Leadshine Technology Co. DM442 User manual

User’s Manual
For
DM442
Fully Digital Stepping Drive
Version 1.0
©2010 All Rights Reserved
Attention: Please read this manual carefully before using the drive!
The content in this manual has been carefully prepared and is believed to be accurate, but no
responsibility is assumed for inaccuracies.
Leadshine reserves the right to make changes without further notice to any products herein to
improve reliability, function or design. Leadshine does not assume any liability 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.
Leadshine’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 Leadshine’s terms and conditions of sales, the user of Leadshine’s products in life
support or aircraft applications assumes all risks of such use and indemnifies Leadshine against all
damages.
©2010 by Leadshine Technology Company Limited.
All Rights Reserved
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Contents
I
Table of Contents
1. Introduction, Features and Applications.................................................................... 1
Introduction ........................................................................................................... 1
Features ................................................................................................................. 1
Applications .......................................................................................................... 1
2. Specifications ............................................................................................................ 2
Electrical Specifications ........................................................................................ 2
Mechanical Specifications..................................................................................... 2
Elimination of Heat ............................................................................................... 2
Operating Environment and other Specifications.................................................. 3
3. Pin Assignment and Description ............................................................................... 3
Connector P1 Configurations ................................................................................ 3
Selecting Active Pulse Edge and Control Signal Mode ........................................ 4
Connector P2 Configurations ................................................................................ 4
4. Control Signal Connector (P1) Interface................................................................... 4
5. Connecting the Motor................................................................................................ 5
Connections to 4-lead Motors ............................................................................... 5
Connections to 6-lead Motors ............................................................................... 5
Half Coil Configurations ............................................................................... 5
Full Coil Configurations................................................................................ 6
Connections to 8-lead Motors ............................................................................... 6
Series Connections ........................................................................................ 6
Parallel Connections...................................................................................... 7
6. Power Supply Selection ............................................................................................ 7
Regulated or Unregulated Power Supply .............................................................. 7
Multiple Drives ..................................................................................................... 8
Selecting Supply Voltage....................................................................................... 8
7. Selecting Microstep Resolution and Drive Output Current....................................... 8
Microstep Resolution Selection ............................................................................ 8
Current Settings..................................................................................................... 9
Contents
II
Dynamic current setting .............................................................................. 10
Standstill current setting.............................................................................. 10
8. Wiring Notes ........................................................................................................... 10
9. Typical Connection.................................................................................................. 11
10. Sequence Chart of Control Signals ....................................................................... 11
11. Protection Functions.............................................................................................. 12
Over-current Protection............................................................................... 12
Over-voltage Protection .............................................................................. 12
Phase Error Protection................................................................................. 12
Protection Indications.................................................................................. 13
12. Frequently Asked Questions.................................................................................. 13
Problem Symptoms and Possible Causes............................................................ 14
13. Professional Tuning Software ProTuner................................................................ 15
Introduction ......................................................................................................... 15
Software Installation ........................................................................................... 15
Connections and Testing ..................................................................................... 19
RS232 Interface Connection ............................................................................... 19
Testing the Stepping System ............................................................................... 19
Software Introduction.......................................................................................... 20
ProTuner Main Window .............................................................................. 20
ProTuner Toolbar......................................................................................... 20
Option.......................................................................................................... 21
Com Config Window .................................................................................. 21
Parameters Configuration Window ............................................................. 21
Tuning ......................................................................................................... 22
Anti-Resonance Introduction ...................................................................... 26
Internal Pluser( Pulse Generator) ................................................................ 27
Procedure for Achieving Optimum Performance ........................................ 28
Err_check .................................................................................................... 29
About........................................................................................................... 30
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DM442 Digital Stepping Drive Manual V1.0
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1. Introduction, Features and Applications
Introduction
The DM442 is a versatility fully digital stepping drive based on a DSP with advanced control
algorithm. The DM442 is the next generation of digital stepping motor controls. It brings a unique
level of system smoothness, providing optimum torque and nulls mid-range instability. Motor
self-test and parameter auto-setup technology offers optimum responses with different motors and
easy-to-use. The driven motors can run with much smaller noise, lower heating, smoother
movement than most of the drives in the markets. Its unique features make the DM442 an ideal
solution for applications that require low-speed smoothness.
Compared to the DM432C, DM442 can output more current. What’s more, owing to its higher
performance DSP, driven motors can achieve much higher speed (above 3000RPM) than that of
the DM432C, offering servo-like performances.
