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-1-

Hardware Manual
Si3540
Programmable St ep Mot or Driver
mot ors dri ves cont rol s
POWER
M
O
T
O
R
A
C
P
O
W
E
R
A+
A-
B+
B-
G
L
N
P
C
/
M
M
I
INPUT 1
INPUT 2
INPUT 3
INPUT 4
IN 5/JOG CW
IN 6 JOG CCW
INPUT COM
INPUT COM
CCW -
CCW +
CW +
CW -
OUT 1 +
OUT 1 -
OUT 2 +
OUT 2 -
OUT 3 +
OUT 3 -
L
I
M
I
T
S
S
i
3
5
4
0
P
r
o
g
r
a
m
m
a
b
l
e

S
t
e
p

M
o
t
o
r

D
r
i
v
e
r
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Introducti on - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Features - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Bl ock Di agram - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3
Getti ng Started - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4
Connecti ng the AC Li ne - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5
Connecti ng the Motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7
Connecti ng to the PC- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8
Joggi ng - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Li mi t Swi tches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9
Wi ri ng a Mechani cal Li mi t Swi tch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Wi ri ng a Li mi t Sensor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10
Wi ri ng Inputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11
Wi ri ng Outputs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13
Mi crosteppi ng - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 14
Mounti ng the Dri ve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Mounti ng the Opti onal MMI - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 15
Recommended Motors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Mechani cal Outl i ne - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17
Techni cal Speci fi cati ons - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 18
Mechani cal Outl i ne - Opti onal MMI - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 19
Table of Cont ent s
-3-
MOSFET
3 State
PWM
Power
Amplifier
m
o
t
o
r

p
h
a
s
e

A
m
o
t
o
r

p
h
a
s
e

B
110 or
220 VAC
INPUT1
INPUT2
INPUT3
INPUT4
CW J OG/IN5
CCW J OG/IN6
to PC/MMI
CW LIMIT/IN7
CCW LIMIT/IN8
OUT1
OUT2
OUT3
RS232
Optical
Isolation
Microstepping
Indexer
Sequencer
eeprom
Optical
Isolation
Internal
Power
Supply
power LED
fuse
I ntroduction
Thank you for sel ecti ng an Appl i ed Moti on Products motor control . We hope our
dedi cati on to performance, qual i ty and economy wi l l make your moti on control
proj ect successful . If theres anythi ng we can do to i mprove our products or hel p
you use them better, pl ease cal l or fax. Wed l i ke to hear from you. Our phone
number i s (800) 525- 1609 or you can reach us by fax at (831) 761- 6544.
Features
Powerful , preci se and effi ci ent MOSFET dri ver provi di ng up to 3.5 amps per phase
and mi crosteppi ng to 50,800 steps per revol uti on.
Rel i abl e, effi ci ent, l ow noi se 40 VDC l i near, toroi dal power suppl y.
Powerful , fl exi bl e, easy to use i ndexer.
Connects by a si mpl e cabl e to your PC for programmi ng (cabl e i ncl uded).
Mi crosoft Wi ndows
TM
- based software for easy setup and programmi ng
Ei ght i nputs for i nteracti ng wi th the user and other equi pment.
Three outputs for coordi nati ng external equi pment.
Accepts 110 or 220 vol t AC power (factory preset for 110 vol ts).
External tri gger I/ O i s opti cal l y i sol ated, 5- 24V, si nki ng or sourci ng si gnal s. PC/
MMI port i s RS- 232.
Sturdy 2.25 x 7.8 x 5 i nch metal chassi s.
Pl uggabl e screw termi nal connectors for motor, AC power and I/ O si gnal s.
Opti onal man machi ne i nterface (MMI) al l ows operator to enter di stances, speeds,
cycl e counts and more.
CE and TUV Compl i ant
Block Diagram
Si
TM
-4-
Get t ing St art ed
To use your Si 3540 motor control , you wi l l need the fol l owi ng:
a power cabl e (l i ne cord)
a compati bl e step motor
a smal l fl at bl ade screwdri ver for ti ghteni ng the connectors - an Appl i ed Moti on
Products screwdri ver sui tabl e for thi s purpose i s i ncl uded wi th your dri ve.
a personal computer runni ng Wi ndows 3.1, 95, 98 or NT wi th a 9 pi n seri al port
(486 or better wi th 8 MB ram recommended)
the Si Programmer
TM
software that came wi th your Si 3540
the programmi ng cabl e that came wi th your Si 3540
Si Programmer
TM
software manual
The sketch bel ow shows where to fi nd the i mportant connecti on and adj ustment
poi nts. Pl ease exami ne i t now.
All Mating connectors included.
Al ways use the bl ue & whi te Appl i ed
Moti on screwdri ver wi th the above
I/ O connectors. Larger screwdri vers
may remove the pl asti c di mpl es that
prevent the screws from fal l i ng out.
POWER
M
O
T
O
R
A
C
P
O
W
E
R
A+
A-
B+
B-
G
L
N
P
C
/ M
M
I
INPUT 1
INPUT 2
INPUT 3
INPUT 4
IN 5 / JOG CW
IN 6 / JOG CCW
IN / JOG COM
IN / JOG COM
CCW -
CCW +
CW +
CW -
OUT 1 +
OUT 1 -
OUT 2 +
OUT 2 -
OUT 3 +
OUT 3 -
L
IM
IT
S
S
i
3
5
4
0
P
r
o
g
r
a
m
m
a
b
l
e

