The MA6410 is a two-phase bipolar, chopper current-regulated stepper motor drive designed for use in various automation applications. It converts step and direction inputs into motor winding currents to control a two-phase stepper motor. The drive offers microstepping and mid-band instability compensation for high resolution and smooth operation across low speed and mid-band resonance regions.
Function Description:
The MA6410 drive is designed to control stepper motors in a variety of applications, including X-Y tables and slides, packaging machinery, robotics, specialty machinery, index feed of material, and labeling machines. It operates by regulating the phase current to the motor windings based on step and direction commands. The drive incorporates several features to enhance performance and reliability:
- Bipolar Chopper Drive: Utilizes a 4-phase PWM (pulse width modulation) chopping electronically to control motor winding current, with a 20 KHz frequency. This provides best-in-class regulating and over-regulating current regulation, producing high back EMF rejection with low chopping ripple current. Benefits include reduced heat dissipation, low electric noise, and improved current control during motor breaking.
- Microstepping: Offers switch-selectable step sizes from full step to 1/256 microstep. This allows for smoother motor motion and higher resolution.
- Digital Electronic Damping: Patented circuitry eliminates torque and/or motor stalling through mid-speed regions, inherent in all open loop stepper applications. This feature is enabled by placing DIP switch S1 position 4 in the open position.
- Short Circuit Protection Circuitry: Disables the drive if a short circuit occurs on the motor outputs, protecting the drive from damage.
- MOSFET Power Devices: Allows chopper frequency of approximately 20 KHz, eliminating acoustical noise often associated with choppers.
- Optically Isolated Signal Interface Connection: Provides optical isolation for step, direction, and enable inputs, enhancing noise immunity and protecting the control electronics.
- Idle Current Reduction (ICR): Enables or disables idle current reduction, which reduces motor winding current by 50% during periods of no motion. This reduces motor and drive heating during standby operation. The time delay for current reduction can be set to 0.05, 0.1, or 1.0 second.
- Enable Sense: Allows the polarity of the enable input to be reversed via a jumper setting (J6 5-6).
Important Technical Specifications:
- Input Power Supply: 24 - 75 Vdc @ 5.0 Amps.
- Rated Drive Current (Motor Phase Current): Selectable settings from 0.625 A to 5 A RMS.
- 5 A ± 0.25A
- 4.375 ± 0.2A
- 3.75 ± 0.2 A
- 3.125 ± 0.15 A
- 2.5 ± 0.15 A
- 1.875 ± 0.125
- 1.25 ± 0.125
- 0.625 ± 0.1 A
- Chopper Frequency: 20 KHz, nominal.
- Step Size: Switch settable from Full (200 steps/revolution for 1.8° motor) to 1/250 (50000 steps/revolution for 1.8° motor). Binary and Decimal step sizes are available.
- Maximum Step Rate: 2 MHz with step filter disabled, 500 KHz with step filter enabled.
- Signal Input Requirements (Optically Isolated Inputs):
- J1-1, J1-6 - Step: Min Input Current - Opto ON: 5.5 mA, Max Input Current: 10 mA, Max Reverse Voltage: 5 volts.
- J1-2, J1-7 - Direction: Min Input Current - Opto ON: 3.0 mA, Max Input Current: 4.5 mA, Max Reverse Voltage: 5 volts.
- J1-3, J1-7 - Enable: Min Input Current - Opto ON: 3.0 mA, Max Input Current: 4.5 mA, Max Reverse Voltage: 5 volts.
- Signal Output Characteristics (J1-4, J1-9 Enabled): Optically isolated NPN transistor with open collector and open emitter. Maximum low level voltage while sinking 2 mA: 0.5 volts.
- Step/Direction Timing Requirements: Setup time 50 µs min. Step input 250 ns min (1 µs min with step filter enabled). Direction data must be stable over the step input interval.
- Minimum Ramp Time for Step Rate (Accel/Decel): 50 milliseconds (with mid-band stability control circuit enabled).
- Drive State Generator Transition Delay Relative to Input Step:
- With mid-band stability control circuit enabled: < 500 µs at pulse frequencies < 500 full steps/sec; < 270° of input pulse period at frequencies > 500 full steps/sec.
- With mid-band stability control circuit disabled: < 10 µs at all step frequencies.
- Environmental:
- Operating Temperature: Full rated current 0 to 50° C ambient air with or without cover, provided chassis properly mounted so as not to exceed 60° C.
- Storage Temperature: -55° C to +70° C.
- Maximum Chassis Temperature: 60° C.
- Humidity Range: 10 to 90%, non-condensing.
- Mechanical:
- Dimensions: 4.30" [109.2mm] x 5.00" [127.0mm] x 1.10" [27.9mm] (main body). Optional side mounting available.
- Weight: 1.0 lb nominal.
- Connectors:
- Power Supply: PCD ELVH0310 connector (mating: PCD ELVP03100).
- Signal: 9 contact female D connector (mating: ITT Cannon DE-9P with ITT Cannon DE110963 Hood and D20419 Clamp Kit).
- Motor: PCD ELVH0510 connector (mating: PCD ELVP05100).
Usage Features:
- Easy Installation: The drive is designed for bookcase-style mounting to a cooling plate or heatsink for optimal thermal performance. It can also be mounted with its side against the cooling plate.
- Configurable Settings: DIP switches (S1) and jumpers (J6) allow for easy configuration of step size, motor current level, digital electronic damping, idle current reduction, enable sense, and step filter response time.
- Motor Compatibility: The drive is compatible with Pacific Scientific hybrid stepper motors. The motor winding current rating must be compatible with the output current of the drive package.
- Power Supply Flexibility: Can be powered by a single unregulated DC power supply (24-75 volts). Guidelines for selecting power supply components (transformer, rectifier diodes, capacitors, fuses) are provided, including considerations for regeneration.
- Signal Interface: Optically isolated inputs for STEP, DIR, and ENABLE signals ensure robust communication with user control electronics. Higher voltage interfaces (up to 30V) are supported with external resistors.
- Motor Cabling: Pacific Scientific offers pre-assembled motor cables (SPC-xxx-6410) for direct connection to their system motors. Instructions for making custom motor cables are also provided, including wiring diagrams for 4-lead and 8-lead motors in parallel or series configurations.
Maintenance Features:
- Troubleshooting Guide: A comprehensive table is provided to diagnose and correct common problems such as no torque, incorrect motor rotation, or failure to reach expected position.
- Cleaning: The drive is designed for minimum maintenance, with a cleaning procedure recommended to remove superficial dust and dirt using clean, dry, low-pressure air.
- Fault Detection: The 6410 has an "enabled" output that indicates when the drive is enabled and off when disabled or faulted due to output overcurrent, bus overvoltage, or low voltage supply out of tolerance.
- Return Procedure: In case of a defective unit, a clear return procedure is outlined, requiring a Returned Materials Authorization Number (RMA#) from Pacific Scientific.
- ESD Protection: Electronic drives contain electrostatic sensitive devices, so qualified personnel must follow ESD protection measures (e.g., wear grounded heel and wrist straps) when handling the drive.
- EMC Compliance: The MA6410 is designed for use within machines requiring compliance with European Safety and EMC Directives (EN 61800-3). Detailed installation guidelines are provided to maintain EMC compliance, including recommendations for cable shielding and grounding.
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