Phases 3

Poles 8

Recommended Motors for BLx7080



BLx7080 Extension Cables

Note: All electrical specs are phase to phase.BLX7080 amplifier uses 2X peak current limit.

151



SERVOSYSTEMS

Recommended 28 mm Alpha Motor for the BLx7080

Recommended 40 mm Alpha Motor for the BLx7080

305 +76–0




Ø28

LABEL

L ± 1

A

POTTING

5.0

2.020 ± 1

0.080.05

AB

Ø6.000 –0.0120

Ø25.000 –0.0210

0.6 X 45˚

B

28

Ø38 REF

2 X Ø3.0 ONA Ø33 B.C.

(57)


A0030-104-2-000 87.0 (3.43)

305 +76–0

29.215.0




A

2.525 ± 1

5.0 0.080.05

Ø30.00 –0.021

AB

+0

0.75(.03) X 45˚

Ø8.000 –.009+0

B2 X Ø4.5 THRU


40

LABEL

L ±1

10.0

22.1512.2


A0050-104-3-000 70.6 (2.78)

A0100-104-3-000 88.4 (3.48)

152



SERVOSYSTEMS




A

3.030 ± 1

6.00.080.05

AB

Ø14.0 –0.0110

0.75 X 45˚

Ø50.0 –0.025+0

305 +76–0


60

L ± 1LABEL

Recommended 60 mm Alpha Motor for the BLx7080DIMENSION “L”PART NUMBER L mm (inch)

A0200-104-4-000 93 (3.66)

A0400-105-4-000 121 (4.76)

153



SERVOSYSTEMS

BLx7080 Torque Curveswith 28mm, 40 mm & 60 mm Alpha Brushless Servo Motors

0 1000 2000 3000 4000 50000

10

20

30

40

50

Peak Continuous

A0050-104-3-000, Alpha Motor

rpm

oz-in

BLX7080 set at 2.0 amps (4.0 peak)

0 1000 2000 3000 4000 50000

20

40

60

80

100

Peak Continuous

A0100-104-3-000, Alpha Motor

rpm

oz-in


0 1000 2000 3000 4000 50000

40

80

120

160

200

Peak Continuous

A0200-104-4-000, Alpha Motor

rpm

oz-in


0 1000 2000 3000 4000 50000

60

120

180

240

300

360

Peak Continuous

A0400-105-4-000, Alpha Motor

rpm

oz-in


0 1000 2000 3000 4000 50000

5

10

15

20

25

30

Peak Continuous

A0030-104-2-000, Alpha Motor

rpm

oz-in


154



SERVOSYSTEMS

123

71114

15 16

106



(11) Hall 1(12) Hall 2



AM

P

“L” +3–0





1 2 3 4 5 6 7 8

9 10 11 12 13 14 15


4 feet BLENC-CA-04

10 feet BLENC-CA-10

20 feet BLENC-CA-20

123

4


“L” + 3–0

4 x 1.5





4 feet BLMTR-CA-04

10 feet BLMTR-CA-10

20 feet BLMTR-CA-20

BLx7080 Motor Extension Cable DrawingsENCODER EXTENSION CABLE


0° 60° 120° 180° 240° 300° 360° 0° 15° 30° 45° 60° 75° 90°

VAB VBC VCA

Hall 1+

D


Mot

or B

ack

EMF


Hall 2+

Hall 3+




155



SERVOSYSTEMSCOMPLETE SYSTEM ORDERING

Drive Type Motor System Number Extension Cable System Number

BLSi7080 2802 04

BLx7080 4002 10

4012 20

6001

6011

PROGRAMMABLE DRIVE ORDERING


BLSi7080 Packaged 7.0 amp continuous, 80 VDC programmableservo drive with Si™ software.

BLx7080 Packaged 7.0 amp continuous, 80 VDC programmableor pulse & direction servo drive

INDIVIDUAL MOTOR ORDERING

Motor Part Number Description System Number






INDIVIDUAL EXTENSION MOTOR CABLE ORDERING

Motor Cable Length System Number




BLMTR-CA-XX Custom Length N/A

INDIVIDUAL EXTENSION ENCODER CABLE ORDERING

Encoder Cable Length System Number




BLENC-CA-XX Custom Length N/A

System Ordering Example: BLX7080-4002-10

BLx7

080

Orde

ring

Info

rmat

ion


Type Description





OPEN FRAMESERVO

AMPLIFIERS

156

SERVOSYSTEMS



OPEN FRAMESERVO

AMPLIFIERS

157

Open

Fra

me

Serv

o Am

plifi

ers



OPEN FRAMESERVO

AMPLIFIERS

158

BL70

80x

Serv

o Am

plifi

er

BL7080x Servo Amplifier

Description:

The BL7080x servo amplifier is suitable for a widerange of motion applications and is designedaround a precise, powerful and efficient PWM am-plifier. BL7080x is a servo amplifier that can acceptpulse and direction commands from any type ofmotion controller as well as providing the user withpreset programming capabilities.

Tuning the PID loop on the BL7080x is easy withour Quick Tuner™ software, featuring a built-in os-cilloscope. Software selection of encoder linecount and commutation sequence allows the motorto be configured without swapping wires.

Features:

• BL7080x can be used with any motion controller,PLC indexer or other controller that generatespulse and direction commands, or can be set toperform preset moves or jog functions.

• Requires 24-80 VDC power supply.• Continuous current of 7A, peak current to 14A• Speeds to 6000 rpm. Motor and load dependent.• 20 kHz precision PWM amplifier.• Compatible motors and extension cables avail-

able from stock.• Compact size (2 x 3 x 6 inches).• Screw terminal connectors for power, motor

phases and I/O.• Pluggable, industry standard D connector for en-

coder and commutation signals.

Options:

• Eight Applied Motion Alpha series servo motorsspecifically designed for optimized performancewith the BL7080X amplifier. These motors featurelow profile right angle strain relief, shielded motorand encoder cables and mil style connectors.

• Standard or custom length extension cables forthe motor and encoder that allow for quick, plugand play system set up.

• Regeneration clamp circuit (recommended).• Recommended power supplies: PS430, PS1050

and PS1070.



OPEN FRAMESERVO

AMPLIFIERS

159

POWER AMPLIFIER:

AMPLIFIER TYPE ....................................... 3 phase MOSFET.CURRENT CONTROL .................................. 4 quadrant, pulse width modulated, switching at 20 KHz.OUTPUT CURRENT .................................... 7.0 amps continuous. 14 amps peak current, 2 seconds max.DC BUS VOLTAGE ...................................... 24 to 80 VDC. 7 amps typical maximum load.MAXIMUM CONTINUOUS OUTPUT POWER 560 Watts.PROTECTION CIRCUITS ............................. Drive over temperature.POSITION RESOLUTION ............................ Electronic gearing feature allows any resolution from 200 to

65,535 steps per rev.MOTION UPDATE ....................................... 12800 Hz.SERVO UPDATE ......................................... 4266 Hz.ENABLE INPUT ........................................... Two terminals on the logic connector (EN+ AND EN–) that can be

used to disable the drive. The current to the servo motor will beturned off. The BL7080x operates normally without any connectionsto the enable circuit. Use this feature only to disable the amplifier.

CONTROLLER SECTION BL7080x:

INPUTS....................................................... IN1/STEP & IN2/DIR: differential, high speed, optically isolated.5V, 440 ohm, 2 MHz max step rate, 1 msec direction set up andhold time. IN3/SPEED & IN4/SENSOR: differential, optically iso-lated, 5 – 24V, 2200 ohm. ANALOG1: 0 – 5V, 10 bit resolution.Maximum impedance of driving signal or potentiometer: 10 k ohm.

OUTPUT ..................................................... Differential (can source or sink current), optically isolated. 100mA, 30V max.

ENCODER INPUTS ..................................... Differential O – 5 V, A & B quadrature.COMMUTATION INPUTS ............................ O – 5 V TTL level, filtered.ENCODER POWER ..................................... 5 VDC, 200 mA provided by drive.ENCODER RESOLUTION ............................ 100 – 50,000 counts/rev (25 – 12,500 lines).


OVERALL SIZE ........................................... 2 x 3 x 6 inches.CHASSIS MATERIAL .................................. Aluminum, black anodized with integral heat sink.WEIGHT ...................................................... 1 Lb.AMBIENT TEMPERATURE .......................... 0˚ to 70˚C (32˚ to 50˚F).HUMIDITY .................................................. Maximum of 90% non-condensing.CONNECTORS ............................................ Screw terminal connectors for input power, I/O signals and motor,

DB-15 for encoder/Hall signals.RECOMMENDED MOTORS ........................ Can drive 30W to 400W BLDC motor.

BL7080x Technical Specifications



OPEN FRAMESERVO

AMPLIFIERS

160

IN1/STEPIN2/DIR

IN3/SPEEDIN4/SENSOR

OUT1

+5V OUTANALOG IN

GND

MOSFETPWM Power

Amplifier

24 - 80 VDC

PC RS232

PIDServoLoop

xController

eeprom

OpticalIsolation

Filter

InternalLogicSupply

motor

encoder

2.45"

5.70"0.150"

3.00"

0.25"

0.25"

6.00"

0.15"

0.17"

5.70"

2.00"

.720"

1.345"

2.08"6 x Ø.170

BL7080x Technical Drawings

MECHANICAL OUTLINE

BLOCK DIAGRAM



OPEN FRAMESERVO

AMPLIFIERS

161

Note: All electrical specs are phase to phase.BL7080x amplifier uses 2X peak current limit.




Part Number A0030-103-2-000 A0030-104-2-000 A0050-103-3-000 A0050-104-3-000 A0100-103-3-000 A0100-104-3-000 A0200-104-4-000 A0400-105-4-000

Voltage V 24 48 24 48 24 48 48 60

Output Power W 30 30 50 50 100 100 200 400

Maximum OperatingSpeed rpm 5,000 5,000 5,000 5,000 4,000 5,000 5,000 3,600



0.0950.84

0.0950.84

0.1591.41

0.1591.41

0.3182.81

0.3182.81

0.645.66

1.2711.24


N.m.lb-in

0.2862.53

0.2862.53

0.484.25

0.484.25

0.958.41

0.958.41

1.9116.9

3.8233.8


0.030.33

0.060.64

0.030.27

0.080.71

0.070.63

0.110.97

0.0950.84

0.191.68

KE Voltage Constant V/krpm 3.40 6.60 5.40 8.40 7.40 11.7 10.0 20.4

Winding Resistance Ohm 0.78 2.80 1.11 2.60 0.79 2.00 0.37 0.63

Winding Inductance mH 0.480 1.80 1.27 3.10 1.17 2.60 1.10 2.00

Continuous StallCurrent amps 2.9 1.5 3.1 2 4.5 3 6.7 6.5

Rotor Inertia g-cm2

oz-in-sec210

1.42 x 10-410

1.42 x 10-423

3.26 x 10-423

3.26 x 10-442

5.95 x 10-442

5.95 x 10-4200

2.83 x 10-3360

5.10 x 10-3

Maximum WindingTemp Class B (130° C)


0.020.18

0.020.18

0.030.27

0.030.27

0.030.27

0.030.27

0.040.35

0.040.35

Weight (lbs) .077 0.88 1.10 2.42 3.52

Phases 3

Poles 8

Recommended Motors for the BL7080x

Recommended Extension Cables



OPEN FRAMESERVO

AMPLIFIERS

162

Recommended 28 mm Alpha Motor for the BL7080x


305 +76–0




Ø28

LABEL

L ± 1

A

POTTING

5.0

2.020 ± 1

0.080.05

AB

Ø6.000 –0.0120

Ø25.000 –0.0210

0.6 X 45˚

B

28

Ø38 REF

2 X Ø3.0 ONA Ø33 B.C.

(57)

305 +76–0

29.215.0




A

2.525 ± 1

5.0 0.080.05

Ø30.00 –0.021

AB

+0

0.75(.03) X 45˚

Ø8.000 –.009+0

B2 X Ø4.5 THRU


40

LABEL

L ±1

10.0

22.1512.2


A0030-103-2-000 87.0 (3.43)

A0030-104-2-000 87.0 (3.43)


A0030-101-3-000 61.5 (2.42)

A0030-102-3-000 61.5 (2.42)

A0050-101-3-000 70.6 (2.78)

A0050-102-3-000 70.6 (2.78)

A0050-103-3-000 70.6 (2.78)

A0050-104-3-000 70.6 (2.78)

A0100-101-3-000 88.4 (3.48)

A0100-102-3-000 88.4 (3.48)

A0100-103-3-000 88.4 (3.48)

A0100-104-3-000 88.4 (3.48)



OPEN FRAMESERVO

AMPLIFIERS

163





A

3.030 ± 1

6.00.080.05

AB

Ø14.0 –0.0110

0.75 X 45˚

Ø50.0 –0.025+0

305 +76–0


60

L ± 1LABEL

12 3

4

PIN NUMBER FUNCTION COLOR

1 A RED

2 B WHITE

3 C BLACK

4 DRAIN GREEN

CONNECTOR MATINGCONNECTOR

HOUSING AMP# 206153-1 AMP# 206060-1

PINS AMP# 1-66099-4 (4 pcs) AMP# 1-66101-8 (4 pcs)