S
t
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p

M
o
t
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r

D
r
i
v
e
r
AC power
connector
Motor connector
RS232 connector
pc
mmi
I/O connector
outputs 1-3
I/O connector
cw, ccw limits
I/O connector
inputs 1-4
jog cw, ccw
Power LED
-5-
Connect ing t he AC Line
The Si 3540 i s set for 110 VAC operati on at the factory. If you use 110 VAC power,
al l you need to do i s i nstal l a power cord and pl ug i t i n. If you pl an to use 220
VAC power, fol l ow the i nstructi ons bel ow.
Note: If you pl an to hard wi re the Si 3540 to AC power, consul t a qual i fi ed el ectri -
ci an and observe al l bui l di ng and el ectri cal codes. AC power can be dangerous.
220 VAC Instructions
In order to use 220 vol ts, youl l need to change a fuse and a swi tch setti ng i nsi de
the case.
Remove al l mati ng connectors from the dri ve.
Set the dri ve on i ts wi dest si de, so that you can read Si3540 Programmable
St ep Mot or Driver properl y.
Remove the four (4) phi l l i ps head screws that mount the chassi s sheet metal to
the chassi s heat si nk. See page 17 for a mechani cal outl i ne of the dri ve.
The 110/ 220 swi tch i s l ocated near the posi ti on of the AC power connector, next
to the toroi dal transformer (see sketch bel ow).
For 220 VAC operati on sl i de the swi tch towards the bottom of the dri ve, or
towards the transformer end of the dri ve. The posi ti on of the swi tch i s l abel ed on
the PC board al so, 230 bei ng for 200- 240 VAC operati on, and 115 for 100- 120
VAC operati on.
Repl ace the fuse next to the swi tch wi th the 220 VAC fuse that came wi th the
dri ve. See techni cal speci fi cati ons on page 18 to order more fuses.
Repl ace the dri ves cover and assembl y screws.
2
3
0
1
1
5
S
W
1
C
N
1
PC Board
AC Power
Connector
Fuse
110/220 VAC
Switch
Swi tch set for 110 VAC
2
3
0
1
1
5
S
W
1
C
N
1
Swi tch set for 220 VAC
-6-
Installing an AC Line Cord
Remove about 5 mm (3/ 16 i nces) of i nsul ati on from each of the three wi res of your
l i ne cord. (Thats ri ght, three wi res. For safety, al ways use a three wi re power cord
on anythi ng wi th a metal case). dependi ng on where you got your power cord, i t
may have bl ack, whi te and green wi res, or brown, whi te and green wi res.
The AC power pl ug that was shi pped wi th your Si 3540 mi ght be one of two types.
The ol d styl e i s shown bel ow, on the l eft. The new styl e , whi ch comes wi th an
i nsul ati ng rubber boot, i s shown bel ow, on the ri ght.
Make sure you follow the proper sketch for your connector style.
Always unplug the line cord from the wall before attaching
it to the Si3540.
Connect the bl ack or brown wi re to the Si 3540 L termi nal of the AC power
connector. That i s the l i ne, or hot connecti on.
Connect the wi te or bl ue wi re to neutral , the N termi nal .
Fi nal l y, and most i mportantl y, connect the green wi re to the GND termi nal . That
connects the Si 3540 metal encl osure and DC power suppl y ground to earth ground.
!
k c a l b
e t i h w
n e e r g
To Earth Ground
To Neutral
To Li ne (Hot)
To Earth Ground
To Neutral
To Li ne (Hot)
green
bl ack or brown
w
hi t e or bl ue
"Old Style"
AC Power Plug
"New Style"
AC Power Plug
-7-
Connect ing t he Mot or
Never connect or disconnect the motor to the driver when the AC
power is on.
Secure any unused motor leads.
Never disconnect the motor while the AC power is on.
Never connect motor leads to ground or to a power supply.
You must now deci de how to connect your
motor to the dri ve.
Four lead motors can onl y be connected
one way. Pl ease fol l ow the sketch at the
ri ght.
Six lead motors can be connected i n seri es or center tap. In seri es mode, motors
produce more torque at l ow speeds, but cannot run as fast as i n the center tap
confi gurati on. In seri es operati on, the motor shoul d be operated at 30% l ess than
the rated current to prevent overheati ng. Wi ri ng di agrams for both connecti on
methods are shown bel ow.
!
Note: NC means not connected to anythi ng.
A+
A
B+ B
4
lead
