Intelligent Motion Systems Welding System IM1007 I IE User Manual

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Table of Contents

Introduction .................................................................................................... 1

Pin Description ............................................................................................... 2

Pin Description ............................................................................................... 3

Absolute Maximum Rating ............................................................................. 4

Electrical Specifications ................................................................................. 5

Mechanical Specifications .............................................................................. 6

Thermal Specifications................................................................................... 7

Over Temperature Protection.................................................................. 7

Output Current ............................................................................................... 8

Determining Output Current .................................................................... 8

Setting Output Current ............................................................................ 9

Encoder Interface ........................................................................................... 9

Motor ............................................................................................................ 10

Motor Selection ..................................................................................... 10

Connecting the Motor........................................................................... 11

Connecting Power ........................................................................................ 12

Optically Isolated Inputs (Limit A, Limit B, Home, Party) .............................. 13

General Purpose Inputs ............................................................................... 14

Dedicated Inputs .......................................................................................... 15

Moving Output .............................................................................................. 15

Fault Protection ............................................................................................ 16

Party Line Operation .................................................................................... 17

Party Line Connection (using RS-232 Option) ...................................... 17

+5 VDC Output ............................................................................................ 18

Options/Accessories .................................................................................... 18

Application Notes ......................................................................................... 19

Appendix A: Recommended Cable Configurations ...................................... 20

Warranty ...................................................................................................... 27

IM1007ie Operating Manual Rev 052404

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A P P E N D I X A

R e c o m m e n d e d C a b l e C o n f ig u r a t io n s :

D C S u p p l y t o IM S D r iv e r

Cable length, wire gauge and power conditioning devices play a major role

in the performance of your IMS Driver and Motor.

NOTE: The length of the DC power supply cable to the IMS Driver should

not exceed 50 feet.

Example A demonstrates the recommended cable configuration for DC

power supply cabling under 50 feet long. If cabling of 50 feet or longer is

required, the additional length may be gained by adding an AC power

supply cable (see Examples B & C).

Correct AWG wire size is determined by the current requirement plus cable

length. Please see the IMS Driver Supply Cable AWG Table in this

Appendix.

Exa m p le A – C a b lin g U n d e r 5 0 F e e t , D C P o w e r

To IMS Driver

Type RFI Filter

≥ Required Current

Ferrite

Beads

Braided

Shield

Shielded/Twisted Pair

(Wire Size from

IMS Driver Supply Cable AWG Table)

Cable Length

less then 50 Feet

DC Voltage from

Power Supply

Shield to Earth Ground

on Supply End Only

500 µf

Per Amp

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Exa m p le B – C a b lin g 5 0 F e e t o r G r e a t e r,

AC P o w e r t o F u ll W a ve B r id g e

NOTE:

To Cable A

Connect the cable illustrated

in Example A to the output of

the Full Wave Bridge

Full Wave Bridge

Braided

Shield

Cable Length

50 Feet or greater

Shielded/Twisted Pair

(Wire Size from

IMS Driver Supply Cable AWG Table)

π Type RFI Filter

≥ Required Current

Shield to Earth Ground

on Supply End Only

Transformer :

0 to 28 VAC RMS

for 48 VDC Systems

20 to 48 VAC RMS

for 75 VDC Systems

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Exa m p le C – C a b lin g 5 0 F e e t o r G r e a t e r,

AC P o w e r t o P o w e r S u p p ly

DC Volts Out

To Cable A

NOTE:

Connect the cable illustrated

in Example A to the output of

the Power Supply

Power Supply

Braided

Shield

Cable Length

50 Feet or greater

Shielded/Twisted Pair

(Wire Size from

IMS Driver Supply Cable AWG Table)

Type RFI Filter

≥ Required Current

Shield to Earth Ground

on Supply End Only

120 or 240 VAC

Dependent on

Power Supply

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NOTE: These recommendations will provide optimal

protection against EMI and RFI. The actual cable type,

wire gauge, shield type and filtering devices used are dependent

on the customer’s application and system.

IMS Driver Supply Cable AWG Table

1 Ampere (Peak)

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 20 20 18 18 16

2 Amperes (Peak)

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 20 18 16 14 14

3 Amperes (Peak)

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 18 16 14 12 12

4 Amperes (Peak)

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 18 16 14 12 12

Use the alternative methods illustrated in

Examples A and B when the cable length is ≥ 50

feet. Also, use the same current rating when the

alternate AC power is used.

Driver Supply Cable Wire Size

NOTE: Always use Shielded/Twisted Pairs for the IMS Driver

DC Supply Cable, the AC Supply Cable and the IMS Driver to

Motor Cable.

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R e c o m m e n d e d C a b l e C o n f ig u r a t io n s :

IM S D r iv e r t o M o t o r

Cable length, wire gauge and power conditioning devices play a major role

in the performance of your IMS Driver and Motor.

NOTE: The length of the DC power supply cable between the IMS Driver

and the Motor should not exceed 50 feet.

Example A demonstrates the recommended cable configuration for the IMS

Driver to Motor cabling under 50 Feet long. If cabling of 50 feet or longer is

required, the additional length can be gained with the cable configuration in

Example B.

Correct AWG wire size is determined by the current requirement plus cable

length. Please see the IMS Driver to Motor Cable AWG Table in this Appendix.