CABLECLAMP AMP# 206062-3 AMP# 206062-3

PIN NUMBER FUNCTION COLOR PIN NUMBER FUNCTION COLOR

1 A+ BLUE 9 Hall 2+ GREY

2 A– BLUE/BLACK 10 Hall 2– GREY/BLACK

3 B+ GREEN 11 Hall 3+ WHITE

4 B– GREEN/BLACK 12 Hall 3– WHITE/BLACK

5 Index Z+ YELLOW 13 +5V RED

6 Index Z– YELLOW/BLACK 14 OV BLACK

7 Hall 1+ BROWN 15 DRAIN W/SHRINK TUBING

8 Hall 1– BROWN/BLACK 16 N/C N/C

1 23

711 1415 16

106

MOTOR POWER CONNECTOR

MOTOR CONNECTION TABLE

MOTOR ENCODER CONNECTOR

ENCODER CONNECTION TABLE


HOUSING AMP# 206036-3 AMP# 206037-1



BL7080x Motor & Encoder Connector Detail


A0200-104-4-000 93 (3.66)

A0400-105-4-000 121 (4.76)



OPEN FRAMESERVO

AMPLIFIERS

164

A0030-103-2-000, Alpha Motorw/PS430 Power Supply (30 VDC)BL7080x set at 2.9 amps (5.8 peak)

0 2000 4000 6000 8000 10000 120000

5

10

15

20

25

30

Peak Continuous

rpm

oz-in


0 2000 4000 6000 8000 100000

5

10

15

20

25

30

Peak Continuous

rpm

oz-in


0 1000 2000 3000 4000 5000 6000 7000 80000

10

20

30

40

50

Peak Continuousrpm

oz-in


0 1000 2000 3000 4000 5000 6000 7000 80000

10

20

30

40

50

Peak Continuous

rpm

oz-in

BL7080x Torque Curveswith 28 mm & 40 mm Brushless Servo Motors



OPEN FRAMESERVO

AMPLIFIERS

165


0 1000 2000 3000 4000 5000 60000

20

40

60

80

100

Peak Continuous

rpm

oz-in


0 1000 2000 3000 4000 5000 60000

20

40

60

80

100

Peak Continuous

rpm

oz-in


0 1000 2000 3000 4000 5000 6000 7000 80000

50

100

150

200

Peak Continuous

rpm

oz-in


0 1000 2000 3000 4000 50000

50

100

150

200

250

300

350

Peak Continuous

rpm

oz-in

BL7080x Torque Curveswith 40 mm & 60 mm Brushless Servo Motors



OPEN FRAMESERVO

AMPLIFIERS

166

123

71114

15 16

106



(11) Hall 1(12) Hall 2



AM

P

“L” +3–0





1 2 3 4 5 6 7 8

9 10 11 12 13 14 15


4 feet BLENC-CA-04

10 feet BLENC-CA-10

20 feet BLENC-CA-20

123

4


“L” + 3–0

4 x 1.5





4 feet BLMTR-CA-04

10 feet BLMTR-CA-10

20 feet BLMTR-CA-20

BL7080x Motor Extension Cable DrawingsENCODER EXTENSION CABLE


0° 60° 120° 180° 240° 300° 360° 0° 15° 30° 45° 60° 75° 90°

VAB VBC VCA

Hall 1+

D


Mot

or B

ack

EMF


Hall 2+

Hall 3+






OPEN FRAMESERVO

AMPLIFIERS

167



OPEN FRAMESERVO

AMPLIFIERS

168

BL70

80i P

rogr

amm

able

Ser

vo A

mpl

ifier

BL7080i Servo Amplifier

Description

The BL7080i programmable servo amplifier is suit-able for a wide range of motion applications and isdesigned around a precise, powerful and efficientPWM amplifier. BL7080i is an intelligent servo am-plifier that includes a sophisticated motion control-ler integrated with a PID control loop.

The BL7080i includes Applied Motion’s easy to useSi Programmer™ Windows software for the rapiddevelopment of stand-alone motion control pro-grams. BL7080i can also be commanded in realtime from a host PC or PLC, using the Si CommandLanguage™ (SCL).

Tuning the PID loop on the BL7080i is easy withour Quick Tuner™ software, featuring a built-in os-cilloscope. Software selection of encoder linecount and commutation sequence allows the motorto be configured without swapping wires.

For multi-axis applications, up to eight BL7080idrives can be networked using the SiNet Hub. Thehub also allows BL7080i to be mixed with otherSi™ drive models, stepper and servo.

The BL7080i includes 8 programmable optical iso-lated inputs for triggering, branching, positionsensing and end of travel detection. 3 program-mable optical isolated outputs can send signals toother electronic devices and activate relays.

Features:

• BL7080i can be programmed for stand-alone op-eration with the easy to use Si Programmer™Windows software (software and programmingcable included).

• BL7080i can be operated in real time from a hostPC or PLC using the Si Command Language(SCL), via RS232.

• Requires 24-80 VDC power supply.• Continuous current of 7A, peak currents to 14A• Speeds to 6000 rpm. Motor and load dependent.• 20 kHz precision PWM amplifier.• Compatible motors and extension cables avail-

able from stock.• Compact size (2 x 3 x 6 inches).• Screw terminal connectors for power, motor

phases and I/O.• Pluggable, industry standard D connector for en-

coder and commutation signals.

Options:

• Eight Applied Motion Alpha series servo motorsspecifically designed for optimized performancewith the BL7080i amplifier. These motors featurelow profile right angle strain relief, shielded mo-tor and encoder cables and mil style connectors.

• Standard or custom length extension cables forthe motor and encoder that allow for quick, plugand play system set up.

• Regeneration clamp circuit (recommended).• Recommended power supplies: PS430, PS1050

and PS1070.



OPEN FRAMESERVO

AMPLIFIERS

169

POWER AMPLIFIER:

AMPLIFIER TYPE ....................................... 3 phase MOSFET.CURRENT CONTROL .................................. 4 quadrant, pulse width modulated, switching at 20 KHz.OUTPUT CURRENT .................................... 7.0 amps continuous. 14 amps peak current, 2 seconds max.DC BUS VOLTAGE ...................................... 24 to 80 VDC. 7 amps typical maximum load.MAXIMUM CONTINUOUS OUTPUT POWER 560 Watts.PROTECTION CIRCUITS ............................. Drive over temperature.POSITION RESOLUTION ............................ Set via software to match encoder resolutions from a minimum of

25 lines to a maximum of 12,500 lines per revolution producing aminimum of 100 counts to a maximum of 50,000 counts per revo-lution in quadrature.

MOTION UPDATE ....................................... 12800 Hz.SERVO UPDATE ......................................... 4266 Hz.

CONTROLLER SECTION:

SERIAL COMMUNICATION ......................... RS-232 programming port.STATUS LED'S ............................................ DC power (red), Overtemp (yellow).INPUTS....................................................... 8 user programmable inputs:

2 dedicated, optically isolated limit switch inputs, 5 – 24 VDC.4 general purpose, filtered inputs. The Feed to Sensor instructioncan use these inputs for homing or other sensing needs. TheWait Input instruction can wait for one of the inputs to see agiven voltage state or signal edge. The If Input instruction canbranch based on the state of an input. 2 jog inputs (cw and ccw)that can also be used as general purpose inputs.

OUTPUTS ................................................... 4 user outputs:Drive fault (activated by overcurrent or overtemperature condition).3 general purpose, optically isolated outputs for interfacing toother equipment. Can be set, opened or closed, or programmedto send a pulse by the Set Output instruction.

PARAMETER RANGES ............................... Distance: 1 to 16,000,000 (CW or CCW), absolute position ± 2 billion.Speed: .025 to 100 revolutions per second.Acceleration: 1 to 3,000 rev/sec/sec.Deceleration: 1 to 3,000 rev/sec/sec (set independently from ac-celeration).Time Delays: .01 to 300 seconds.Output Pulse Widths: 2 to 500 milliseconds.Iterations per loop: 1 to 65,535.

OPTIONAL OPERATOR INTERFACE (MMI) NEMA 4X rated (splash proof & dust proof).4 x 20 characters liquid crystal display (LCD) standard or backlit.20 key membrane keypad.Overall size: 4.9 x 4.9 x 1.42 inches.Optional backlit display.


OVERALL SIZE ........................................... 2 x 3 x 6 inches.CHASSIS MATERIAL .................................. Aluminum, black anodized with integral heat sink.WEIGHT ...................................................... 1 Lb.AMBIENT TEMPERATURE .......................... 0˚ to 70˚C (32˚ to 50˚F).HUMIDITY .................................................. Maximum of 90% non-condensing.CONNECTORS ............................................ Screw terminal connectors for input power, I/O signals and motor,

DB-15 for encoder/Hall signals.RECOMMENDED MOTORS ........................ Can drive 30W to 400W BLDC motor.

BL7080i Technical Specifications



OPEN FRAMESERVO

AMPLIFIERS

170

BL7080i Technical Drawings

MECHANICAL OUTLINE

BLOCK DIAGRAM

2.45"

5.70"0.150"

3.00"

0.25"

0.25"

6.00"

0.15"

0.17"

5.70"

2.00"

.720"

1.345"

6 x Ø.170 2.08"

MOSFETPWM Power

Amplifier

24 - 80 VDC



PC/MMI

CW LIMITCCW LIMIT

OUT1OUT2OUT3

RS232

PIDServoLoop

Si™Programmable

Controller

eeprom

OpticalIsolation

InternalLogicSupply

motor

encoder



OPEN FRAMESERVO

AMPLIFIERS

171

Note: All electrical specs are phase to phase.BL7080i amplifier uses 2X peak current limit.




Part Number A0030-103-2-000 A0030-104-2-000 A0050-103-3-000 A0050-104-3-000 A0100-103-3-000 A0100-104-3-000 A0200-104-4-000 A0400-105-4-000

Voltage V 24 48 24 48 24 48 48 60

Output Power W 30 30 50 50 100 100 200 400

Maximum OperatingSpeed rpm 5,000 5,000 5,000 5,000 4,000 5,000 5,000 3,600



0.0950.84

0.0950.84

0.1591.41

0.1591.41

0.3182.81

0.3182.81

0.645.66

1.2711.24


N.m.lb-in

0.2862.53

0.2862.53

0.484.25

0.484.25

0.958.41

0.958.41

1.9116.9

3.8233.8


0.030.33

0.060.64

0.030.27

0.080.71

0.070.63

0.110.97

0.0950.84

0.191.68

KE Voltage Constant V/krpm 3.40 6.60 5.40 8.40 7.40 11.7 10.0 20.4

Winding Resistance Ohm 0.78 2.80 1.11 2.60 0.79 2.00 0.37 0.63

Winding Inductance mH 0.480 1.80 1.27 3.10 1.17 2.60 1.10 2.00

Continuous StallCurrent amps 2.9 1.5 3.1 2 4.5 3 6.7 6.5

Rotor Inertia g-cm2

oz-in-sec210

1.42 x 10-410

1.42 x 10-423

3.26 x 10-423

3.26 x 10-442

5.95 x 10-442

5.95 x 10-4200

2.83 x 10-3360

5.10 x 10-3



0.020.18

0.020.18

0.030.27

0.030.27

0.030.27

0.030.27

0.040.35

0.040.35

Weight (lbs) .077 0.88 1.10 2.42 3.52

Phases 3

Poles 8

Recommended Motors for the BL7080i




OPEN FRAMESERVO

AMPLIFIERS

172

Recommended 28 mm Alpha Motor for the BL7080i


305 +76–0




Ø28

LABEL

L ± 1

A

POTTING

5.0

2.020 ± 1

0.080.05

AB

Ø6.000 –0.0120

Ø25.000 –0.0210

0.6 X 45˚

B

28

Ø38 REF

2 X Ø3.0 ONA Ø33 B.C.

(57)

305 +76–0

29.215.0




A

2.525 ± 1

5.0 0.080.05

Ø30.00 –0.021

AB

+0

0.75(.03) X 45˚

Ø8.000 –.009+0

B2 X Ø4.5 THRU


40

LABEL

L ±1

10.0

22.1512.2


A0030-103-2-000 87.0 (3.43)

A0030-104-2-000 87.0 (3.43)


A0030-101-3-000 61.5 (2.42)

A0030-102-3-000 61.5 (2.42)

A0050-101-3-000 70.6 (2.78)

A0050-102-3-000 70.6 (2.78)

A0050-103-3-000 70.6 (2.78)

A0050-104-3-000 70.6 (2.78)

A0100-101-3-000 88.4 (3.48)

A0100-102-3-000 88.4 (3.48)

A0100-103-3-000 88.4 (3.48)

A0100-104-3-000 88.4 (3.48)



OPEN FRAMESERVO

AMPLIFIERS

173





A

3.030 ± 1

6.00.080.05

AB

Ø14.0 –0.0110

0.75 X 45˚

Ø50.0 –0.025+0

305 +76–0


60

L ± 1LABEL

12 3

4


1 A RED

2 B WHITE

3 C BLACK

4 DRAIN GREEN


HOUSING AMP# 206153-1 AMP# 206060-1












1 23

711 1415 16

106






HOUSING AMP# 206036-3 AMP# 206037-1



BL7080i Motor & Encoder Connector Detail


A0200-104-4-000 93 (3.66)

A0400-105-4-000 121 (4.76)



OPEN FRAMESERVO

AMPLIFIERS

174

BL7080i Torque Curveswith 28 mm & 40 mm Brushless Servo Motors

A0030-103-2-000, Alpha Motorw/PS430 Power Supply (30 VDC)BL7080i set at 2.9 amps (5.8 peak)