motor
Red
Blue
Yellow White
4 Leads
A+
A
NC
B+ B NC
6
lead
motor
Red
Black
Red/
Wht
Green
Grn/Wht
White
A+
A
NC
B+ B NC
6
lead
motor
Grn/Wht
White
Green
Red
Red/
Wht
Black
6 Leads Series Connected 6 Leads Center Tap Connected
-8-
Connect ing t o t he PC
Locate your computer wi thi n 6 feet of the Si 3540.
Your Si 3540 was shi pped wi th a bl ack adapter pl ug. It has a tel ephone styl e j ack
at one end and a l arger 9 pi n connector at the other. Pl ug the l arge end i nto the
COM1 seri al port of your PC. Secure the adapter wi th the screws on the si des. If
the COM1 port on your PC i s al ready used by somethi ng el se, you may use the
COM2 port for the Si 3540. On some PCs, COM2 wi l l have a 25 pi n connector that
does not fi t the bl ack adapter pl ug. If thi s i s the case, and you must use COM2,
you may have to purchase a 25 to 9 pi n seri al adapter at your l ocal computer store.
Your Si 3540 was al so shi pped wi th a 7 foot tel ephone l i ne cord. Pl ug one end
i nto the adapter we j ust attached to your PC, and the other end i nto the PC/ MMI
j ack on your Si 3540.
Never connect the Si3540 to a telephone circuit. It uses the
same connectors and cords as telephones and modems, but the
voltages are not compatible.
Programmi ng Note: Al ways appl y power to the Si 3540 after the Si
TM
Programmer
software i s runni ng on your PC.
A+
A
B+ B
8
lead
motor
8 Leads Series Connected 8 Leads Parallel Connected
A+
A
B+
B
8
lead
motor
Orange
Org/Wht
Blk/Wht
Black
Red Red/
Wht
Yel/
Wht
Yellow
Orange
Org/
Wht
Blk/Wht
Black
Red
Red/Wht
Yel/
Wht
Yel
low
Ei ght l ead mot ors can al so be connected i n two ways: seri es and paral l el . As
wi th si x l ead motors, seri es operati on gi ves you more torque at l ow speeds and l ess
torque at hi gh speeds. In seri es operati on, the motor shoul d be operated at 30%
l ess than the rated current to prevent overheati ng. The wi ri ng di agrams for ei ght
l ead motors are shown bel ow.
!
-9-
Limit Swit ches
The Si 3540 has two l i mi t swi tch i nputs, LIMIT CW and LIMIT CCW. By connect-
i ng swi tches or sensors that are tri ggered by the moti on of the motor or l oad, you
can force the Si 3540 to operate wi thi n certai n l i mi ts. Thi s i s useful i f a program
error coul d cause damage to your system by travel i ng too far.
The l i mi t i nputs are opti cal l y i sol ated. Thi s al l ows you to choose a vol tage for your
l i mi t ci rcui ts of 5 to 24 vol ts DC. Thi s al so al l ows you to have l ong wi res on l i mi t
sensors that may be far from the Si 3540 wi th l ess ri sk of i ntoduci ng noi se to the
Si 3540. The schemati c di agram of the l i mi t swi tch i nput ci rcui t i s shown bel ow.
2200
2200
inside Si3540
COM
CWJOG
CCWJOG
+
5-24
VDC
SUPPLY
-
Si3540
Controller
Chip
2200
10K
+5V +5V
3
4
1
2
CW LIMIT+
CW LIMIT
CCW LIMIT+
CCW LIMIT
TLP621 or
NEC PS2501
inside Si3540
Jogging
Two of the Si 3540 i nput termi nal s are provi ded for j oggi ng the motor. The i nputs
are l abel ed JOG CW and JOG CCW . Acti vati ng one of the i nputs commands the
dri ve to move the motor at a pre- desi gnated speed unti l the contact i s opened. A
rel ay or mechani cal swi tch can be used to acti vate the j og i nputs. 5- 24 vol t ci r-
cui try can be used. The schemati c di agram of the i nput ci rcui t i s shown bel ow.
If youre usi ng a swi tch or rel ay, wi re one end to the JOG i nput and the other to the
power suppl y negati ve (- ) termi nal . Then connect the COM i nput to the power
suppl y posi ti ve (+) termi nal s.
-10-
If the sensor output goes l ow at the l i mi t, sel ect the opti on cl osed . If the output
i s open, or hi gh vol tage, choose open .
Other sensors have sourcing outputs. That means that current can fl ow out of the
sensor output, but not i nto i t. In that case, wi re the sensor thi s way:
If the sensor output goes hi gh at the l i mi t, choose the program opti on cl osed . i f
the output i s l ow at the l i mi t, sel ect open .
Si3540
CCW LIMIT+
CCW LIMIT-
CW LIMIT-
+
5-24
VDC
SUPPLY
-
CW LIMIT+
Si3540
CW LIMIT-
+
DC
Power
Supply

