Fulling Motor MD2278 User manual

User’s Manual
For
MD2278
High Performance Microstepping Driver
Version 1.0
©2000 All Rights Reserved
Attention: Please read this manual carefully before using driver!
The content in this manual has been carefully prepared and is believed to be accurate, but no
responsibility is assumed for inaccuracies.
FULLING reserves the right to make changes without further notice to anyproducts herein to
improve reliability,function or design. FULLING does not assume anyliability arising out of the
application or use of any product or circuit described herein; neither does it convey any license
under its patent rights of others.
FULLING’s general policy does not recommend the use of its products in life support or aircraft
applications wherein a failure or malfunction of the product may directly threaten life or injury.
According to FULLING’s terms and conditions ofsales,the user of FULLING’s products in life
support or aircraft applications assumes all risks of such use and indemnifies FULLING against all
damages.

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Table of Contents
1. Introduction, Features and Applications ···································································2
2. Specifications and Operating Environment ······························································3
3. Driver Connectors P1 and P2 ···················································································4
4. Control Signal Connector (P1) Interface ····································································5
5. Driver Connection to Motors (P2) ············································································6
6. Power Supply and Driver Voltage and Current···························································9
7. Selecting Microstep Resolution and Driver Current Output········································11
8. Protection Functions··································································································12
9. Connection Diagram for Driver, Motor, Controller ····················································13
10. Control Signal Waveform and Timing······································································13
11. Wire Connection······································································································14
Appendix: Limited Warranty ·························································································15
1. Introduction, Features and Applications
MD2278 are high performance microstepping drivers incorporating the most advanced
technology in the world today. They are suitable for driving any 2-phase and 4-phase
hybrid step motors(current 7.8A/3.9A). By using advanced bipolar constant-current
chopping technique, they can produce more motor torque at high speed than other
drivers. The microstep capability allows stepping motors run at higher smoothness,
less vibration and lower noise. The 3-state current control feature leads to lower motor
heating.
Features of this driver
 High quality, low price
 Low heating for motor & driver
 Supply voltage AC80-250V
 TTL compatible inputs
 Automatic idle-current reduction
 Output current up to 7.8A peak (RMS 5.57A)
 Input frequency up to 400KHz
 Opto-isolated inputs
 Microstep resolution pulse per rotation selectable vary from 400, 500, 600, 800, 1000,
1200, 1600, 2000, 2400, 3200, 4000, 5000, 6000, 6400, 8000 and 10000
 Suitable for any 2-phase stepping motor with 4,6,8 leads
 DIP switch current setting
 CW/CCW mode available (optional)
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Applications of this driver
Applicable for automated machinery and equipment, for instance, air-driven
inscription machines, labeling machines, cutting machines, laser engraving,
plotter, medical instruments, and pick-place devices.
2. Specifications and Operating Environment
Electric Specifications (Tj = 25℃)
MD2278
Parameters Min. Typical Max. Unit
Output Current 0.42 (RMS0.3A) - 7.8 Amps
Supply voltage (DC) 80 180 250 VAC
Logic signal current 7 10 16 mA
Pulse input frequency 0 - 400 Khz
Isolation resistance 500 MΩ
Operating Environment and Parameters
Cooling Natural cooling or forced convection
Space Avoid dust, oil frost and corrosive gas
Temperature 0°－ 50℃
Humidity 40 －90%RH
Environment
Vibration 5.9m/s2Max
Storge Temp. -20℃－125℃
Weight Approx. 1.16 kg (41 oz)
Mechanical Dimensions (unit:mm, 1 inch = 25.4 mm)
FrontView SideView
Figure 1: Mechanical dimensions
*Recommended to use side mounting for better heat dissipation