0 2000 4000 6000 8000 10000 120000

5

10

15

20

25

30

Peak Continuous

rpm

oz-in


0 2000 4000 6000 8000 100000

5

10

15

20

25

30

Peak Continuous

rpm

oz-in


0 1000 2000 3000 4000 5000 6000 7000 80000

10

20

30

40

50

Peak Continuousrpm

oz-in


0 1000 2000 3000 4000 5000 6000 7000 80000

10

20

30

40

50

Peak Continuous

rpm

oz-in



OPEN FRAMESERVO

AMPLIFIERS

175

BL7080i Torque Curveswith 40 mm & 60 mm Brushless Servo Motors


0 1000 2000 3000 4000 5000 60000

20

40

60

80

100

Peak Continuous

rpm

oz-in


0 1000 2000 3000 4000 5000 6000 7000 80000

50

100

150

200

Peak Continuous

rpm

oz-in


0 1000 2000 3000 4000 50000

50

100

150

200

250

300

350

Peak Continuous

rpm

oz-in


0 1000 2000 3000 4000 5000 60000

20

40

60

80

100

Peak Continuous

rpm

oz-in



OPEN FRAMESERVO

AMPLIFIERS

176

123

71114

15 16

106



(11) Hall 1(12) Hall 2



AM

P

“L” +3–0





1 2 3 4 5 6 7 8

9 10 11 12 13 14 15


4 feet BLENC-CA-04

10 feet BLENC-CA-10

20 feet BLENC-CA-20

123

4


“L” + 3–0

4 x 1.5





4 feet BLMTR-CA-04

10 feet BLMTR-CA-10

20 feet BLMTR-CA-20

BL7080i Motor Extension Cable DrawingsENCODER EXTENSION CABLE


0° 60° 120° 180° 240° 300° 360° 0° 15° 30° 45° 60° 75° 90°

VAB VBC VCA

Hall 1+

D


Mot

or B

ack

EMF


Hall 2+

Hall 3+






OPEN FRAMESERVO

AMPLIFIERS

177



OPEN FRAMESERVO

AMPLIFIERS

178

Description

As with most servo systems a clamp circuit is re-quired to limit increase power supply buss voltagewhen the motor is decelerating under load. This iscommonly referred to as “regeneration” which iswhat happens when DC motors are driven by theirload. During regeneration the DC motor can pro-duce enough voltage to actually exceed the inputpower supply voltage. More sophisticated servoamplifiers deal with this by channeling the in-creased motor voltage back to the source powersupply. If the voltage is not clamped to a safe levelthe amplifier can be damaged or destroyed.

The BL7080i and BL7080x servo amplifier/control-lers are types that channel the increasing voltageback to the input power supply. In some cases thiscan be handled by placing a significant size capaci-tor at the input to “absorb” the voltage impulse.However, this is often not enough especially incases where a large inertial mass is being deceler-ated.

For this reason Applied Motion Products offers a“Regen Clamp” module for our servo drive prod-ucts. With this module one or more servo drivescan be protected from “Over Voltage” conditionsby placing the clamp module between the powersupply and the drive. The clamp tracks the inputpower supply and will operate from 24 to 80 volts.No adjustments are needed.

The Regen Clamp is designed to handle a widerange of conditions. The voltage input matches theneeds of the AMP servo drives by providing 24 to80 VDC capabilities. The clamps come in differentversions for moderate to high power operation. Ex-ternal power resistors can be added for evengreater continuous power requirements. The mod-ules are small and compact to minimize impact onthe system design. More than one servo drive canbe connected to the clamp module with the poten-tial to handle an entire multi-axis sytem.

Features

Two versions are available:The RC-010 is a lower cost version with an openframe design that mounts to the target systemwith nylon standoffs.The RC-050 is mounted on a heat sink and has a50 watt power resistor for more continuous cur-rent handling.

Size:RC-010 is 2.6˝ x 2.75˝ x 2˝ tall (with stand offs).RC-050 is 3˝ x 4˝ x 2.25˝ tall.

Voltage Range:24 to 80 VDC, no user adjustments.

Peak Power:RC-010 – 800 Watts.RC-050 – 800 Watts.

Continuous Power:RC-010 – 10 Watts.RC-050 – 50 Watts.

Connection:6 pin screw terminal block accepts 12 – 18 guagewire.

Indicators:A green LED indicates power supply voltage ispresent. A red LED indicates when the clamp isoperating. This is typically a very short time sinceit is only on when the servo is decelerating.

Protection:The power supply is internally connected to an“Input Diode” that protects it from the higher re-generation voltages. The diode protects the sys-tem from connecting the power supply inreverse. If the clamp circuit were to fail the diodewill continue to protect the power supply fromover-voltage.

Rege

nera

tion

Clam

p

Regeneration Clamp



OPEN FRAMESERVO

AMPLIFIERS

179

Technical Specifications

Circuit Diagram:

The regeneration circuit is designed to provide a widerange of voltage clamping operation with a simple andreliable design. The block diagram gives a simplifiedview of the circuit design showing the major parts.

Terminal Block:

A 6 connection terminal block provides easy connectionaccess to the clamp. The terminal are designed for wiresizes from 12 – 28 AWG.

Input Diode:

The input diode provides over-voltage and reverse volt-age protection. If the input power supply is connected inreverse this diode will prevent failure. During over-volt-age conditions the diode blocks the higher regenerationvoltage from feeding into the input power supply. The in-put is designed to handle 20 amps continuous (RC-050)with peaks greater than 100 amps.

Internal Power Resistor:

For moderate power operation this may be all that is re-quired for safe operation. This resistor is designed to“sink” up to 8 amps when using an 80 volt power sup-ply, but only 2.5 amps when using a 24 volt supply.Larger power resistors can be added to the circuit byconnecting between the “R1” and the “R2” terminals.

Filter Capacitor:

To smooth out operation and allow the “Clamp” to workat a low switching frequency a large capacitor is addedacross the voltage output.

Over-Voltage Sense Circuit:

This part of the clamp senses when on over-voltage oc-curs. When the “Vout” exceeds the “Vin” by approxi-mately 1.2 volts the clamp will turn on. When “Vout”drops to about 1 volt below “Vin” the clamp turns off.

Clamp MOSFET:

At the heart of the circuit is a power MOSFET designedfor 20 amp continuous operation (with the RC-050 ver-sion).

Indicator LEDS:

A green LED is used to indicate power supply input whilea red LED is used to indicate when the clamp is on.

External Power Resistor:

An external Power Resistor may be added to increasethe continuous and/or peak power of the clamp circuit.The internal resistor is a 10 ohm value with either 10Watt or 50 Watt ratings depending on the version. Anexternal value can be added with a value of no less then10 ohms for a combined resistance of 5 ohms (16 ampspeak). In some cases the internal resistor should be dis-connected and entirely replaced where continuous op-eration will exceed its rating.

Example 1 (using the RC-010)A single servo drive is connected to the Regen Clampmodule with no external resistor required. This design willwork in most cases where the load is primarily “Frictional”as opposed to “Inertial.”

Terminal Block

Green LEDPower Indication

Red LEDClamp Indication

Input Diode

PowerResistor

FilterCap.

Clamp MOSFET

Over-VoltageSense Circuit

VinGND1GND2

VoutR1R2

123456

24 to 80VDC

PowerSupply

RegenClamp

(RC-010)

BL7080i

+ Vin

GND 1

GND 2

Vout

–

+–

24 to 80VDC

PowerSupply

RegenClamp

(RC-050)

BL7080iDrive #2

BL7080iDrive #1

+ Vin

GND 1

GND 2

Vout

R1

R2

–

+–

+–

External PowerResistor

10 ohm 50 W

Example 2 (using the RC-050)Two servo drives are connected to the Regen Clamp mod-ule. An external power resistor is used to supplement theinternal resistor. This design will work in cases where theload has significant “Inertial” content.



ALPHASERVO

MOTORS

180

OPEN FRAMESERVO

AMPLIFIERS



ALPHASERVO

MOTORS

181

Alph

a Br

ushl

ess

Serv

o M

otor

s



ALPHASERVO

MOTORS

182

FEATURES

• Compact size.• Speeds as high as 5,000 rpm.• Built-in high resolution incremental

encoder with differential outputs.• 4 frame sizes: 28 mm, 40 mm, 60 mm,

80 mm.• Power ratings range from 30 to 950

watts.

OPTIONS

• Matching planetary gearheads, stan-dard or metric output.

• Built-in fail-safe holding brake.• Built-in absolute encoder or brushless

resolver.

Alpha Brushless Servo Motors

Applied Motion’s Alpha Series Servo Motors provide approximately twice the torque per framesize as conventional servo motors. The rotor inertia has been optimally designed for typicalloads, giving the Alpha Series optimum power ratings for their size.



ALPHASERVO

MOTORS

183

A0000-000-0-000Custom Features/Optional Gearhead

Wattage RatingA0030 = 30 wattsA0050 = 50 wattsA0100 = 100 wattsA0200 = 200 wattsA0400 = 400 wattsA0600 = 600 wattsA0800 = 800 wattsA0950 = 950 watts

Encoder Type1 = 2,000 C/T2 = 2,048 C/T3 = abs encoder4 = resolver

Shaft Type0 = round1 = one flat2 = two flats3 = keyway4 = N/A5 = brake option w/round shaft6 = brake option w/one flat7 = brake option w/two flats8 = brake option w/keyway

Voltage1 = 1002 = 2003 = 244 = 485 = 606 = 80

Frame Size1 = 22 mm2 = 28 mm3 = 40 mm4 = 60 mm5 = 80 mm

Part Numbering System

EXAMPLE:

A0600-102-5-S10600 watts2,000 count encoderround shaft200 volts80 mm frameStandard 10:1 ratio gearhead



ALPHASERVO

MOTORS

184

28 m

m A

lpha

Mot

ors

305 +76–0




Ø28

LABEL

L ± 1

A

POTTING

5.0

2.020 ± 1

0.080.05

AB

Ø6.000 –0.0120

Ø25.000 –0.0210

0.6 X 45˚

B

28

Ø38 REF

2 X Ø3.0 ONA Ø33 B.C.

(57)


A0030-103-2-000 87.0 (3.43)

A0030-104-2-000 87.0 (3.43)

Mounting Flange inches (mm) ■ 1.10 (28 mm)

Part Number A0030-103-2-000 A0030-104-2-000

Voltage V 24 48

Output Power W 30 30

Maximum OperatingSpeed rpm 5,000 5,000



0.0950.84

0.0950.84


N.m.lb-in

0.2862.53

0.2862.53


0.030.33

0.060.64

KE Voltage Constant V/krpm 3.40 6.60

Winding Resistance Ohm 0.78 2.80

Winding Inductance mH 0.48 1.8

Continuous StallCurrent amps 2.9 1.5

Rotor Inertia g-cm2

oz-in-sec210

1.42 x 10-410

1.42 x 10-4



0.020.18

0.020.18

Weight (lbs) .77 .77

Phases 3

Poles 8



ALPHASERVO

MOTORS

185

Torque Curves28 mm Alpha Motors

A0030-103-2-000

0 1000 2000 3000 4000 50000

1

2

3

4

5

0

.11

.23

.34

.45

.57

Peak Continuousrpm

N•n Lb-in

0 1000 2000 3000 4000 50000

1

2

3

4

5

Peak Continuous

A0030-104-2-000

rpm

0

.11

.23

.34

.45

.57N•n Lb-in



ALPHASERVO

MOTORS

186

40 m

m A

lpha

Mot

ors

305 +76–0

29.215.0




A

2.525 ± 1

5.0 0.080.05

Ø30.00 –0.021

AB

+0

0.75(.03) X 45˚

Ø8.000 –.009+0

B2 X Ø4.5 THRU


40

LABEL

L ±1

10.0

22.1512.2


A0030-101-3-000 61.5 (2.42)

A0030-102-3-000 61.5 (2.42)

A0050-101-3-000 70.6 (2.78)

A0050-102-3-000 70.6 (2.78)

A0050-103-3-000 70.6 (2.78)

A0050-104-3-000 70.6 (2.78)

A0100-101-3-000 88.4 (3.48)

A0100-102-3-000 88.4 (3.48)

A0100-103-3-000 88.4 (3.48)

A0100-104-3-000 88.4 (3.48)



Voltage V 100 200 100 200 24

Output Power W 30 30 50 50 50

Maximum OperatingSpeed rpm 5,000



0.095.84

0.095.84

0.1591.41

0.1591.41

0.1591.41


N.m.lb-in

0.292.57

0.292.57

0.484.25

0.484.25

0.484.25


.181.59

.373.27

.191.68

.363.19

0.030.27




Continuous Stall Current amps 0.6 0.3 0.9 0.5 3.1

Rotor Inertia g-cm2

oz-in-sec213

1.84 x 10-413

1.84 x 10-423

3.26 x 10-423

3.26 x 10-423

3.26 x 10-4

Maximum Winding Temp Class B (130˚ C)