Limit
Sensor
CW LIMIT+
output
+

Si3540
LIMIT-
+
DC
Power
Supply

Proximity
Sensor
LIMIT+
output
+

Wiring a Mechanical Limit Swit ch


You can use normal l y open or normal l y cl osed l i mi t swi tches. Ei ther way, wi re
them as shown here.
Wiring a Limit Sensor
Some systems use acti ve l i mi t sensors that produce a vol tage output rather than a
swi tch or rel ay cl osure. These devi ces must be wi red di fferentl y than swi tches.
If your sensor has an open col l ector output or a si nki ng output, wi re i t l i ke thi s:
Wiring for Sinking or Open Collector Output
Wiring for Sourcing Output
-11-
Wiring I nput s
The Si 3540 i nput ci rcui ts can be used wi th
sourci ng or si nki ng si gnal s, 5 to 24 vol ts.
Thi s al l ows connecti on to TTL ci rcui ts,
PLCs, rel ays and mechani cal swi tches.
Because the i nput ci rcui ts are i sol ated, they
requi re a source of power. If you are con-
necti ng to a TTL ci rcui t or to a PLC, you
shoul d be abl e to get power from the PLC or
TTL power suppl y. If you are usi ng rel ays or
mechani cal swi tches, you wi l l need a 5- 24
power suppl y. Thi s al so appl i es i f you are
connecti ng the Si 3540 i nputs to another Si
product from Appl i ed Moti on, l i ke the Si - 1
and Si - 100 i ndexers or the Si 5580, 7080i
and MC8400 i ndexer- dri ves.
Connecti ng an Input to a Swi tch or Rel ay Connecti ng an Input to a Swi tch or Rel ay Connecti ng an Input to a Swi tch or Rel ay Connecti ng an Input to a Swi tch or Rel ay Connecti ng an Input to a Swi tch or Rel ay
Use normal l y open momentary swi tch to tri gger Si 3540 usi ng Wai t Input i nstructi on.
Use si ngl e throw swi tch for parameter sel ecti on usi ng If Input i nstructi on.
Use normal l y open momentary swi tch for j oggi ng.
2200
2200
2200
2200
2200
2200
inside Si3540
COM
COM
COM
IN1
IN2
IN3
IN4
CWJOG
CCWJOG
Si3540
switch or relay
(closed=logic low)
IN
COM
5-24
VDC
Power
Supply -
+
Note: If current i s fl owi ng i nto or out of an Si 3540 i nput, the l ogi c state of that
i nput i s l ow. If no current i s fl owi ng, or the i nput i s not connected, the l ogi c state
i s hi gh.
The di agrams on the fol l owi ng pages show how to connect Si 3540 i nputs to vari ous
devi ces.
The maximum voltage that can be applied to an input terminal is
24 volts DC. Never apply AC voltage to an input terminal. !
-12-
Connecting an Input to the Si-1 Motion Output
(Set Si - 1 moti on si gnal to i n posi ti on . Si - 1 wi l l tri gger Si 3540 at end of each move).
Connecting a 3540i, Si5580, 7080i or MC8400
(When output cl oses, Si 3540 i nput goes l ow).
Connect i ng an NPN Type Proxi mi t y Sensor t o an Si 3540 i nput
(When prox sensor acti vates, Si 3540 i nput goes l ow).
Connecting a PNP Type Proximity Sensor to an Si3540 input
(When prox sensor acti vates, Si 3540 i nput goes l ow).
S
i
3
5
4
0 IN
IN/J OG COM
S
I
-
1