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Extra Heat Sink
 Driver’s reliable working temperature should be <65℃, motor temperature <80℃;
 It is recommended automatic half-current mode, i.e. current automatically reduced by
60% when motor stops, so as to decrease driver and motor’s heating;
 Please mount the driver vertically to maximize heat sink area.
3. Driver Connectors, P1 and P2
The driver has two connectors, P1 for control signals, and P2 for power and motor connections.
The following is a brief description of the two connectors of the driver. More detailed descriptions
of the pins and related issues are presented in section 4, 5, 6, 9.
Control Signal Connector P1-pins
Signal Functions
PUL﹢(+5V)
PUL- (PUL)
Pulse signal: in single pulse(pulse/direction) mode, this input represents
pulse signal, effective for each upward – rising edge; in double pulse
mode (pulse/pulse) this input represents clockwise(CW)pulse. For
reliable response, pulse width should be longer than 1.5µs.
DIR+ (+5V)
DIR- (DIR)
Direction signal: in single-pulse mode, this signal has low/high voltage
levels, representing two directions of motor rotation; in double-pulse
mode (set by inside jumper JMP1), this signal is counter-clock (CCW)
pulse, effective on each rising edge. For reliable motion response,
direction signal should be sent to driver 2µs before the first pulse in the
reverse motion direction.
ENA+ (+5V)
ENA- (ENA) Enable signal: this signal is used for enable/disable, high level for
enabling driver and low level for disabling driver. Usually left
unconnected(enabled).
READY+ Output alarm signal positive: READY is a photocouper output from
open-collector circuit, effectively output when driver operate normally,
maximum permitted input voltage 30VDC; maximum output current
20mA, generally can be serial connected to PLC input terminal.
READY- Output alarm signal negative.
Remark 1: SW5 ON means PUL/DIR mode , OFF means CW/CCW (pulse/pulse) mode.
Remark 2: Please note motion direction is also related to motor-driver wiring match.
Exchanging the connection of two wires for a coil to the driver will reverse motion
direction. (for example, reconnecting motor A+ to driver A- and motor A- to driver A+ will
invert motion direction).
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Power connector P2 pins
Signal Functions
AC
AC
AC input, varies from 80V to 220V, recommended to
use 180V.
Phase A Motor coil A (leads A+ and A-)
Phase B Motor coil B (leads B+ and B-)
PE Connect ground terminal
4. Control Signal Connector (P1) Interface
This driver uses differential inputs to increase noise immunity and interface flexibility.
Single-ended control signals from the indexer/controller can also be accepted by this interface. The
input circuit has built-in high-speed opto -coupler, and can accept signals in the format of line
driver, open-collector, or PNP output. Line driver (differential) signals are suggested for reliability.
In the following figures, connections to open-collector and PNP signals are illustrated.

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5. Driver Connection to Step Motors
MD2278 driver can drive any 4, 6, 8 lead hybrid step motors. The following diagrams illustrate
connection to various kinds of motor leads:
Figure 3: Driver Connection to Step Motor
Note that when two coils are parallelly connected, coil inductance is reduced by half and motor
speed can be significantly increased. Serial connection will lead to increased inductance and thus
the motor can be run well only at lower speeds.
5.1 Connecting to 8-Lead Motors
8 lead motors offer a high degree of flexibility to the system designer in that they may be
connected in series or parallel, thus satisfying a wide range of applications.
Series Connection
A series motor configuration would typically be used in applications where a higher torque at
lower speeds is required. Because this configuration has the most inductance, the performance will
start to degrade at higher speeds. Use the per phase (or unipolar) current rating as the peak output
current, or multiply the bipolar current rating by 1.4 to determine the peak output current.
Figure 4: 8 Lead Motor Series Connections
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Parallel Connection
An 8 lead motor in a parallel configuration offers a more stable, but lower torque at lower speeds.
But because of the lower inductance, there will be higher torque at higher speeds. Multiply the per
phase (or unipolar) current rating by 1.96, or the bipolar current rating by 1.4, to determine the
peak output current.
Figure 5: 8 Lead Motor Parallel Connections
5.2 Connection to 6-Lead Motors
Like 8 lead stepping motors, 6 lead motors have two configurations available for high speed or
high torque operation. The higher speed configuration, or balf coil, is so described because it uses
one half of the motor’s inductor windings. The higher torque configuration, or full coil, use the full
windings of the phases.
Half Coil Configuration
As previously stated, the half coil configuration uses 50% of the motor phase windings. This gives
lower inductance, hence, lower torque output. Like the parallel connection of 8 lead motor, the
torque output will be more stable at higher speeds. This confi8guration is also referred to as bal
copper. In setting the driver output current multiply the specified per phase (or unipolar) current
rating by 1.4 to determine the peak output current.