0.030.27

Weight (lbs) .66 .66 .88 .88 .88

Phases 3

Poles 8



ALPHASERVO

MOTORS

187



Voltage V 48 100 200 24 48

Output Power W 50 100 100 100 100

Maximum OperatingSpeed rpm 5,000 4,000 5,000



0.1591.41

0.3182.81

0.3182.81

0.3182.81

0.3182.81


N.m.lb-in

0.484.25

0.958.41

0.958.41

0.958.41

0.958.41


0.080.71

.221.95

.383.36

0.0710.63

0.110.97




Continuous Stall Current amps 2 1.5 0.9 4.5 3

Rotor Inertia g-cm2

oz-in-sec223

3.26 x 10-442

5.95 x 10-442

5.95 x 10-442

5.95 x 10-442

5.95 x 10-4

Maximum Winding Temp Class B (130˚ C)


0.030.27

Weight (lbs) 0.88 1.10 1.10 1.10 1.10

Phases 3

Poles 8

305 +76–0

29.215.0




A

2.525 ± 1

5.0 0.080.05

Ø30.00 –0.021

AB

+0

0.75(.03) X 45˚

Ø8.000 –.009+0

B2 X Ø4.5 THRU


40

LABEL

L ±1

10.0

22.1512.2


A0030-101-3-000 61.5 (2.42)

A0030-102-3-000 61.5 (2.42)

A0050-101-3-000 70.6 (2.78)

A0050-102-3-000 70.6 (2.78)

A0050-103-3-000 70.6 (2.78)

A0050-104-3-000 70.6 (2.78)

A0100-101-3-000 88.4 (3.48)

A0100-102-3-000 88.4 (3.48)

A0100-103-3-000 88.4 (3.48)

A0100-104-3-000 88.4 (3.48)



ALPHASERVO

MOTORS

188


0 1000 2000 3000 4000 50000

1

2

3

4

5

0

.11

.23

.34

.45

.57N•mTORQUE

SPEED (rpm)

Lb•inA0050-101-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

1

2

3

4

5

0

.11

.23

.34

.45

.57N•mTORQUE

SPEED (rpm)

Lb•inA0050-102-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

1

2

3

4

5

0

.11

.23

.34

.45

.57N•mTORQUE

SPEED (rpm)

Lb•inA0050-104-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

1

2

3

4

5

0

.11

.23

.34

.45

.57N•mTORQUE

SPEED (rpm)

Lb•inA0050-103-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

1

2

3

4

0

.11

.23

.34

.45N•mTORQUE

SPEED (rpm)

Lb•inA0030-101-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

1

2

3

4

0

.11

.23

.34

.45N•mTORQUE

SPEED (rpm)

Lb•inA0030-102-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE



ALPHASERVO

MOTORS

189

0 1000 2000 3000 4000 50000

2

4

6

8

10

0

.23

.45

.68

.90

1.13N•mTORQUE

SPEED (rpm)

Lb•inA0100-103-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

2

4

6

8

10

0

.23

.45

.68

.90

1.13N•mTORQUE

SPEED (rpm)

Lb•inA0100-104-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

2

4

6

8

10

0

.23

.45

.68

.90

1.13N•mTORQUE

SPEED (rpm)

Lb•inA0100-101-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

2

4

6

8

10

0

.23

.45

.68

.90

1.13N•mTORQUE

SPEED (rpm)

Lb•inA0100-102-3-000

MAXIMUM TORQUE

CONTINUOUS TORQUE



ALPHASERVO

MOTORS

190

60 m

m A

lpha

Mot

ors




A

3.030 ± 1

6.00.080.05

AB

Ø14.0 –0.0110

0.75 X 45˚

Ø50.0 –0.025+0

305 +76–0


60

L ± 1LABEL


Part Number A0200-101-4-000 A200-102-4-000 A0200-104-4-000 A0400-101-4-000 A0400-102-4-000 A0400-105-4-000

Voltage V 100 200 48 100 200 60

Output Power W 200 400




0.645.66

1.2711.24


N.m.lb-in

1.9116.9

3.8233.8


.201.77

.484.25

0.0950.84

.262.30

.423.72

0.191.68

KE Voltage Constant V/krpm 21.3 50.4 10.0 26.9 43.6 20.4

Winding Resistance Ohm 1.4 7.4 .37 0.9 2.4 0.63

Winding Inductance mH 4.8 27.0 1.10 3.4 9.0 2.00

Continuous StallCurrent amps 3.2 1.4 6.7 5.2 3.2 6.5

Rotor Inertia g-cm2

oz-in-sec2200

2.83 x 10-3200

2.83 x 10-3200

2.83 x 10-3360

5.10 x 10-3360

5.10 x 10-3360

5.10 x 10-3



0.040.35

Weight (lbs) 2.42 3.52

Phases 3

Poles 8


A0200-104-4-000 93 (3.66)

A0400-105-4-000 121 (4.76)



ALPHASERVO

MOTORS

191


0 1000 2000 3000 4000 50000

3

6

9

12

15

18N•mTORQUE

SPEED (rpm)

Lb•inA0200-101-4-000

0

.34

.68

1.02

1.36

1.70

2.03

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

3

6

9

12

15

18N•mTORQUE

SPEED (rpm)

Lb•inA0200-102-4-000

0

.34

.68

1.02

1.36

1.70

2.03

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

5

10

15

20

25

30

35N•mTORQUE

SPEED (rpm)

Lb•inA0400-101-4-000

0

.57

1.13

1.70

2.26

2.83

3.39

3.95

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

5

10

15

20

25

30

35N•mTORQUE

SPEED (rpm)

Lb•inA0400-102-4-000

0

.57

1.13

1.70

2.26

2.83

3.39

3.95

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

5

10

15

20N•mTORQUE

SPEED (rpm)

Lb•inA0200-104-4-000

0

.57

1.13

1.70

2.26

MAXIMUM TORQUE

CONTINUOUS TORQUE

0 1000 2000 3000 4000 50000

5

10

15

20

25

30

35N•mTORQUE

SPEED (rpm)

Lb•inA0400-105-4-000

0

.57

1.13

1.70

2.26

2.83

3.39

3.95

MAXIMUM TORQUE

CONTINUOUS TORQUE



ALPHASERVO

MOTORS

192




A

3.0 ± 0.335 ± 1.0

8.00.070.06

AB

Ø19.0 –0.0130

1.0 X 45˚

Ø70.0 ± .05

305 +76–0

B 4 X Ø6.6Ø90.0 B.C. REF

2X 63.73

2X 80.0

L ± 1LABEL

Mounting Flange inches (mm) ■ 3.15 (80)

Part Number A0600-102-5-000 A0800-102-5-000 A0950-102-5-000

Voltage V 200 200 200

Output Power W 600 800 950



Continuous StallTorque

N.m.lb-in

1.9116.9

2.5522.57

3.0226.75

Peak Torque N.m.lb-in

5.7350.71

7.6467.61

9.0680.19


.474.16

.575.05

0.716.28

KE Voltage Constant V/krpm 49.0 59.4 74.3

Winding Resistance Ohm 1.25 1.20 1.45

Winding Inductance mH 8.0 8.7 10.9

Continuous StallCurrent amps 4.2 4.6 4.4

Rotor Inertia g-cm2

oz-in-sec21000

1.42 x 10-21300

1.84 x 10-21620

2.29 x 10-2

Maximum WindingTemp °C 130˚C

Friction Torque N.m.lb-in

0.100.89

Motor Weight lbs. 5.73 7.04 8.36

Phases 3

Poles 8


A0600-102-5-000 128 (5.04)

A0800-102-5-000 145 (5.71)

A0950-102-5-000 160 (6.30)

80 m

m A

lpha

Mot

ors



ALPHASERVO

MOTORS

193


0 1000 2000 3000 4000 50000

10

20

30

40

50

60

MAXIMUM TORQUE

CONTINUOUS TORQUE

N•mTORQUE

SPEED (rpm)

Lb•inA0600-102-5-000

0

1.13

2.26

3.39

4.52

5.65

6.78

0 1000 2000 3000 4000 50000

10

20

30

40

50

60

70

MAXIMUM TORQUE

CONTINUOUS TORQUE

N•mTORQUE

SPEED (rpm)

Lb•inA0800-102-5-000

0

1.13

2.26

3.39

4.52

5.65

6.78

7.91

0 1000 2000 3000 4000 50000

20

40

60

80

100

0

2.3

4.5

6.8

9.0

11.3

MAXIMUM TORQUE

CONTINUOUS TORQUE

N•mTORQUE

SPEED (rpm)

Lb•inA0950-102-5-000



ALPHASERVO

MOTORS

194

LABEL

L

0.866

0.1251.25

.4995

.50000.062

0.0632.050 0.562

0.187

1.725

1.65SQ.

40 mm Alpha Motor with Optional GearheadStandard Dimension Gearhead

40 m

m A

lpha

Mot

ors

w/O

ptio

nal G

earh

ead



ALPHASERVO

MOTORS

195

Motor Rated Gearhead RatedTorque Torque

Length Motor Winding Cont Peak Cont PeakP/N Ratio* Inches Watts Volts lb-in lb-in lb-in lb-in

A0030-101-3-S05 5:1 5.05 30 100 0.84 2.57 143 223A0030-101-3-S10 10:1 5.05 30 100 0.84 2.57 56 84A0030-101-3-S25 25:1 5.68 30 100 0.84 2.57 171 267A0030-102-3-S05 5:1 5.05 30 200 0.84 2.57 143 223A0030-102-3-S10 10:1 5.05 30 200 0.84 2.57 56 84A0030-102-3-S25 25:1 5.68 30 200 0.84 2.57 171 267

A0050-101-3-S05 5:1 5.41 50 100 1.41 4.25 143 223A0050-101-3-S10 10:1 5.41 50 100 1.41 4.25 56 84A0050-101-3-S25 25:1 6.04 50 100 1.41 4.25 171 267A0050-102-3-S05 5:1 5.41 50 200 1.41 4.25 143 223A0050-102-3-S10 10:1 5.41 50 200 1.41 4.25 56 84A0050-102-3-S25 25:1 6.04 50 200 1.41 4.25 171 267A0050-103-3-S05 5:1 5.41 50 24 1.41 4.25 143 223A0050-103-3-S10 10:1 5.41 50 24 1.41 4.25 56 84A0050-103-3-S25 25:1 6.04 50 24 1.41 4.25 171 267A0050-104-3-S05 5:1 5.41 50 48 1.41 4.25 143 223A0050-104-3-S10 10:1 5.41 50 48 1.41 4.25 56 84A0050-104-3-S25 25:1 6.04 50 48 1.41 4.25 171 267

A0100-101-3-S05 5:1 6.11 100 100 2.81 8.41 143 223A0100-101-3-S10 10:1 6.11 100 100 2.81 8.41 56 84A0100-101-3-S25 25:1 6.74 100 100 2.81 8.41 171 267A0100-102-3-S05 5:1 6.11 100 200 2.81 8.41 143 223A0100-102-3-S10 10:1 6.11 100 200 2.81 8.41 56 84A0100-102-3-S25 25:1 6.74 100 200 2.81 8.41 171 267A0100-103-3-S05 5:1 6.11 100 24 2.81 8.41 143 223A0100-103-3-S10 10:1 6.11 100 24 2.81 8.41 56 84A0100-103-3-S25 25:1 6.74 100 24 2.81 8.41 171 267A0100-104-3-S05 5:1 6.11 100 48 2.81 8.41 143 223A0100-104-3-S10 10:1 6.11 100 48 2.81 8.41 56 84A0100-104-3-S25 25:1 6.74 100 48 2.81 8.41 171 267

*Other ratios available upon request

Radial Load (lbs.) 400Axial Load (lbs.) 400

Backlash Ratings (arc minutes) Standard LowSingle Stage (3:1 – 10:1) 6 3Double Stage (15:1 – 100:1) 10 5

Note:Servo drive should be current limited if the continuous or peak torque of the motor exceeds the gearheadtorque ratings.




ALPHASERVO

MOTORS

196

LABEL

L

5.0

12.0

30.0

16.013.0

5.0

52.04.530.0

M4 X 0.7

12.0

42.040.0

40 mm Alpha Motor with Optional GearheadMetric Dimension Gearhead

40 m

m A

lpha

Mot

ors

w/O

ptio

nal G

earh

ead



ALPHASERVO

MOTORS

197


Length Motor Winding Cont Peak Cont PeakP/N Ratio* mm Watts Volts lb-in lb-in lb-in lb-in

A0030-101-3-M05 5:1 141 30 100 0.84 2.57 148 232A0030-101-3-M10 10:1 141 30 100 0.84 2.57 56 84A0030-101-3-M25 25:1 154 30 100 0.84 2.57 153 238A0030-102-3-M05 5:1 141 30 200 0.84 2.57 148 232A0030-102-3-M10 10:1 141 30 200 0.84 2.57 56 84A0030-102-3-M25 25:1 154 30 200 0.84 2.57 153 238

A0050-101-3-M05 5:1 141 50 100 1.41 4.25 148 232A0050-101-3-M10 10:1 141 50 100 1.41 4.25 56 84A0050-101-3-M25 25:1 154 50 100 1.41 4.25 153 238A0050-102-3-M05 5:1 141 50 200 1.41 4.25 148 232A0050-102-3-M10 10:1 141 50 200 1.41 4.25 56 84A0050-102-3-M25 25:1 154 50 200 1.41 4.25 153 238A0050-103-3-M05 5:1 141 50 24 1.41 4.25 148 232A0050-103-3-M10 10:1 141 50 24 1.41 4.25 56 84A0050-103-3-M25 25:1 154 50 24 1.41 4.25 153 238A0050-104-3-M05 5:1 141 50 48 1.41 4.25 148 232A0050-104-3-M10 10:1 141 50 48 1.41 4.25 56 84A0050-104-3-M25 25:1 154 50 48 1.41 4.25 153 238

A0100-101-3-M05 5:1 141 100 100 2.81 8.41 148 232A0100-101-3-M10 10:1 141 100 100 2.81 8.41 56 84A0100-101-3-M25 25:1 154 100 100 2.81 8.41 153 238A0100-102-3-M05 5:1 141 100 200 2.81 8.41 148 232A0100-102-3-M10 10:1 141 100 200 2.81 8.41 56 84A0100-102-3-M25 25:1 154 100 200 2.81 8.41 153 238A0100-103-3-M05 5:1 141 100 24 2.81 8.41 148 232A0100-103-3-M10 10:1 141 100 24 2.81 8.41 56 84A0100-103-3-M25 25:1 154 100 24 2.81 8.41 153 238A0100-104-3-M05 5:1 141 100 48 2.81 8.41 148 232A0100-104-3-M10 10:1 141 100 48 2.81 8.41 56 84A0100-104-3-M25 25:1 154 100 48 2.81 8.41 153 238








ALPHASERVO

MOTORS

198

L

1.500

0.2051.25

.4995

.50000.062

0.0632.950 0.562

0.250

2.625

2.25SQ.