i
n
d
e
x
e
r
MOTION+
MOTION
5-24
VDC
Power
Supply
-
+
S
i
3
5
4
0 IN
COM
S
i
5
5
8
0
,

7
0
8
0
i
o
r

M
C
8
4
0
0
OUT+
OUT
5-24
VDC
Power
Supply
-
+
Si3540
NPN
Proximity
Sensor
IN
COM
output
+

5-24
VDC
Power
Supply
-
+
NPN
Proximity
Sensor
IN
COM
output
+

5-24
VDC
Power
Supply
-
+
Si3540
PNP
Proximity
Sensor
IN
output
+

COM
5-24
VDC
Power
Supply
-
+
PNP
Proximity
Sensor
IN
output
+

COM
5-24
VDC
Power
Supply
-
+
-13-
Wiring Out put s
Before we di scuss the output condi ti ons, we need to tal k about the ci rcui try. Al l
three Si 3540 outputs are opti cal l y i sol ated. That means that there i s no el ectri cal
connecti on between the i ndexer- dri ve and the output termi nal s. The si gnal i s
transmi tted to the output as l i ght. What you see i s a transi stor (NPN type) that
cl oses, or conducts current, when the output i s l ow . When the output i s hi gh, the
transi stor i s open.
Note: At power- up, the Si 3540 sets al l three programmabl e outputs hi gh (open
ci rcui t).
Si nce there i s no el ectri cal conneci ton to the Si 3540, you must provi de the source
of current and vol tage, typi cal l y from a power suppl y. You must al so l i mi t the
current to l ess than 100 mA so that the output transi stor i s not damaged. You
woul d normal l y use a resi stor for thi s, but some l oads (such as PLC i nputs) l i mi t
the current automati cal l y.
The di agram bel ow shows how to connect an Si 3540 output to an opti cal l y i sol ated
PLC i nput.
Schematic Diagram of Si3540 Output Circuit
PLC
COMMON
INPUT
Si3540
OUTPUT-
OUTPUT+
12-24 VDC
Power Supply
+
330
+5V
OUT1
OUT1+
Optoisolator
NEC PS2502
or equiv.
Si3540
Controller Chip
inside Si3540
The maximum voltage between any pair of + and - output
terminals is 24 volts DC. Never connect AC voltages to the
Si3540 output terminals. Maximum current is 100 mA per
output.
!
-14-
Microstepping
Most step motor dri ves offer a choi ce between ful l step and hal f step resol uti ons.
In ful l step mode, both motor phases are used al l the ti me. Hal f steppi ng di vi des
each step i nto two smal l er steps by al ternati ng between both phases on and one
phase on.
Mi crosteppi ng dri ves l i ke the Si 3540 preci sel y control the amount of current i n each
phase at each step posi ti on as a means of el ectroni cal l y subdi vi di ng the steps even
further. The Si 3540 offers a choi ce of 13 step resol uti ons. The hi ghest setti ng
di vi des each ful l step i nto 254 mi crosteps, provi di ng 50,800 steps per revol uti on
when usi ng a 1.8 motor.
In addi ti on to provi di ng preci se posi ti oni ng and smooth moti on, mi crostep dri ves
can be used for moti on conversi on between di fferent uni ts. The 25,400 step/ rev
setti ng i s provded as a means of converti ng moti on from metri c to engl i sh (there are
25.4 mm i n an i nch). Other setti ngs provi de step angl es that are deci mal degrees
(36,000 steps/ rev makes the motor take 0.01 steps). Some setti ngs are used wi th
l ead screws. When the dri ve i s set to 2000 steps/ rev and used wi th a 0.2 pi tch l ead
screw, you get 0.0001 i nches/ step.