Exa m p le A - C a b lin g U n d e r 5 0 F e e t ,

IM S D r ive r t o M o t o r

Phase A

Phase B

Ferrite

Beads

Braided

Shield

Cable Length

Two Shielded/Twisted Pairs

(Wire Size from

less than 50 Feet

IMS Driver to Motor Cable AWG Table)

Phase A

Phase B

Shield to Earth Ground

on Supply End Only

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Exa m p le B - C a b lin g 5 0 F e e t o r G r e a t e r,

IM S D r ive r t o M o t o r

Phase A

Phase B

Ferrite

Beads

Braided

Shield

Cable Length

50 Feet or greater

Two Shielded/Twisted Pairs

(Wire Size from

IMS Driver to Motor Cable AWG Table)

Phase A

Shield to Earth Ground

on Supply End Only

Common Mode

Line Filters (2x)

Phase B

*L ≈ 0.5 MH

* 0.5 MH is a typical starting point for the

Common Mode Line Filters. By increasing

or decreasing the value of L you can set the

drain current to a minimum to meet your requirements.

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IMS Driver to Motor Cable AWG Table

1 Ampere (Peak)

5 Amperes (Peak)

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 20 20 18 18 16

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 16 16 14 12 12

2 Amperes (Peak)

6 Amperes (Peak)

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 20 18 16 14 14

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 14 14 14 12 12

3 Amperes (Peak)

7 Amperes (Peak)

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 18 16 14 12 12

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 12 12 12 12 12

4 Amperes (Peak)

Use the alternate method illustrated in Example B

Length (Feet) 10 25 50* 75* 100*

Minimum AWG 18 16 14 12 12

when cable length is ≥ 50 feet.

Driver to Motor Supply Cable Wire Size

NOTE: These recommendations will provide optimal

protection against EMI and RFI. The actual cable type,

wire gauge, shield type and filtering devices used are dependent on

the customer’s application and system.

NOTE: Always use Shielded/Twisted Pairs for the IMS Driver

DC Supply Cable, the AC Supply Cable and the IMS Driver to

Motor Cable.

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WARRANTY

TWENTY-FOUR (24) MONTH LIMITED WARRANTY

Intelligent Motion Systems, Inc. (“IMS”), warrants only to the purchaser of the Product

from IMS (the “Customer”) that the product purchased from IMS (the “Product”) will be free

from defects in materials and workmanship under the normal use and service for which the

Product was designed for a period of 24 months from the date of purchase of the Product by

the Customer. Customer’s exclusive remedy under this Limited Warranty shall be the repair

or replacement, at Company’s sole option, of the Product, or any part of the Product,

determined by IMS to be defective. In order to exercise its warranty rights, Customer must

notify Company in accordance with the instructions described under the heading “Obtaining

Warranty Service.”

This Limited Warranty does not extend to any Product damaged by reason of alteration,

accident, abuse, neglect or misuse or improper or inadequate handling; improper or

inadequate wiring utilized or installed in connection with the Product; installation, operation

or use of the Product not made in strict accordance with the specifications and written

instructions provided by IMS; use of the Product for any purpose other than those for which

it was designed; ordinary wear and tear; disasters or Acts of God; unauthorized attachments,

alterations or modifications to the Product; the misuse or failure of any item or equipment

connected to the Product not supplied by IMS; improper maintenance or repair of the Product;

or any other reason or event not caused by IMS.

IMS HEREBY DISCLAIMS ALL OTHER WARRANTIES, WHETHER WRITTEN OR

ORAL, EXPRESS OR IMPLIED BY LAW OR OTHERWISE, INCLUDING WITHOUT

LIMITATION, ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR ANY

PARTICULAR PURPOSE. CUSTOMER’S SOLE REMEDY FOR ANY DEFECTIVE

PRODUCT WILL BE AS STATED ABOVE, AND IN NO EVENT WILL THE IMS BE LIABLE

FOR INCIDENTAL, CONSEQUENTIAL, SPECIAL OR INDIRECT DAMAGES IN

CONNECTION WITH THE PRODUCT.

This Limited Warranty shall be void if the Customer fails to comply with all of the terms set

forth in this Limited Warranty. This Limited Warranty is the sole warranty offered by IMS with

respect to the Product. IMS does not assume any other liability in connection with the sale of

the Product. No representative of IMS is authorized to extend this Limited Warranty or to

change it in any manner whatsoever. No warranty applies to any party other than the original

Customer.

IMS and its directors, officers, employees, subsidiaries and affiliates shall not be liable for

any damages arising from any loss of equipment, loss or distortion of data, loss of time, loss

or destruction of software or other property, loss of production or profits, overhead costs,

claims of third parties, labor or materials, penalties or liquidated damages or punitive damages,

whatsoever, whether based upon breach of warranty, breach of contract, negligence, strict

liability or any other legal theory, or other losses or expenses incurred by the Customer or

any third party.

OBTAINING WARRANTY SERVICE

Warranty service may obtained by a distributor, if the Product was purchased from IMS by

a distributor, or by the Customer directly from IMS, if the Product was purchased directly

from IMS. Prior to returning the Product for service, a Returned Material Authorization (RMA)

number must be obtained. Complete the form at http://www.imshome.com/rma.html after

which an RMA Authorization Form with RMA number will then be faxed to you. Any questions,

contact IMS Customer Service (860) 295-6102.

Include a copy of the RMA Authorization Form, contact name and address, and any

additional notes regarding the Product failure with shipment. Return Product in its original

packaging, or packaged so it is protected against electrostatic discharge or physical damage

in transit. The RMA number MUST appear on the box or packing slip. Send Product to:

Intelligent Motion Systems, Inc., 370 N. Main Street, Marlborough, CT 06447.

Customer shall prepay shipping changes for Products returned to IMS for warranty service

and IMS shall pay for return of Products to Customer by ground transportation. However,

Customer shall pay all shipping charges, duties and taxes for Products returned to IMS from

outside the United States.

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