60 m

m A

lpha

Mot

ors

w/O

ptio

nal G

earh

ead



A0200-101-4-S05 5:1 6.46 200 100 5.66 16.9 317 496A0200-101-4-S10 10:1 6.46 200 100 5.66 16.9 119 179A0200-101-4-S25 25:1 7.56 200 100 5.66 16.9 380 594A0200-102-4-S05 5:1 6.46 200 200 5.66 16.9 317 496A0200-102-4-S10 10:1 6.46 200 200 5.66 16.9 119 179A0200-102-4-S25 25:1 7.56 200 200 5.66 16.9 380 594A0200-104-4-S05 5:1 6.46 200 48 5.66 16.9 317 496A0200-104-4-S10 10:1 6.46 200 48 5.66 16.9 119 179A0200-104-4-S25 25:1 7.56 200 48 5.66 16.9 380 594

A0400-101-4-S05 5:1 7.56 400 100 11.24 33.8 317 496A0400-101-4-S10 10:1 7.56 400 100 11.24 33.8 119 179A0400-101-4-S25 25:1 8.36 400 100 11.24 33.8 380 594A0400-102-4-S05 5:1 7.56 400 200 11.24 33.8 317 496A0400-102-4-S10 10:1 7.56 400 200 11.24 33.8 119 179A0400-102-4-S25 25:1 8.36 400 200 11.24 33.8 380 594A0400-105-4-S05 5:1 7.56 400 60 11.24 33.8 317 496A0400-105-4-S10 10:1 7.56 400 60 11.24 33.8 119 179A0400-105-4-S25 25:1 8.36 400 60 11.24 33.8 380 594







ALPHASERVO

MOTORS

199

6.0

20.0

47.0

20.016.0

5.0

85.05.568.0

M5 X 0.8

12.7

62.0

60.0

L


60 m

m A

lpha

Mot

ors

w/O

ptio

nal G

earh

ead



A0200-101-4-M05 5:1 166 200 100 5.66 16.9 328 521A0200-101-4-M10 10:1 166 200 100 5.66 16.9 119 179A0200-101-4-M25 25:1 187 200 100 5.66 16.9 339 530A0200-102-4-M05 5:1 166 200 200 5.66 16.9 328 521A0200-102-4-M10 10:1 166 200 200 5.66 16.9 119 179A0200-102-4-M25 25:1 187 200 200 5.66 16.9 339 530A0200-104-4-M05 5:1 166 200 48 5.66 16.9 328 521A0200-104-4-M10 10:1 166 200 48 5.66 16.9 119 179A0200-104-4-M25 25:1 187 200 48 5.66 16.9 339 530

A0400-101-4-M05 5:1 166 400 100 11.24 33.8 328 521A0400-101-4-M10 10:1 166 400 100 11.24 33.8 119 179A0400-101-4-M25 25:1 187 400 100 11.24 33.8 339 530A0400-102-4-M05 5:1 166 400 200 11.24 33.8 328 521A0400-102-4-M10 10:1 166 400 200 11.24 33.8 119 179A0400-102-4-M25 25:1 187 400 200 11.24 33.8 339 530A0400-105-4-M05 5:1 166 400 60 11.24 33.8 328 521A0400-105-4-M10 10:1 166 400 60 11.24 33.8 119 179A0400-105-4-M25 25:1 187 400 60 11.24 33.8 339 530







ALPHASERVO

MOTORS

200

L

2.875

0.2201.50

.7495

.75000.062

0.0944.375 0.562

0.312

3.875

3.25SQ.


80 m

m A

lpha

Mot

ors

w/O

ptio

nal G

earh

ead



A0600-102-5-S05 5:1 7.84 600 200 16.9 50.71 1113 1740A0600-102-5-S10 10:1 7.84 600 200 16.9 50.71 552 828A0600-102-5-S25 25:1 8.64 600 200 16.9 50.71 1333 2083

A0800-102-5-S05 5:1 8.51 800 200 22.57 67.61 1113 1740A0800-102-5-S10 10:1 8.51 800 200 22.57 67.61 552 828A0800-102-5-S25 25:1 9.31 800 200 22.57 67.61 1333 2083

A0950-102-5-S05 5:1 9.10 950 200 26.73 80.19 1113 1740A0950-102-5-S10 10:1 9.10 950 200 26.73 80.19 552 828A0950-102-5-S25 25:1 9.90 950 200 26.73 80.19 1333 2083







ALPHASERVO

MOTORS

201

L

7.0

20.0

56.0

30.022.0

8.0

111.06.685.0

M8 X 1.25

16.0

76.0

70.0




A0600-102-5-M05 5:1 234 600 200 16.9 50.71 1145 1798A0600-102-5-M10 10:1 234 600 200 16.9 50.71 552 828A0600-102-5-M25 25:1 262 600 200 16.9 50.71 1205 1883

A0800-102-5-M05 5:1 234 800 200 22.57 67.61 1145 1798A0800-102-5-M10 10:1 234 800 200 22.57 67.61 552 828A0800-102-5-M25 25:1 262 800 200 22.57 67.61 1205 1883

A0950-102-5-M05 5:1 234 950 200 26.73 80.19 1145 1798A0950-102-5-M10 10:1 234 950 200 26.73 80.19 552 828A0950-102-5-M25 25:1 262 950 200 26.73 80.19 1205 1883







ALPHASERVO

MOTORS

202

12 3

4


1 A RED

2 B WHITE

3 C BLACK

4 DRAIN GREEN


HOUSING AMP# 206153-1 AMP# 206060-1














1 23

711 1415 16

106




HOUSING AMP# 206036-3 AMP# 206037-1



Motor Connectors



ALPHASERVO

MOTORS

203




123

71114

15 16

106



(11) Hall 1(12) Hall 2



AM

P

“L” +3–0





1 2 3 4 5 6 7 8

9 10 11 12 13 14 15


4 feet BLENC-CA-04

10 feet BLENC-CA-10

20 feet BLENC-CA-20

123

4


“L” + 3–0

4 x 1.5





4 feet BLMTR-CA-04

10 feet BLMTR-CA-10

20 feet BLMTR-CA-20

Extension Cable DrawingsENCODER EXTENSION CABLE




204

MOTORCONTROLS

ALPHASERVO

MOTORS



205

MOTORCONTROLS

Mot

or C

ontro

ls



206

MOTORCONTROLS

MECHANICAL OUTLINE

Si-1

Mot

or C

ontro

l

STOP

PRESSTO ENTER

SI-1Step Motor Indexer

8 - 35 VDCGNDGND+5V OUTSTEPDIRECTIONAUXILIARYTRIGGERMOTION+MOTION–V LIMITCW LIMITCCW LIMIT

2.75 in

5.25 in

2x 0.20 in

PLUGGABLESCREW TERMINAL

CONNECTOR

RUGGED ALUMINUM CASELCD DISPLAY

MENU SELECT

REVERSIBLE FLANGES

STOP SWITCH

2x 0.30 in

6.50 in

1.125 in

1.375 in

1.9 in max

Si-1 Motor ControlFeatures

• Menu driven—no programming language to learn.• Can connect to any pulse & direction step motor driver.• Ideal for use with Applied Motion Products recom-

mended drives models 1030, 1030D, 2035, 2035XD,BL7080X, 3535, BLX7080, 3540M, 5560, 7780, PDO2035, PDO 3540, PDO 5580.

• Eight built-in programs:- Feed to Length moves a preset distance when TRIG-

GER is pulsed low (to 0 volts).- Feed & Jog also moves a preset distance. Jogs when-

ever AUX is held low.- Feed & Return moves a preset distance, then returns

to the starting point.- Feed & Back Off moves a preset distance, then moves

a second distance in either direction.- Feed to Sensor moves until the AUX changes state

(can be set for rising or falling edge to accommodatemost sensors).

- Feed to Sensor & Return moves until AUX changesstate, then returns to the start.

- Register & Feed finds a registration mark, then movespreset distance.

- Learn Speed allows user to adjust speed “on the fly,”via the knob, then press to record new speed.

• Parameters can be entered in motor steps or customunits such as inches, revolutions or gallons.

• All programs can be executed between 1 and 255times from a single trigger. Nonstop operation canalso be specified.

Input/Output

• Two 5-24 volt optically isolated limit switch inputs,also used for power up homing feature.

• TRIGGER input to initiate motion.• AUXILIARY input for sensor or jog control.• Optically isolated MOTION output can signal “in mo-

tion” or “in position.” “In position” pulse width is pro-grammable, 0.1 - 25.5 msec.

• STEP and DIRECTION outputs to motor driver, opencollector, 5-24 volts, 10 microsecond STEP pulsewidth.

• +5V output for motor driver optoisolators, filtered &fused.

Description

The Si-1 Indexer is reliable, versatile and easy to use.The programming terminal is built-in to simplify wiringand set up. All configuration is menu driven—the usersimply picks a program and the Si-1 will request the pa-rameters it needs. The Si-1 is CE compliant.

Once configured, the Si-1 waits for a trigger pulse to be-gin the program. This pulse can come from a momen-tary contact switch or from a logic source like a com-puter, PLC or another Si-1.

The Si-1 can be programmed to seek a home positionupon power up. Limit switches can be attached to preventunwanted travel beyond designated limits. A built in stopbutton allows the operator to halt the motor at anytime.

Options

• 10 volt AC wall transformerP/N: WT-1

System Features

• Up to 255 moves per trigger can be selected by settingthe Moves/Trigger parameter. Nonstop can also beselected.

• The SI-1 can seek a home position upon power up bysetting the Home on Power Up parameter to clockwiseor counterclockwise.

• User Units allow the user to work in units other thanmotor steps. Simply enter the number of motor stepsper unit and name the unit (up to three characters.)

• Timing is adjustable on all programs. Delay can beadded between the trigger pulse and the start of mo-tion for system syncronization. On multiple movesper trigger, the delay between moves can be set. Onmoves that return (Feed & Return, Feed to Sensor &Return and Feed & Back Off) the delay between feed-ing and returning is adjustable.

• The MOTION output can be programmed to provide asignal edge at the start and finish of each move (“inmotion”), or it can provide a pulse at the end of eachmove (“in position”). This allows maximum flexibilitywhen coordinating the SI-1 with other equipment.

• Can be programmed to search for rising or fallingedge of sensor, allowing many types of sensors to beeasily configured.



207

MOTORCONTROLS

Si-1 Menu Tree

Set Return Delay0-25.5 sec

Set Repeat Delay0-25.5 sec

Set Jog Accel1000-255000 steps/s/s

Set Accel1000-255000 steps/s/s

Set Decel1000-255000 steps/s/s

Set Feed Distance1-8000000 steps

Running

Select Program

Select Menu

Program Menu

System Menu

Timing Menu

Applied MotionProducts V2.1

Feed & Return

Feed to Sensor& Return

Feed to Sensor

Feed & Back OffFeed & Jog

Set Pulse Width0.1-25.5 msec

User Units?











Set Feed Speed100-25000 steps/sec






Set Feed Dircw - ccw - aux


Set Jog Speed100-25000 steps/sec

Set Return Speed100-25000 steps/sec

Set Back Speed100-25000 steps/sec

Set Jog Dircw - ccw

Set Feed Dircw - ccw








Set Back Distance1-8000000 steps

Home On Pwr Up?cw - ccw - no

Set Sensor Edgerising - falling

Feed To Length

In MotionIn Positionout - back - both

Set Motion Signal

Steps/Unit?1-65535

Enter Unit Name(3 chars)

Set Back Dircw - ccw

Set Return Speed100-25000 steps/sec

Register & Feed








Learn Speed

NoYes

Moves/Trigger?1-255 or nonstop

Set Trigger Delay0-512 msec

SO

FTWARE

V E R S I O N

2.1

START



208

MOTORCONTROLS

Si-1

00 M

otor

Con

trol Si-100 Motor Control

Features

• Programmable for stand alone operation withApplied Motion’s easy to use Si Programmer™Windows software (software and programmingcable included)

• Can be operated in real time from a host PC orPLC using Applied Motion’s Si Command Lan-guage™ (SCL)

• Can be networked with all other Si™ products viaApplied Motion’s SiNet™ Hub

• 110 or 220 AC input, switch selectable• 25 VDC and 5 VDC output voltages• 8 optically isolated, 5–24 VDC, user program-

mable inputs• 3 optically isolated, 24 VDC, outputs• High speed, differential step & direction outputs

interface easily to step and servo motor drives• Communication via RS232• Screw terminal connector blocks for power and I/O

RJ11 for RS232 port• Optional operator terminal (MMI) either standard

or backlit• Eight Applied Motion recommended pulse and

direction Stepper drives and two pulse and direc-tion Servo amplifiers

• CE and TUV compliant

Description

The Si-100 is a programmable motor control suit-able for a wide range of motion control applica-tions. It includes Applied Motion’s easy to use

Si Programmer™ Windows software for the rapiddevelopment of stand-alone motion control pro-grams. The Si-100 can also be commanded in realtime from a host PC or PLC, using the Si CommandLanguage™ (SCL).