The mi crostep resol uti on of the Si 3540 i s set by the Si Programmer
TM
software.
-15-
Mount ing t he Drive.
You can mount your dri ve on the wi de or the narrow si de of the chassi s.
Mount ing t he Opt ional MMI
There are two ways to mount the MMI i n your appl i cati on. No matter whi ch method
you choose, youl l need to connect the MMI to your Si 3540 wi th the programmi ng
cabl e. You wi l l not, however, need the adapter pl ug. The MMI has the same
tel ephone styl e connector as the Si 3540.
Dependi ng on how you mount the MMI and cabl e i n your appl i cati on, you may fi nd
that i t i s di ffi cul t to remove the cabl e from the back of the MMI. If thi s i s the case,
and you need to reprogram the Si 3540, you can use any tel ephone l i ne cord as a
programmi ng cabl e. They are avai l abl e at most supermarkets and di scount stores.
Pl eae be careful not to l ose the adapter pl ug that connects the tel ephone cord to the
COM port of your PC. The adapter i s a custom made part and i s onl y avai l abl e
from Appl i ed Moti on.
Use for NARROW-SIDE
mounting.
Use for WIDE-SIDE
mounting.
Never use your drive in a space where there is no air flow or
where the ambient temperature exceeds 50C (120F).
Never put the drive where it can get wet.
Never allow metal particles near the drive.
!
-16-
Flush Mounting
When you remove the MMI from the shi ppi ng carton, you wi l l noti ce that i t has two
parts. The fi rst i s a fai rl y thi n secti on that contai ns the keypad, di spl ay and some
ci rcui t boards. The other part i s thi cker and contai ns the tel ephone j ack and a cabl e
that connects to the keypad assembl y.
When you fl ush mount the MMI i n a
panel , onl y the thi n secti on wi l l sti ck out
from your panel - the l arge porti on mounts
behi nd your panel . Youl l need to cut a
preci se secti on from your panel . There i s
a cardboard templ ate i n the MMIs
shi ppi ng box for thi s purpose.
If you want the MMI to be dust proof and
waterti ght, you must pl ace the bl ack
rubber gasket between the thi n part of the
MMI and your panel . Assembl e the two
hal ves usi ng the ei ght smal l screws
provi ded.
Surface Mounting
An easi er way to mount the MMI i s to bol t the two hal ves together ahead of ti me,
usi ng the ei ght smal l screws. If you want the MMI to be dust proof and waterti ght,
put the bl ack rubber gasket between the two hal ves before screwi ng them together.
Then cut a hol e i n your panel for the cabl e
that runs between the MMI and the
Si 3540. The hol e must be at l east 5/ 8 i n
di ameter for the connector to fi t thorugh.
You wi l l al so need two hol es that l i ne up
wi th the bi g mounti ng hol es i n the MMI.
The mechani cal outl i ne on page 19 shows
the l ocati on of the bi g mounti ng hol es.
When you mount the MMI to your panel ,
you wi l l need to use some ki nd of seal ant
to keep dust and l i qui d out. Si l i cone or
l atex caul ki ng i s okay, or you can make
your own gasket from a sheet of compl i ant
materi al l i ke rubber or RTV.
1
2
3

4
5
6

7
8
9
YES
NO
.
0
SPACE
BKSP
ENTER
panel
MMI
(front section
and gasket)
MMI
(rear section)
1
2
3