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Figure 6: 6 Lead Half Coil (Higher Speed) Motor Connections
Full Coil Confuguration
The full coil configuration on a six lead motor should be used in applications where higher torque
at lower speeds is desired. This configuration is also referred to as full copper. Use the per phase
(or unipolar) current rating as the peak output current.
Figure 7: 6 Lead Full Coil (Higher Torque) Motor
5.3 Connection to 4-Lead Motors
4 lead motors are the least flexible but easiest to wire. Speed and torque will depend on winding
inductance. In setting the driver output current, multiply the specified phase current by 1.4 to
determine the peak output current.
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Figure 8: 4 Lead Motor Connections
6. Power supply Selection, Driver Voltage and Current
Selection
6.1 Power Supply Selection
It is important to choose appropriate power supply to make the driver operate properly and
deliver optimal performance.
Maximum Voltage Input:
The power MOSFETS inside the driver can actually operate within +80－+220VAC, including
power input fluctuation and back EMF voltage generated by motor coils during motor shaft
deceleration. Higher voltage will damage the driver. Therefore, it is suggested to use power
supplies with theoretical output voltage of no more than +220V, leaving room for power line
fluatuation and Back EMF.
Regulated or Unregulated power supply:
Both regulated and unregulated power supplies can be used to supply DC power to the driver.
However, unregulated power supplies are preferred due to their ability to withstand current
surge. If regulated power supply (such as most switching supplies.) is indeed used, it is
important to have large current output rating to avoid problems like current clamp, for example
using 4A supply for 3A motor-driver operation. On the other hand, if unregulated supply is
used, one may use a power supply of lower current rating than that of motor (typically 50%～
70% of motor current). The reason is that the driver draws current from the power supply
capacitor of the unregulated supply only during the ON duration of the PWM cycle, but not
during OFF duration. Therefore, the average current withdrawn from power supply is
considerably less than motor current. For example, two 3A motors can be well supplied by one
power supply of 4A rating.

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Multiple drivers:
It is recommended to have multiple drivers to share one power supply to reduce cost, provided
that the supply has enough capacity. To avoid cross interference, DO NOT dazy-chain the
power supply input pin of the drivers. (instead, please connect them to power supply
separately.)
Higher supply voltage will allow higher motor speed to be achieved, at the price of more noise and
heating. If the motion speed requirement is low, it’s better to use lower supply voltage to improve
noise, heating and reliability.
NEVER connect power and ground in the wrong direction, as it will damage the driver.
6.2 Driver Voltage and Current Selection
This driver can match small and medium size step motors (NEMA 43 and 51) made byFULLING
or other motor manufactures from around the world. To achieve good driving results, it is
important to select supply voltage and output current properly. Generally, supply voltage
determines the high speed performance of the motor, while output current determines the output
torque of the driven motor (particularly at lower speed).
●Selecting Supply Voltage:
Higher supply voltage can increase motor torque at higher speeds, thus helpful for avoiding losing
steps. However, higher voltage may cause more motor vibration at lower speed, and it may also
cause over-voltage protection and even driver damage. Therefore, it is suggested to choose only
sufficiently high supply voltage for intended applications.
●Setting Proper Output Current
a. For a given motor, higher driver current will make the motor to output more torque, but at the
same time causes more heating in the motor and driver. Therefore, output current is generally
set to be such that the motor will not overheat for long time operation.
b. Since parallel and serial connections of motor coils will significantly change resulting
inductance and resistance, it is therefore important to set driver output current depending on
motor phase current, motor leads and connection methods.
c. Phase current rating supplied by motor manufacturer is important to selecting driver current,
but the selection also depends on leads and connection.
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7. Selecting Microstep Resolution and Driver Current Output
This driver uses a 9-bit DIP switch to set microstep resolution, motor operating current and pulse
mode selection, as shown below:
7.1 Microstep Resolution Selection
Microstep resolution is set by SW1-SW4 of the DIP switch as shown in the following table:
ustep/rev.(for 1.8°motor) SW1 SW2 SW3 SW4
400 ON ON ON ON
500 OFF ON ON ON
600 ON OFF ON ON
800 OFF OFF ON ON
1000 ON ON OFF ON
1200 OFF ON OFF ON
1600 ON OFF OFF ON
2000 OFF OFF OFF ON
2400 ON ON ON OFF
3200 OFF ON ON OFF
4000 ON OFF ON OFF
5000 OFF OFF ON OFF
6000 ON ON OFF OFF
6400 OFF ON OFF OFF
8000 ON OFF OFF OFF
10000 OFF OFF OFF OFF
7.2 Current Setting
The SW6-SW9 of the DIP switch are used to set the current during motion (dynamic current ).
Select a setting closest to your motor’s required current.