For multi-axis applications, up to eight Applied Mo-tion Si™ products (Stepper or Servo) can be net-worked using the SiNet™ Hub, fulfilling the exactrequirements of your application.

The Si-100 includes 8 optically isolated program-mable inputs for triggering, branching, positionsensing and end of travel detection. 3 optically iso-lated programmable outputs can send signals toother electronic devices and activate relays. Highspeed, differential step & direction outputs are pro-vided for easy interfacing to industry popular stepand servo motor drives.

Recommended drives for the Si-100:

Stepper Servo———— ————1030 BL7080X1030D BLX708020352035XD35353540M55607080PDO 2035PDO 3540



209

MOTORCONTROLS

AC INPUT POWER ...................................... 110 or 220 VAC (switch selectable), 50–60 Hz.MOTOR RESOLUTION ................................ 16 resolutions. Steps per revolution with 1.8˚ motor: 200, 400,

1000, 2000, 5000, 10000, 12800, 18000, 20000, 21600, 25000,25400, 25600, 36000, 50000, 50800.

STEP AND DIRECTION OUTPUTS .............. 2 sourcing outputs (step+ and dir+) and 2 sinking outputs (step–and dir–). Step+ and dir+ are 2.5min., 3.4V typ. with a 20na load.Step– and dir– are 8.5V max., 0.3V typ. with a 20ma load. Thestep frequency is 50Hz to 2.54MHz. The step duty cycle is 50%and the step rate is updated at 12,800Hz.

POWER SUPPLY OUTPUTS........................ 5 and 24 VDC., 100ma max. The 24 VDC supply is isolated fromthe internal circuitry. The 5 VDC supply is not. Each supply is pro-tected by a self resetting fuse.

SERIAL COMMUNICATION ......................... RS-232 programming port.STATUS LED'S ............................................ Two color, normal (green), limit (red).INPUTS....................................................... 8 inputs, 5–24 VDC, bidirectional, optically isolated.

2 dedicated limit switch inputs.4 dedicated general purpose inputs (for triggering, sensing & pro-gram branching).2 JOG inputs (cw and ccw) can be also used as general purposeinputs.

OUTPUTS ................................................... 3 general purpose, optically isolated outputs for interfacing toother equipment. Can be set to a high or low voltage or pro-grammed to send a pulse by the Set Output instruction.

PARAMETER RANGES ............................... Distance: 1 to 16,000,000 steps. Speed: .025 to 50 revolutions persecond (in any microstep resolution). Acceleration: 1 to 3,000 rev/sec/sec. Deceleration: 1 to 3,000 rev/sec/sec (set independentlyfrom acceleration). Time Delays: .01 to 300 seconds. Output PulseWidths: 2 to 500 milliseconds. Iterations per loop: 1 to 65,535.

OPTIONAL OPERATOR INTERFACE (MMI) NEMA 4X rated (splash proof & dust proof). 4 x 20 characters liq-uid crystal display (LCD). 20 key membrane keypad. Overall size:4.9 x 4.9 x 1.42 inches.


OVERALL SIZE ........................................... 1.25 x 3.86 x 8 inches. See mechanical outline.CASE MATERIAL ........................................ Steel, finished with black textured paint and white silk screen.WEIGHT ...................................................... 2 lbs.AMBIENT TEMPERATURE .......................... 0˚ to 50˚C (32˚ to 122˚F).HUMIDITY .................................................. Maximum of 90% non-condensing.CONNECTORS ............................................ Screw terminal connectors for input power and I/O signals.DRIVES ....................................................... Indexer for step and direction compatible stepper and brushless

DC drives.

Si-100 Technical Specifications



210

MOTORCONTROLS

BLOCK DIAGRAM:

MECHANICAL OUTLINE:

power/status LED

110/220 VACfuse

INPUT1INPUT2INPUT3INPUT4CW JOG

CCW JOG

to PCor MMI

24VDC OUT

CW LIMITCCW LIMIT

OUT1OUT2OUT3

STEP+STEP-DIR+DIR-

OpticalIsolation

InternalPowerSupply

eeprom

linedrivers

Si™High

SpeedIndexer

RS232

OpticalIsolation

OpticalIsolation

1.25"

7.17"

0.20" .625"

7.625" 8.00"

3.86"

0.06"

Si-100Motion Controller

POWER

PC/M

MI

G

L2/N

L1

AC POWER

STOP

STEP+STEP–

DIR+DIR–

GND+5 VDC

24V GND+24 VDC

OUT3+OUT3–

IN/JOG COMIN1

OUT2–OUT2+OUT1–OUT1+

CCWJOG/IN6LIMIT COM

CW LIMITCCW LIMIT

CWJOG/IN5IN4IN3IN2

Si-100 Technical Drawings



211

MOTORCONTROLS

Si-100 Connectors and Switches

user power supply outputs

input connector

inputs/limits connector

power LED

AC power

RS232 connector

USER POWER OUTPUTS

position no.1 +24 VDC2 24 V GND3 +5 VDC4 GND

I/O

position no.1 step+2 step–3 dir+4 dir–5 out 1+6 out 1–7 out 2+8 out 2–9 out 3+

10 out 3–11 in/jog com12 in 113 in 214 in 315 in 416 cw jog/in 517 ccw jog/in 618 limit com19 cw limit20 ccw limit

AC POWER

position no.1 G2 L2/N3 L1

output connector



212

MOTORCONTROLS

SiNe

t™ H

ub SiNet™ HubMulti-Axis Motion Hub

Features

• Networks all Applied Motion Stepper or Servo Si™products for multi-axis motion applications

• For real time execution of commands down-loaded from a host PC or PLC using AppliedMotion’s Si Command Language™ (SCL)

• Programmable for stand alone single or multi-axis operations with Applied Motion’s easy to useSiNet Programmer™ Windows software (soft-ware and programming cable included)

• Communication via RS232

Description

The SiNet™ Hub allows up to 8 Stepper or ServoSi™ drives to be controlled in host mode from asingle PC or PLC’s RS-232 serial port or will run instand-alone mode.

Each indexer-drive acquires its unique address fromthe port to which it is connected. This simple ad-dressing scheme minimizes the cost of the drives,and more importantly, the cost of configuring and/orreplacing drives in your system. Connections aremade with low cost, reliable telephone cabling.

Any of our popular, cost effective programmableStepper or Servo Si™ drives or Si™ motor controlscan be used with the SiNet™ Hub. By choosing thepower level and features you need for each axis ofyour application, SiNet™ can provide a cost effec-tive single or multi-axis motion solution.

The SiNet™ Hub is powered by the drive that’s con-nected to port #1, saving you the cost and installa-tion expense of using a separate power supply. OurSi™ Command Language (SCL) allows a host PC orPLC to execute relative, absolute and homingmoves, make status inquires, sample inputs, setoutputs, and more.

If your application requires a single axes to operatein “host mode”, you can connect any of our pro-grammable Si™ drives directly to your PC via theSiNet Hub and invoke the Si™ Command Language(SCL).

Our SiNet Programmer™ Windows software allowsthe user to create and store multi-axis motion con-trol programs in the SiNet™ Hub and run themwithout a PC. Thus allowing the user to create acomplex multi-axis motion system controlled froman operator interface or trigger.

Recommended Drives

Stepper ServoSi3540 BLSi7080Si5580 BL7080i1240i3540i7080i



213

MOTORCONTROLS

Power ......................................................... Power is provided by Si™ indexer-drive on Port 1. Provides up to50 mA for MMI via PC/MMI port.

Communication .......................................... Ports 1 - 8: RS232, 9600 bps, 8 data bits, one stop bit, no parity.MMI: same.PC in router mode: same.PC when running SiNet Programmer software: 19200 bps.Max cable length, any port: 50 feet.

Physical ...................................................... Molded plastic case. RJ11 connectors. 1.35 x 3.8 x 6.5 inches(34.3 x 96.5 x 165.1 mm). Weighs 9 ounces (250 grams). Two redLEDs. Operating temperature range: 0 - 70° C.

Program. .................................................... Move distances: +/- 16,000,000 stepsMove speeds: .025 to 50 rev/secAccel/Decel range: 1 to 3000 rev/sec/secTime delays: .01 to 300 secondsLoops counts: 1 to 65,535Number of nested loops: unlimitedNumber of subroutines: unlimitedSubroutine stack depth: 5 calls maximumNumber of comments: limited only by 200 line program lengthMMI variables for storing speeds, distances and loop counts en-tered by operator: 50Maximum size of messages displayed by an MMI Prompt: 60characters (80 for an MMI Menu instruction)Maximum total size of all MMI Prompt messages: 1500 charactersSteps/revolution: 2,000 - 50,800 (200 - 50,800 with Si-100 in-dexer)

SiNet Hub Technical Specifications

1

3

5

7

2

4

6

8

PC/MMISiNet™Hub-8

COMM POWER

5.54"

6.50"

3.79"

6.00"

2X Ø 0.19"

1.35"

0.125"

SiNet™

Hub-8

drive #1

drive #2

drive #8

HostPCor

PLC

MECHANICAL OUTLINE: BLOCK DIAGRAM:

SiNet Hub Technical Drawings



214

MOTORCONTROLS

SiNe

t™ H

ub 4

44 SiNet™ Hub 444Multi-Axis Motion Hub with I/O

Features

• Networks all Applied Motion Stepper or Servo Si™products for multi-axis motion applications

• For real time execution of commands down-loaded from a host PC or PLC using AppliedMotion’s Si Command Language™ (SCL)

• Programmable for stand alone single or multi-axis operations with Applied Motion’s easy to useSiNet Hub Programmer™ Windows software(software and programming cable included)

• Communication via RS232• Four optically isolated programmable inputs• Four optically isolated programmable outputs• Optional DIN rail mounting kit

Description

The SiNet™ Hub 444 allows up to 4 Stepper orServo Si™ drives to be controlled in host modefrom a single PC or PLC’s RS-232 serial port or willrun in stand-alone mode.

Each indexer-drive acquires its unique address fromthe port to which it is connected. This simple ad-dressing scheme minimizes the cost of the drives,and more importantly, the cost of configuring and/orreplacing drives in your system. Connections aremade with low cost, reliable telephone cabling.

Any of our popular, cost effective programmableStepper or Servo Si™ drives or Si™ motor controlscan be used with the SiNet™ Hub 444. By choosingthe power level and features you need for each axisof your application, SiNet™ can provide a cost ef-fective single or multi-axis motion solution.

The SiNet™ Hub 444 is powered by the drive that’sconnected to port #1, saving you the cost and in-stallation expense of using a separate power sup-ply. Our Si™ Command Language (SCL) allows ahost PC or PLC to execute relative, absolute andhoming moves, make status inquiries, sample in-puts, set outputs, and more.

If your application requires a single axis to operatein “host mode”, you can connect any of our pro-grammable Si™ drives directly to your PC via theSiNet Hub 444 and invoke the Si™ Command Lan-guage (SCL).

Our SiNet Programmer™ Windows software allowsthe user to create and store multi-axis motion con-trol programs in the SiNet™ Hub 444 and run themwithout a PC. Thus allowing the user to create acomplex multi-axis motion system controlled froman operator interface or trigger.

Recommended Drives

Stepper Servo ControlSi3540 BLSi7080 Si-100Si5580 BL7080i1240i3540i7080i



215

MOTORCONTROLS

Power ......................................................... Power is provided by Si™ indexer-drive on Port 1. Provides up to50 mA for MMI via PC/MMI port.

Communication .......................................... Ports 1 - 4: RS232, 9600 bps, 8 data bits, one stop bit, no parity.MMI: same.PC in router mode: same.PC when running SiNet Programmer software: 19200 bps.Max cable length, any port: 50 feet.

Physical ...................................................... Constructed on .062˝ fiberglass printed circuit board with 4 .156˝mounting holes (nylon spacers included).4.2˝ x 2.85˝ x 0.72˝.Two red LEDs.Operating temperature range: 0 - 70° C.Optional DIN rail mounting kit (fits ENS0022 35 mm rail).