4
5
6

7
8
9
YES
NO
.
0
SPACE
BKSP
ENTER
panel
sealant (not included)
MMI
gasket
(included)
-17-
Motor Size Winding Max Torque Current
Number inches Connection oz-in Amps
5014- 842 1.38 x 1.38 x 1.57 4 l ead 19 1.0
HT17- 068 1.65 x 1.65 x 1.30 paral l el 23 1.0
HT17- 071 1.65 x 1.65 x 1.54 paral l el 30 1.25
HT17- 075 1.65 x 1.65 x 1.85 paral l el 40 1.7
5023- 122 2.22 x 2.22 x 2.0 paral l el 60 2.0
5023- 123 2.22 x 2.22 x 3.0 paral l el 100 2.5
5023- 124 2.22 x 2.22 x 4.0 paral l el 150 3.5
HT23- 394 2.22 x 2.22 x 1.54 paral l el 60 2.8
HT23- 397 2.22 x 2.22 x 2.13 paral l el 140 2.8
HT23- 400 2.22 x 2.22 x 2.99 paral l el 180 2.0
5034- 348 3.38 x 3.38 x 2.50 paral l el 130 3.5
Recommended Motors
Mechanical Outline
7.80"
2.25"
1.125" 0.750" 0.750"
5.00"
5.40"
POWER
M
O
T
O
R
A
C
P
O
W
E
R
A+
A-
B+
B-
G
L
N
P
C
/ M
M
I
INPUT 1
INPUT 2
INPUT 3
INPUT 4
IN 5 / JOG CW
IN 6 / JOG CCW
IN / JOG COM
IN / JOG COM
CCW -
CCW +
CW +
CW -
OUT 1 +
OUT 1 -
OUT 2 +
OUT 2 -
OUT 3 +
OUT 3 -
L
IM
IT
S
S
i
3
5
4
0
P
r
o
g
r
a
m
m
a
b
l
e

S
t
e
p

M
o
t
o
r

D
r
i
v
e
r
-18-
Ampl i f i ers
Power Suppl y
I nput s
Out put s
Mi crost eppi ng
Mot i on Updat e
Physi cal
Connect ors
Agency
Approval s
Fuses
Dual , MOSFET H- bri dge, 3 state, pul se wi dth modul ated (PWM)
swi tchi ng at 20 kHz. 0.2 - 3.5 amps/ phase output current, software
sel ectabl e. 122 watts maxi mum output power. Automati c i dl e current
reducti on (software programmabl e) reduces current to motor when
i dl e. Mi ni mum motor i nductance i s 0.8 mH.
Li near, toroi dal transformer based for hi gh rel i abi l i ty and l ow noi se.
100- 120 or 200- 240 VAC i nput, swi tch sel ectabl e. 50/ 60 Hz. DC
vol tage at nomi nal l i ne vol tage: 35 VDC ful l l oad, 40 VDC no l oad.
5 - 24 VDC, opti cal l y i sol ated. 2200 ohms i nternal resi stance. Can be
confi gured for si nki ng (NPN) or sourci ng (PNP) si gnal s.
Opti cal l y i sol ated. 12- 24 VDC, 100 mA max.
13 software sel ectabl e resol uti ons. Steps per revol uti on wi th 1.8
motor: 2000, 5000, 10000, 12800, 18000, 20000, 21600, 25000,
25400, 25600, 36000, 50000, 50800. Waveform: pure si ne.
12800 Hz.
Constructed wi th bl ack anodi zed al umi num heat si nk and heavy
gauge steel housi ng. 2.25 x 5.40 x 7.80 i nches overal l . 4.0 l bs. 0 to
50C ambi ent operati ng temperature. See page 17 for detai l ed
drawi ng.
European styl e, pl uggabl e screw termi nal bl ocks. Motor: 4 posi ti on
(A+, A- , B+, B- ). Si gnal Input/ Output: 18 posi ti on (8 i nput, 6 output,
4 l i mi t). AC i nput: 3 posi ti on (L, N, G).
CE (compl i es wi th EN55011A, EN50082- 1(1997), EN50178(1997))
and TUV.
Wi ckman TR- 5 styl e. Order from Di gi key (1- 800- DIGIKEY).
110V: P/ N WK4250BK- ND (T 1.25 A IEC)
220V: P/ N WK4243BK- ND (T O.63 A IEC).
Technical Specifications
-19-
Mechanical Out line - Opt ional MMI
4
.
9
0

4
.
9
0

1
.
3
8
0
.
1
3
3
.
8
7
5
C
E
N
T
E
R
E
D
3
.
8
7
5
C
E
N
T
E
R
E
D
1
2
3

4
5
6

7
8
9
Y
E
S
N
O
.
0
S
P
A
C
E
B
K
S
P
E
N
T
E
R
2
.
9
8
8
1
.
9
7
5
0
.
4
2
5
0
.
9
6
3
0
.
9
6
0
-20-
Applied Mot ion Product s, I nc.
404 Westri dge Dri ve Watsonvi l l e, CA 95076
Tel (831) 761- 6555 (800) 525- 1609 Fax (831)- 761- 6544
http:/ / www.appl i ed- moti on.com
Copyri ght 1999
11/2/99