Motion Control: Module Jumper Settings (Part 4 of 8) from AutomationDirect

Now that I have all of my components selected, and have determined the control method, it is time for me to assembly and wire all of the devices. I’ll also need to set up my hardware configuration jumpers and DIP switch settings. Let’s see how this is done. Before I cover the schematic diagram I used for wiring the control system, let me review the components that were put together to make up the Motion Control system I will be using to control my linear lead screw slide. The system includes the DirectLOGIC DL05 Micro PLC. I used part number D0-05DD that provides DC inputs and outputs. A High Speed Counter Interface Module, part number H0-CTRIO, is installed into the available expansion slot on the DL05 PLC. The SureStep stepping system components I selected include a Micro Stepping Drive, part number STP-DRV-4035, a NEMA 23 stepping motor, part number STP-MTR-23079, a power supply, part number STP-PWR-4805, and an extension cable, part number STP-EXT-020. The C-more Micro-Graphic Touch Panel I am using is a part number EA1-S3ML, and I have added a C-more Serial Port with DC Power Adapter, part number EA-MG-SP1, that plugs into my panel to provide a second serial port, and is also a convenient method to power the panel from a 24 Volts DC source. I complete the C-more components by using a part number EA-2CBL C-more Communications Cable to connect between my panel and the DL05 PLC. If I didn’t mention it earlier, I am using the Serial Port with DC Power Adapter to give me a second communications port to allow me to have communications port one on the panel connected to my programming PC during development. The last of the components I have selected include an AutomationDirect Rhino 24 Volt DC Power Supply, part number PSC-24-030, providing power to the C-more panel and the proximity sensors I am using. Speaking of the proximity sensors, I have selected an AutomationDirect ProSense part number APS4-12S-E-D. I am using the proximity sensors to detect my axis home position, and also my over travel limits. The Linear Leadscrew Slide I am using is a commercial unit with a ‘Pitch’ of 0.125 inches per revolution, and a total slide travel of 300 millimeters. Shown here is a wiring schematic of the components that I used for the Motion Control demonstration unit. The schematic shows the DL05 PLC with its serial communications connection to the C-more Micro-Graphic panel, its I/O connections to the over travel proximity sensors, the CTRIO high speed counter interface module with its output pulse and direction connections to the SureStep drive, and the home proximity sensor connection to a CTRIO input. The linear slide with its lead screw is represented showing the location of the SureStep stepping motor and the home and over travel proximity sensors. Next I will set the jumpers on the CTRIO module. The module’s jumpers can be configured for either DC Voltage sinking or sourcing operation. In our example we will be sinking the pulse and direction signals that feed the SureStep STP-DRV-4035 micro stepping motor driver. I place the four jumpers over the set of pins to the left as shown here. Let me point out that the H0-CTRIO module has one input channel which consists of four optically isolated input points. The input terminals are labeled ‘A’, ‘B’, ‘C’, ‘D’ and are common to terminal ‘M’. The inputs can be wired so that all four either sink or source current, no jumper selection required, it’s all in how they are wired. The module also has two optically isolated outputs. The output terminals are labeled ‘Y0’and ‘Y1’ and are common to terminal ‘YC’. Do not confuse the CTRIO’s ‘Y0’ and ‘Y1’ labeling with the DL05 PLC’s outputs with the same designations, they are not the same. The outputs can be wired to either sink or source current. The sink/source jumper selection we just made sets both outputs to the same option. Sourcing outputs must be wired so positive current flows into the ‘YC’ terminal and then out the ‘Y0’ or ‘Y1’ terminal. Sinking outputs must be wired so positive current flows into the ‘Y0’ or ‘Y1’ terminals and then out the ‘YC’ terminal, so just the opposite of sourcing. Source operation is the factory default setting for the outputs, but in my application I needed to set them for sink operation. The STP-DRV-4035 drive includes a 9-position DIP switch. The DIP switch is used to set the drive’s various parameters which include a self test function, micro stepping resolutions of 400, 1,000, 2,000 or 10,000 steps, current reduction at idle, and the step motor’s phase current. The SureStep drive includes a Self Test feature which aids in trouble shooting the stepping system. To use it, slide DIP switch position 1 toward the label marked “TEST”. The stepping motor will slowly rotate 1/2 revolution forward and then 1/2 revolution backwards. This motion will repeat until the DIP switch is returned to the ‘Off’ position. The self test will use half step mode and ignore any input signals on the “STEP” and “DIRECTION” terminals. The “ENABLE” input will continue to function normally. Precisely controlling the amount of current in each phase, at each step position, allows the steps to be electronically subdivided, which produces the ability to Micro Step. The drive can be configured for “half step” operation, or one of three different micro step resolutions. These are the “1/5”, “1/10” or “1/50” micro steps. In a typical 1.8 degree step motor, this will equate to “400”, “1,000”, “2,000” or “10,000” steps per revolution. DIP switch positions “2” and “3” are used to set the resolution as shown here. The SureStep drive’s Current Reduction feature can be enabled to reduce the stepping motor’s current by “50%” anytime the motor is not moving. Drive heating is reduced by about “50%” by using Current Reduction, and the feature lowers motor heating by “75%”. Slide DIP switch position “4” toward the label marked “50% Idle” to enable Current Reduction as shown here. Be aware that the stepping motor’s holding torque will be reduced. The last five positions of the DIP switch, positions “5” through “9”, are used for setting the Motor Current of the stepping motor. The value of current for each position is printed adjacent to the DIP switch. There is always a base current of 0.4 Amps. To add to the base current, slide the appropriate switches toward their labels marked on the drive’s Printed Circuit board. The factory default is set for 2.8 Amps, which happens to be the current rating for the stepping motor, part number STP-MTR-23079, that I am using in my demonstration. Shown here is a summary of all of the drive’s DIP Switch settings. The Self Test position is “Off”. The Micro Stepping Resolution is set for 1/10 which will allow me to use 2,000 steps per revolution. The Current Reduction position is On to allow 50% current reduction at idle. The Motor Current per the stepping motor nameplate data has been confirmed for 2.8 Amps. In part five I will get into the programming; starting with the CTRIO configuration, along with creating motion profiles using the CTRIO Workbench Utility. Motion Control – VID: L-PC-DL-STP-001-4 Part 4 of 8 – Wiring, CTRIO Jumper Settings & Drive DIP Switch Settings 0 2