Program. .................................................... Move distances: +/- 16,000,000 stepsMove speeds: .025 to 50 rev/secAccel/Decel range: 1 to 3000 rev/sec/secTime delays: .01 to 300 secondsLoop counts: 1 to 65,535Number of nested loops: unlimitedNumber of subroutines: unlimitedSubroutine stack depth: 5 calls maximumNumber of comments: limited only by 200 line program lengthMMI variables for storing speeds, distances and loop counts en-tered by operator: 50Maximum size of messages displayed by an MMI Prompt: 60characters (80 for an MMI Menu instruction)Maximum total size of all MMI Prompt messages: 1500 charactersSteps/revolution: 2,000 - 50,800 (200 - 50,800 with Si-100 indexer)

Connectors ................................................. RJ11 for drives and PC/MMI. Screw terminals for programmableinputs and outputs. Accept AWG 16-28 wire.

Programmable Inputs ................................ Optically isolated, 2200 ohms internal impedance, 5–24 VDC.Programmable Outputs .............................. Optically isolated (photo darlington), 28 VDC max, 100 mA max.

SiNet Hub Technical Specifications

MECHANICAL OUTLINE: BLOCK DIAGRAM:

SiNet Hub 444 Technical Drawings

drive #1

drive #2

drive #3

drive #4

HostPCor

PLC

OpticalIsolation

OpticalIsolation

OUT1OUT2OUT3OUT4

IN1IN2IN3IN4

4.2"

2.85"

1

2

3

4

PC-MMI

INHUB 444 OUT



216

POWERSUPPLIES

Oper

ator

Inte

rface

The MMI-01 is an easy to use, flexible device thatallows an operator to enter move speeds, movedistances or repeat loop counts. Messages canalso be displayed and the program can be pauseduntil the user presses a key, such as ENTER, YESor NO. Program branching can be accomplishedbased on the response of YES or NO.

The MMI-01 is compact, easy to install and carriesa NEMA 4/12 rating. (The 4 x 20 character displayand 20 key membrane keypad are sealed.)

Connection to any of our “Si” or “i” indexer drivesis accomplished by the standard programmingcable that is supplied with every drive. This cablealso supplies power to the MMI-01 so that no addi-tional power supply or wiring is needed.

Setup and programming of the MMI-01 is fast andeasy. Our programmable “Si” or “i” drives are fur-nished with Applied Motion’s Si™ Programmersoftware, which allows the user to easily programinstructions for the terminal. Complex, confusingitems like baud rate, parity and cursor positioningare handled automatically by the software.

On screen emulation of the MMI-01 by the Si™Programmer software allows a potential user to trythe MMI before purchasing one.

Features

• Ideal operator interface for Applied’s program-mable drives.

• Connects directly to programmable drives usingthe standard programming cable. No specialwiring required.

• Power is supplied by the drive - no additionalpower supply required.

• Easy to program usingSi™ Programmer soft-ware.

• 4 line, 20 character/lineLCD display

• 20 key keypad• NEMA 4/12 rating

(dustproof and drip proofwhen properly mounted)

• Can be surfaced mountedor flush mounted (NEMA4/12 rating for flushmounting only)

• Optional backlit model,p/n: MMI-02

MMI-01

4.90

4.90 1.38

0.133.875CENTERED

3.875CENTERED 1 2 3 › ›

4 5 6 › ›7 8 9 YES NO

. 0 SPACE BKSP ENTER

2.988

1.975

0.425

0.963

0.960

MECHANICAL OUTLINE

Programming• Easy to program using Si™ Programmer soft-

ware, running on Windows 3.1 or Windows 95.• Six functions are available: 1) Display a message,

up to 60 characters 2) Display a message andpause program until operator presses ENTERkey. 3) Display a message, wait for operator topress YES or NO key. branch program on YES.4) Display message, allow operator to enter aloop count. 5) Display message, allow operatorto enter a speed 6) Display message, allow op-erator to enter a distance

• Speeds, distances and loop counts entered bythe operator can be stored in any of eight non-volatile memory locations for use in repeat loopsand motor moves.

MOTORCONTROLS



217

POWERSUPPLIES

Pow

er S

uppl

ies



218

POWERSUPPLIES

0.08

4x Ø.213

.20

.25.25

8x Ø.156

4.252.75

.91

3.64

2.50

3.752.10

2.90

2.40

7.00

6.50

MECHANICAL OUTLINE

PS43

0 Po

wer

Sup

ply PS430

Power Supply4 amps, 30 VDC

Features

• 30 VDC 4 amp unregulated motor supply• 5 VDC ±5% 500 mA regulated logic power supply• fuse protected outputs• screw terminal AC input connector• 120 or 240 VAC, 50-60 Hz• power on LEDs• screw terminal connectors• made in USA• ideal for use with A.M.P. step motor drives:

1335, 2035, 2035 O, 3535, 3535 O, 3540 M,3540 MO

• includes mounting holes for 057A oscillator/in-terface and one 2035, 2035 O, 3535, 3535 O,3540 M or 3540 MO drive on side panel

Description

The PS430 is a linear, unregulated DC power supplydesigned for use with Applied Motion’s step motorchopper drives model numbers 2035, 2035 0, 3535,3535 0, 3540 M and 3540 MO. The PS430 can alsobe used with the 5560, 7080 or 7080i drive in appli-cations not requiring maximum power.

The PS430 provides the user with a precise, well-regulated 5 VDC power source for logic circuitry.

This power supply is available as a PC board andtransformer mounted on an aluminum anglechassis.

110/220 VAC

fuse

30 VDC, 4Afuse

AC - DC

5 VDC, 0.5Afuse

LED

LED

Transformer

110/220switch

AC - DCconvertor

5 VDCregulatorAC - DC

convertor

BLOCK DIAGRAM



219

POWERSUPPLIES

PS1050Power Supply10 amps, 50 VDC

Features

• Input Voltage: 108–264 VAC• Output Voltage: 50 VDC nominal• Typical Output Voltage:

56.6V no load52.8V at 5 amps48.8V at 10 amps

• Output Current: 10 amps max, continuous• Input Frequency: 47–63 Hz• Max Ambient Temp: 55°C• Filter Capacitor: computer grade (long life)• Rectifier Bridge: 50 amp, 200 volt• Output Voltage Ripple: 3% rms max at nominal

AC line voltage• Weight: 19 pounds• Made in USA

Description

The PS1050 is a heavy duty linear, unregulatedpower supply. It is an ideal power source for Ap-plied Motion’s 5560, 7080 and 7080i series stepmotor drives, combining over 500 watts of outputpower and outstanding reliability.

The PS1050 provides isolation from the AC lineand is fused for safety.

The PS1050 is constructed on an open frame alu-minum chassis.

AC IN108-264 V DC OUT

50 VFilterCapacitor

Rectifier Bridge

Transformer

Output Fuse

1

2

3

4

5

6

7

8

+

–

BLOCK DIAGRAM

4.62

9.00

8.25 0.37

0.358.24

3.75

5.622.50

1.56

8X MOUNTING HOLE DIA .281"+" OUTPUT TERMINAL.250 X .032 MALEQUICK DISCONNECT

"–" OUTPUT TERMINAL

MECHANICAL OUTLINE

PS10

50 P

ower

Sup

ply



220

POWERSUPPLIES

Features:

• Provides up to 10 Amperes of DC power for openframe step and servo motor drives and indexers.

• Operates from 108-132 VAC or 216-264 VAC,50/60 Hz

• Sturdy metal frame design• Unregulated fused output• Provides power for 2 7080 drives, set at 7.0

Amps per phase, and 2 5042-022 motors, wind-ings connected in parallel, full or microstepping.

• Designed to meet European safety standards.

Description:

The PS1070 is a 670 watt open frame power supplydesigned to operate multiple DC input stepping orservo motor drives such as the Applied Motion’s7080/7080i Stepper drives and BL7080X/BL7080iServo drives.

Applied Motion’s PS1070 has a single 70 VDCnominal output and may be operated from either110 or 220 AC, 50/60 Hz source. Input voltageis selected via jumpers on the power supplyterminal strip.

PS1070 Specifications:

Output• 67 VDC with 120 VAC line and 10 Amp. Full Load:

670 watts.• Minimum Voltage: 50.5 at Low Line

and Full Load.• Maximum Voltage: 86 at High Line

and No Load.• Maximum Ripple: 2.0V peak-to-

peak at Full Load.• Connections:

Positive Voltage – .25" faston onfuse holder.Negative Voltage – .25" faston onfilter capacitor.

PS10

70 P

ower

Sup

ply PS1070

Power Supply10 amps, 70 VDC

MECHANICAL OUTLINE

Input• 115/230 volts 50/60 Hz to be fused by user.• 8/4 amp (755 watts).• Suggested fuse 10/5 amps slo-blo.• Voltage selected by terminal strip jumpers.• Low Line: 108/216 Volts AC.• High Line: 132/264 Volts AC.• Connections: Barrier strip with screw terminals.• Open frame construction.• Size: 5.75" X 12" X 4.57" High.• Mounting: 4 each .28" Dia. Holes on 4.37" X 11.0"

Centers.• Weight: 23.8 lbs.Environmental• Maximum Operating Ambient Temperature:

50°C.• Power Supply Derating: 0.2A/°C above 35°C am-

bient.



221

POWERSUPPLIES



222

GLOSSARY

Glos

sary Absolute Position

Position referenced to a fixed zero or datumposition.

Absolute ProgrammingA positioning coordinate reference wherein allpositions are specified relative to some refer-ence or “home” position. This is different fromIncremental programming where distances arespecified relative to the current position.

AccelerationThe change in velocity as a function of time.

AccuracyThe difference between the expected value of aparameter and its actual value.

Accuracy (step)The correctness of the distance a step motormoves during each step. Does not include er-rors due to hysteresis.

Ambient TemperatureThe temperature of the medium immediatelysurrounding a device.

AmplifierElectronic device that converts command sig-nals (analog or digital) to high power voltagesand currents for the operation of the motor.

ASCIIAmerican Standard Code for Information Inter-change. This code assigns a number to eachnumeral and letter of the alphabet. In thismanner, information can be transmitted be-tween machines as a series of binary numbers.

Axial PlayThe axial shaft displacement due to a reversalof an axial force on the shaft. (End play)

Baud RateThe number of binary bits transmitted persecond for serial communications such asRS-232.

Bi-level Drive (dual voltage drive)A driver where two levels of voltage are usedto drive a step motor. A high (over drive) volt-age is applied to the winding each time it isswitched on. The high voltage stays on untilthe current reaches a predetermined level. Thehigh voltage is turned off after a time perioddetermined experimentally or by sensing wind-ing current. The low voltage maintains the de-sired current.

Bipolar DriveA drive which reverses the magnetic polarity ofa pole by electronically switching the polarityof the current to the winding (+ or-). Bipolardrives can be used with 4,6, or 8 lead motors.With 4 and 8 lead motors, bipolar drives areusually more efficient than unipolar drives andgenerally produce more torque.

Brushless Servo DriveA servo drive used to control a permanentmagnet synchronous AC motor.

Chopper DriveA step motor drive that uses switching amplifi-ers to control motor current.

Class B insulationSpecifies motor insulation that is rated for op-eration of 130 degrees centigrade.

Class H InsulationSpecifies motor insulation that is rated for op-eration of 180 degrees centigrade.

Closed LoopA system that uses some form of feedback de-vice to monitor the system output. The signalfrom the device is used to correct any errorsbetween actual and demanded output.

CoggingTerm used to describe uneven velocity in mo-tors, usually at low speeds.



223

GLOSSARY

CommutationA term which refers to the action of steeringcurrents or voltage to the proper motor phasesto produce optimum motor torque. In brushtype motors, commutation is done electrome-chanically via the brushes and commutator. Inbrushless motors, commutation is done by theswitching electronics using rotor position in-formation typically obtained from hall sensors,tachometer, resolver or encoder.

Controller (step motor)A system consisting of a DC power supply andpower switches plus associated circuits tocontrol the switches in the proper sequence.

DampingAn indication of the rate of decay of a signal toits steady state value. Related to settling time.

Dead BandA range of input signals for which there is nosystem response.

DecelerationThe negative change in velocity as a functionof time.

Detent TorqueThe maximum torque required to slowly rotatea step motor shaft with no power applied tothe windings. This applies only to permanentmagnet or hybrid motors. The leads are sepa-rated from each other.

Drive (PWM)A motor drive utilizing Pulse-Width Modulationtechniques to control power to the motor.Typically a high efficiency drive that can beused for high response applications.

Drive (servo)A motor drive which utilizes internal feedbackloops for accurate control of motor and cur-rent an/or velocity.

Drive (stepper)An electronic package to convert digital stepand direction inputs to currents to drive astep motor.

Duty CycleThe percentage of ON time vs. OFF time. A de-vice that is always on has a 100% duty cycle.Half on and half off is a 50% duty cycle.

Dynamic BrakingA passive technique for stopping a permanentmagnet brush or brushless motor. The motorwindings are shorted together through a resis-tor, which results in a motor braking with anexponential decrease in speed.

EncoderA device used to translate motion into electri-cal signals used to close the loop. Often usedas a position/motion feedback device in closedloop systems.

Encoder Marker PulseA once-per-revolution signal that provided bysome incremental encoders to specify a refer-ence point within that revolution.

End PlayThe axial shaft motion due to the reversal of anaxial force acting on a shaft with axial clear-ance or low axial pre-load.

Following ErrorThe positional error during motion betweenthe loads actual position and the commandedposition.

Friction CoulombA resistance to motion between non-lubricatedsurfaces. This force remains constant with ve-locity.

Friction ViscousA resistance to motion between lubricated sur-faces. This force is proportional to the relativevelocity between the surfaces.