Features
Anti-Resonance, provides optimum torque
and nulls mid-range instability
Motor self-test and parameter auto-setup
technology, offers optimum responses with
different motors
Multi-Stepping allows a low resolution step
input to produce a higher microstep output
for smooth system performance
Microstep resolutions programmable, from
full-step to 102,400 steps/rev
Supply voltage up to +40 VDC
Output current programmable, from 0.5A to
4.2A
Pulse input frequency up to 200 KHz
TTL compatible and opticallyisolated input
Automaticidle-current reduction
(Reduction rate can be software configured)
Support PUL/DIR and CW/CCW modes
Over-voltage, over-current, phase-error
protections
Applications
Suitable for a wide range of stepping motors, from NEMA frame size 17 to 34. It can be used in
various kinds of machines, such as laser cutters, laser markers, high precision X-Y tables, labeling
machines, and so on. Its unique features make the DM442 an ideal solution for applications that
require both low-speed smoothness and high speed performances.
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2. Specifications
Electrical Specifications (Tj= 25℃/77℉)
Parameters
Min Typical Max Unit
Output current 0.5 - 4.2 (3.0 RMS) A
Supply voltage +20 +36 +40 VDC
Logic signal current 7 10 16 mA
Pulse input frequency 0 - 200 kHz
Isolation resistance 500 MΩ
Mechanical Specifications (unit: mm [inch])
Figure 1: Mechanical specifications
Elimination of Heat
Drive’s reliable working temperature should be <70℃(158℉), and motor working temperature
should be <80℃(176℉);
It is recommended to use automatic idle-current mode, namely current automatically reduce to
60% when motor stops, so as to reduce drive heating and motor heating;
It is recommended to mount the drive vertically to maximize heat sink area. Use forced cooling
method to cool the system if necessary.
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Operating Environment and other Specifications
Cooling Natural Cooling or Forced cooling
Environment Avoid dust, oil fog and corrosive gases
Ambient Temperature 0℃－50℃(32℉－122℉)
Humidity 40%RH －90%RH
Operating Temperature 70℃(158℉) Max
Operating Environment
Vibration 5.9m/s2 Max
Storage Temperature -20℃－65℃(-4℉－149℉)
Weight Approx. 200g (7.05oz)
3. Pin Assignment and Description
The DM442 has two connectors, connector P1 for control signals connections, and connector P2 for
power and motor connections. The following tables are brief descriptions of the two connectors.
More detailed descriptions of the pins and related issues are presented in section 4, 5, 9.
Connector P1 Configurations
Pin Function Details
PUL+
PUL-
Pulse signal: In single pulse (pulse/direction) mode, this input represents pulse
signal, each rising or falling edge active (software configurable); 4-5V when
PUL-HIGH, 0-0.5V when PUL-LOW. In double pulse mode (pulse/pulse) ,
this input represents clockwise (CW) pulse，active both at high level and low
level (software configurable). For reliable response, pulse width should be
longer than 2.5μs. Series connect resistors for current-limiting when +12V or
+24V used. The same as DIR and ENA signals.
DIR+
DIR-
DIR signal: In single-pulse mode, this signal has low/high voltage levels,
representing two directions of motor rotation; in double-pulse mode (software
configurable), this signal is counter-clock (CCW) pulse，active both at high
level and low level (software configurable). For reliable motion response, DIR
signal should be ahead of PUL signal by 5μs at least. 4-5V when DIR-HIGH,
0-0.5V when DIR-LOW. Please note that rotation direction is also related to
motor-drive wiring match. Exchanging the connection of two wires for a coil
to the drive will reverse motion direction.
ENA+
ENA-
Enable signal: This signal is used for enabling/disabling the drive. High level
(NPN control signal, PNP and Differential control signals are on the contrary,
namely Low level for enabling.) for enabling the drive and low level for
disabling the drive. Usuallyleft UNCONNECTED (ENABLED).
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Selecting Active Pulse Edge and Control Signal Mode
The DM442 supports PUL/DIR and CW/CCW modes and pulse actives at rising or falling edge. See
more information about these settings in Section 13. Default setting is PUL/DIR mode and rising
edge active (NPN, and PNP control signal is on the contrary).
Connector P2 Configurations
Pin Function Details
+Vdc Power supply, 20~40 VDC, Including voltage fluctuation and EMF voltage.
GND Power Ground.
A+, A- Motor Phase A
B+, B- Motor Phase B
4. Control Signal Connector (P1) Interface
The DM442 can accept differential and single-ended inputs (including open-collector and PNP
output). The DM442 has 3 optically isolated logic inputs which are located on connector P1 to accept
line drive control signals. These inputs are isolated to minimize or eliminate electrical noises coupled
onto the drive control signals. Recommend use line drive control signals to increase noise immunity
of the drive in interference environments. In the following figures, connections to open-collector and
PNP signals are illustrated.