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 DIP Setting for current during motion:
MD2278 DIP switch setting
Peak current (A) RMS (A) SW6 SW7 SW8 SW9
0.45 0.32 OFF OFF OFF OFF
0.63 0.45 OFF OFF OFF ON
1.41 1.00 OFF OFF ON OFF
1.88 1.34 OFF OFF ON ON
2.33 1.66 OFF ON OFF OFF
2.85 2.04 OFF ON OFF ON
3.23 2.31 OFF ON ON OFF
3.75 2.68 OFF ON ON ON
4.26 3.04 ON OFF OFF OFF
4.65 3.32 ON OFF OFF ON
5.18 3.70 ON OFF ON OFF
5.55 3.96 ON OFF ON ON
6.15 4.39 ON ON OFF OFF
6.60 4.71 ON ON OFF ON
7.20 5.14 ON ON ON OFF
7.80 5.57 ON ON ON ON
Remarks:
Due to motor inductance the actual current in the coil may be smaller than the dynamic current
settings, particularly at higher speeds.
 Static current
The current automatically reduced to 60% of dynamic current setting 0.2 second after the last
pulse, this will, theoretically, reduce motor heating to 36% (due to I*I) of the original value.
 DIP setting for pulse mode:
SW5 is used for this purpose. ON means CW/CCW mode, OFF means PUL/DIR mode.
8. Protection Functions
Over-voltage, short-voltage, over-current, over-heating and short-circuit protection
To improve reliability, the driver incorporates a number of built-in protections features.
a. Over-voltage protection and short-voltage protection
When power supply voltage exceeds +250VAC, protection will be activated and power indicator
LED will turn red. When power supply voltage is lower than +80VAC, the driver will not works
properly.
b. Coil-ground Short Circuit Protection
Protection will be activated in case of short circuit between motor coil and ground.
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c. Over-current Protection
Protection will activated in case of short current which may otherwise damage the driver.
Attention:since there is no protection against power leads (﹢, ﹣) reversal, it is critical to
make sure that power supply leads correctly connected to driver. Otherwise, the driver will be
damaged instantly.
9. Connection Diagram for Driver, Motor, Controller
A complete stepping system should include stepping motor, stepping driver, power supply and
controller (pulse generator).
A typical connection is shown below:
Figure 9: Driver connection in a stepping system
10. Control signal Waveform and Timing
In order to avoid some fault operation and deviation, PUL, DIR and ENA must accord with some
parameters, as following diagram:

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Remark:
(1) t1: ENA must be ahead of DIR by at least 5us, logic HIGH as valid. Generally
ENA+ and ENA- is NC (not connected).
(2) t2: DIR must be ahead of PUL effective falling edge by 5us to ensure correct direction;
(3) t3: Pulse width not less than 1.2us;
(4) t4: low level width not less than 1.2us.
11. Wire Connection
(1) In order to improve driver noise rejection, it is recommended to use twist ed
pair shield cable.
(2) To prevent noise incurred in pulse/dir signal, Pulse/direction signal wires
and motor wires should not be tied up together. It is better to separate
them by at least 10 cm, otherwise the motor noise will easily disturb pulse
direction signals, motor position error, system instability and other types of
failure.
(3) If a power supply serves several drivers, separate connections drivers is
recommended instead of daisy-chaining.
(4) It is prohibited to pull and plug connector P2 while driver is powered ON,
as there is still high current flowing through coil even when motor is
stopped. Pulling and plugging P2 with power on will cause extremely high
voltage surge EMF, destroy the dirver.
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TWELVEMONTHLIMITEDWARRANTY
FULLING MOTOR Co., Ltd. warrants its products against defects in materials and
workmanship for a period of 12 months from receipt bythe end-user. During the warranty period,
FULLING will either, at its option, repair or replace products which prove to be defective.
EXCLUSIONS
The above warranty shall not apply to defects resulting from: improper or inadequate handling by
customer; improper or inadequate customer wiring; unauthorized modification or misuse; or
operation outside of the electrical and/or environmental specifications for the product.
OBTAININGWARRANTYSERVICE
To obtain warranty service, a returned material authorization number (RMA) must be obtained
from customer service ate-mail: before returning product for service.
Customer shall prepay shipping charges for products returned to FULLING for warranty service,
and FULLING shall pay for return of products to customer.
WARRANTYLIMITATIONS
FULLING makes no other warranty, either expressed or implied, with respect to the product.
FULLING specificallydisclaims the implied warranties of merchantability and fitness for a
particular purpose. Some jurisdictions do not allow limitations on how long and implied warranty
lasts, so the above limitation or exclusion may not apply to you. However,any implied warrantyof
merchantability or fitness is limited to the 12-month duration of this written warranty.
ShippingFailedProduct
If your product should fail during the warranty period, e-mail customer service at
to obtain a returned material authorization number before returning
product for service. Please include a written description of the problem along with contact name
and address. Send failed product to distributor in your area or: Changzhou Fulling motor Co.,Ltd.
66 Zhujiang Road ChangZhou city JiangSu Province China. Alsoenclose information
regarding the circumstances prior to product failure.