224

GLOSSARY

GainThe ratio of system output signal to system in-put signal. The control loop parameter that de-termines system performance characteristics.

Hall SensorsA feedback device used by a servo amplifier toelectronically commutate the motor.

Holding Torque (static torque)The maximum restoring torque that is devel-oped by the energized motor when the shaft isslowly rotated by external means. The wind-ings are on but not being switched.

HorsepowerA term used to measure work done. Defined asHorsepower = (speed in RPM)(torque inft.lbs)/5250. Also, 746 Watts.

Hybrid Step MotorA type of step motor comprising a permanentmagnet and variable reluctance stator and ro-tor structures. It uses a double salient poleconstruction.

Hysteresis (positional)The difference between the step positionswhen moving CW and the step position whenmoving CCW. A step motor may stop slightlyshort of the true position thus producing aslight difference in position CW to CCW.

I/O–Inputs/OutputsThe reception and transmission of informationbetween control devices. I/O has two distinctforms: Digital like switches, relays, etc.whichare either in an On or Off state and Analogwhich is a continuous signal in nature such asspeed, temperature, flow, etc.

Idle Current ReductionReduction of phase current to a step motorwhen no motion is required.

IndexerAn electronic control that converts motioncommands from a computer terminal intopulse and direction signals for use by a stepmotor driver.

Inductance (mutual)The property that exists between two currentcarrying conductors or coils when magneticlines of flux from one link with those of theother.

Inductance (self)The constant by which the time rate of changeof the coil current must be multiplied to givethe self-induced counter emf.

InertiaMeasure of resistance of an object to changesin velocity. The larger the inertia, the moretorque required to accelerate and deceleratethe load.

Inertial Matchratio of reflected load inertia to motor inertia.

Instantaneous Start/Stop RateThe maximum switching rate that an unloadedstep motor will follow without missing stepswhen starting from rest.

L/R DriveA drive that uses external resistance to allow ahigher voltage than that of a voltage drive. L/Rdrives have better performance than voltagedrives, but have less performance and effi-ciency than a chopper drive.

Loop, PIDProportional, Integral and Derivative Loop–Specialized, high performance control loop.

Loop, PositionA feedback control loop in the which controlledparameter is motor position.

Loop, VelocityA feedback control loop in which the controlledparameter is velocity.

Maximum Reversing RateThe maximum switching rate at which an un-loaded motor will reverse direction of rotationwithout missing steps.



225

GLOSSARY

Maximum Slew RateThe maximum pulse rate at which a stepmotor with no load will run and remain insynchronism.

MicrosteppingA technique in which motor steps are elec-tronically divided by the drive into smallersteps. The most common microstep resolu-tions are 10, 25 and 50 steps per full step, butmany resolutions ranging from 2 to 256microsteps per full step are available.

Open Frame Driverefers to AMP amplifiers where a separate DCpower source must be provided to the unit.

Open-loopA system with no feedback. Most step motorsystems are run in this mode.

OscillatorA device that is used to produce pulses fordriving a step motor at a preset speed.Some A.M.P. drives are available with builtin oscillators.

OvershootThe amount a motor shaft rotates beyond thecommanded stopping position.

Packaged DriveRefers to AMP amplifiers where the powersupply is included in the enclosure and 110v/220v is used to power the unit.

Permanent Magnet Step MotorA step motor having a permanent magnet rotorand wound stator.

Positional AccuracyThe maximum error in one revolution of a fullstep in 360 degrees. Expressed as a percent-age of a full step.

Pull-in Rate (response rate)The maximum switching rate at which an un-loaded motor can start without losing steppositions.

Pull-in TorqueThe maximum torque load at which a stepmotor will start and run in synchronism witha fixed frequency pulse train without losingstep positions.

Pull-out TorqueThe maximum torque load that can be appliedto a motor running at a fixed stepping ratewhile maintaining synchronism. Any addi-tional load torque will cause the motor to stallor miss steps.

Pulse RateThe rate at which successive steps are initi-ated or the windings switched. The pulse ratedivided by the resolution of the motor/drivecombination (in steps per revolution) equalsthe rotational speed of the motor in revolu-tions per second.

PWMPulse Width Modulation. A method of con-trolling motor voltage and current used inservo amplifiers.

Radial PlayThe side to side movement of the shaft due toclearances between the shaft and bearing,bearing to housing, and bearing internal clear-ance for ball and roller bearings. (Side play)

RampingThe acceleration and deceleration of a motor.May also refer to the change in frequency ofthe step pulse train

Rated TorqueThe torque producing capability of a motor ata given speed. This is the maximum continu-ous torque the motor can deliver to a load.

RegenerationThe action during braking, in which the motoracts as a generator and takes kinetic energyfrom the load, converts it to electrical energy,and returns it to the amplifier.



226

GLOSSARY

RepeatabilityThe degree to which the positioning accuracyfor a given move performed repetitively can beduplicated.

ResolutionThe smallest positioning increment that can beachieved. Frequently defined as the number ofsteps or feedback units required for a motor’sshaft to rotate one complete revolution.

ResonanceThe effect of a periodic driving force thatcauses large amplitude increase at a particularfrequency.

Response Rate (pull-in rate)The switching rate an unloaded motor can fol-low from a standing start without missingsteps.

RingingOscillation of a system following a suddenchange in state.

RS-232, RS422/485Serial communication protocols

Serial PortA digital data communications port configuredwith a minimum number of signal lines.

Servo Amplifier/Servo DriveAn electronic device which converts a controlsignal into a high voltage/current which is fedinto the motor windings to product torque inthe motor.

Servo SystemAn automatic feedback control system for me-chanical motion in which the controlled or outputquantity is position, velocity, or acceleration.Servo systems are closed loop systems.

Settling TimeThe elapsed time starting the instant the rotorreaches the commanded step position and theoscillations settle to within a specified dis-placement band about the final position, usu-ally +/-3 to +/-5 percent.

SiRefers to the AMP Simple Indexer operatingenvironment. Sequences for machine opera-tion are programmed by the use of point andclick instructions. Shortens learning curve andallows “non-programmers” to easily sequencemachine functions and operations.

SlewThe portion of a move made at a constant non-zero velocity.

Stall Torque (holding or static)The torque available from a motor at stall orzero rpm.

Step AngleThe nominal angle through which the step mo-tor shaft rotates between adjacent step posi-tions.

Step Rate (speed)The number of steps a shaft rotates during aspecified time interval.

Step-to-Step Accuracy (relative accuracy)The maximum error that occurs between anyadjacent step, expressed as a percentage ofone full step.

Switching AmplifierA device that switches a high voltage on and offto control current. Some amplifiers (PWMtypes) switch at a constant frequency and ad-just duty cycle to control current. Other typeshave a fixed off time and adjust the frequency.



227

GLOSSARY

Switching Sequence (energizing sequence)The sequence and polarity of voltages appliedto coils of a step motor that result in a speci-fied direction of rotation.

Thermal Time ConstantThe time required for the motor winding toreach 63.2% of its final temperature.

Thermal ResistanceThe resistance of the flow of heat between twosurfaces of the same body or different bodies.Thermal resistance = Winding temperature/Watts in the winding = C/Watt.

TorqueThe rotary equivalent of force. Equal to theproduct of the force perpendicular to the radiusof motion and distance from the center of rota-tion to the point where the force is applied.

Torque ConstantA number representing the relationship betweenmotor input current and motor output torque.Usually expressed in units of torque/amp.

Torque Displacement CurveThe holding (restoring) torque plotted as afunction of rotor angular displacement with themotor energized

Torque Gradient (stiffness)The ratio of the change in holding torque for aparticular change in shaft position when themotor is energized.

Torque RippleThe cyclical variation of generated torquegiven by the product of motor angular velocityand number of commutator segments.

Torque-to-Inertia RatioRatio of a motor’s torque divided by themotor’s rotor inertia. The higher the ratio, thehigher the acceleration will be.

Unipolar DriveThe motor phase winding current is switched inone direction only. The polarity of the appliedvoltage to each winding is always the same.Unipolar drives require 6 or 8 lead motors.

Variable Reluctance Step Motor (V/R)A step motor having a wound stator or statorswith salient poles working with a soft iron ro-tor having salient poles on the periphery.

VelocityThe change in position as a function of time.Velocity has both magnitude and direction.

Viscous DampingA damper which provides a drag or frictiontorque proportional to speed. At zero speedthe drag torque is reduced to zero.

Viscous DampingA damper which provides a drag or frictiontorque proportional to speed. At zero speed,Friday, February 01, 2002the drag torque is re-duced to zero.

Voltage DriveA drive operated at the minimum voltage re-quired to safely limit motor current. Motorsused with voltage drives produce less torqueat higher speeds than when used with L/R orchopper drives.

Wave DriveEnergizing the phases one at a time. Drivingthe motor one phase or winding at a time.



228

lb•ft lb•in oz•in dyne•cm N•m mN•m kg•cm g•cm

lb•ft 1 12 192 1.356 x 10 7 1.356 1.356 x 10 3 13.825 1.3825 x 10 5

lb•in 8.333 x 10 –2 1 16 1.130 x 10 6 0.113 1.13 x 10 2 1.152 1.152 x 10 3

oz•in 5.208 x 10 –3 6.250 x 10 –2 1 7.062 x 10 4 7.062 x 10 –3 7.062 7.201 x 10 –2 72.01

dyne•cm 7.376 x 10 –8 8.851 x 10 –7 1.416 x 10 –5 1 10 –7 10 –4 1.0197 x 10 –4 1.0197 x 10 –3

N•m 0.7376 8.851 141.62 10 7 1 1,000 10.197 1.0197 x 10 4

mN•m 7.376 x 10 –4 8.851 x 10 –3 0.1416 10 4 10 –3 1 1.0197 x 10 –2 10.197

kg•cm 7.233 x 10 –2 0.8679 13.877 9.8266 x 10 5 9.8066 x 10 –2 98.066 1 1,000

g•cm 7.233 x 10 –4 8.6801 x 10 –4 1.389 x 10 –2 980.67 9.8066 x 10 –5 9.8066 x 10 –2 10 –3 1

Conv

ersi

on Ta

bles

Torque Conversion Tables

A B

To convert from A to B multiply by entry in table.

Example: Convert a torque of 53 oz•in to kg•cm.The multiplier from the table above is 7.201 x 10–2

The new value of torque is 53 x 72.01 = 3.816 kg•cm

Inertia Conversion TablesTo convert from A to B multiply by entry in table.

Example: Convert a rotor inertia of 90 g•cm2 to oz•in•sec2

The multiplier from the table above is 1.416 x 10–5

The new inertia = 90 x 1.416 x 10–5 = 1.27 x 103 oz•in•sec2

lb•ft 2lb•ft•s 2

orslug•ft 2

lb•in 2 lb•in•s 2 oz•in 2 oz•in•s 2 kg•m 2 kg•cm 2 kg•cm•s 2 g•cm 2 g•cm•s 2

lb•ft 2 1 3.108 x 10 –2 144 .373 2.304 x 10 3 5.968 4.214022 x 10 –2 421.40 0.4297 4.214 x 10 5 429.71

lb•ft•s 2 32.174 1 4.633 x 10 –3 12 7.413 x 10 4 192 1.35582 1.356 x 10 4 13.825 1.356 x 10 7 1.383 x 10 4

lb•in 2 6.944 x 10 –4 2.158 x 10 –4 1 2.590 x 10 –3 16 4.144 x 10 –2 2.926404 x 10 –4 2.926 2.984 x 10 –3 2.926 x 10 3 2.984

lb•in•s 2 2.681 8.333 x 10 –2 3.861 1 6.177 x 10 3 16 1.12985 x 10 –1 1.130 x 10 3 1.152 1.130 x 10 6 1.152 x 10 3

oz•in 2 4.34 x 10 –4 1.349 x 10 –5 6.25 x 10 –2 1.619 x 10 –2 1 2.59 x 10 –3 1.829006 x 10 –5 0.183 1.865 x 10 –4 182.901 0.186

oz•in•s 2 0.168 5.208 x 10 –3 24.13 6.25 x 10 –2 386.088 1 7.06155 x 10 –3 70.616 7.201 x 10 –2 7.0616 x 10 4 72.008

kg•m 2 34176.16 0.727561 3,417.16 8.85073 54,674.5 141.162 1 10,000 10.1972 1 x 10 7 10,197.2

kg•cm 2 2.373 x 10 –3 7.376 x 10 –5 0.3417 8.851 x 10 –4 5.467 1.416 x 10 –2 1 x 10 –4 1 1.0197 x 10 –3 1,000 1.0197

kg•cm•s 2 2.327 7.233 x 10 –2 335.109 0.8679 5.362 x 10 3 13.887 9.806614 x 10 –2 980.665 1 9.807 x 10 5 1,000

g•cm 2 2.373 x 10 –4 7.376 x 10 –8 3.417 x 10 –4 8.851 x 10 –7 5.467 x 10 –3 1.416 x 10 –5 1 x 10 –7 10–3 1.0197 x 10–6 1 1.0197 x 10 –3

g•cm•s 2 2.327 x 10 –3 7.233 x 10 –5 0.3351 8.680 x 10 –4 5.362 1.389 x 10 –2 9.806614 x 10 –5 .9807 10–3 980.667 1

A B

404 westridge dr. - mouser electronics404 westridge dr. • watsonville, ca 95076 831/761-6555 •...

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