Figure 2: Connections to open-collector signal (common-anode)
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Figure 3: Connection to PNP signal (common-cathode)
5. Connecting the Motor
The DM442 can drive any 2-phase and 4-phase hybrid stepping motors.
Connections 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 drive output current, multiply the specified phase current by 1.4 to
determine the peak output current.
Figure 4: 4-lead Motor Connections
Connections 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 half coil,is so described because it uses one half
of the motor’s inductor windings. The higher torque configuration, or full coil, uses the full windings
of the phases.
Half Coil Configurations
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 configuration is also referred to as half chopper. In
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setting the drive output current multiply the specified per phase (or unipolar) current rating by 1.4 to
determine the peak output current.
Figure 5: 6-lead motor half coil (higher speed) connections
Full Coil Configurations
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. In full coil mode, the
motors should be run at only 70% of their rated current to prevent over heating.
Figure 6: 6-lead motor full coil (higher torque) connections
Connections 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 Connections
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. In series mode, the motors should also be run at only 70% of their rated
current to prevent over heating.
Figure 7: 8-lead motor series connections
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Parallel Connections
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 8: 8-lead motor parallel connections
NEVER disconnect or connect the motor while the power source is energized.
6. Power Supply Selection
The DM442 can match medium and small size stepping motors (from NEMA frame size 14 to 34)
made by Leadshine or other motor manufactures around the world. To achieve good driving
performances, it is important to select supply voltage and output current properly. Generally speaking,
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). 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 decrease noise, heating and improve
reliability.
Regulated or Unregulated Power Supply
Both regulated and unregulated power supplies can be used to supply the drive. However,
unregulated power supplies are preferred due to their ability to withstand current surge. If regulated
power supplies (such as most switching supplies.) are 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-drive 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 drive draws current from the power supply capacitor of the unregulated supply only during the
ON duration of the PWM cycle, but not during the 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 Drives
It is recommended to have multiple drives to share one power supply to reduce cost, if the supply has
enough capacity. To avoid cross interference, DO NOT daisy-chain the power supply input pins of
the drives. Instead, please connect them to power supply separately.
Selecting Supply Voltage
The power MOSFETS inside the DM442 can actually operate within +20 ~ +40VDC, including
power input fluctuation and back EMF voltage generated by motor coils during motor shaft
deceleration. Higher supply voltage can increase motor torque at higher speeds, thus helpful for
avoiding losing steps. However, higher voltage may cause bigger motor vibration at lower speed, and
it may also cause over-voltage protection or even drive damage. Therefore, it is suggested to choose
only sufficiently high supply voltage for intended applications, and it is suggested to use power
supplies with theoretical output voltage of +20 ~ +36VDC, leaving room for power fluctuation and
back-EMF.
7. Selecting Microstep Resolution and Drive Output Current
Microstep resolutions and output current are programmable, the former can be set from full-step to
102,400 steps/rev and the latter can be set from 0.5A to 4.2A. See more information about Microstep
and Output Current Setting in Section 13.
However, when it’s not in software configured mode, this drive uses an 8-bit DIP switch to set
microstep resolution, and motor operating current, as shown below:
Microstep Resolution Selection
When it’s not in software configured mode, microstep resolution is set by SW5, 6, 7, 8 of the DIP
switch as shown in the following table:
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Microstep
Steps/rev.(for 1.8°motor) SW5 SW6 SW7 SW8
1 to 512 Default/Software configured
ON ON ON ON
2 400 OFF ON ON ON
4 800 ON OFF ON ON
8 1600 OFF OFF ON ON
16 3200 ON ON OFF ON
32 6400 OFF ON OFF ON
64 12800 ON OFF OFF ON
128 25600 OFF OFF OFF ON
5 1000 ON ON ON OFF
10 2000 OFF ON ON OFF
20 4000 ON OFF ON OFF
25 5000 OFF OFF ON OFF
40 8000 ON ON OFF OFF
50 10000 OFF ON OFF OFF
100 20000 ON OFF OFF OFF
125 25000 OFF OFF OFF OFF
Current Settings
For a given motor, higher drive current will make the motor to output more torque, but at the same
time causes more heating in the motor and drive. Therefore, output current is generally set to be such
that the motor will not overheat for long time operation. Since parallel and serial connections of
motor coils will significantly change resulting inductance and resistance, it is therefore important to
set drive output current depending on motor phase current, motor leads and connection methods.
Phase current rating supplied by motor manufacturer is important in selecting drive current, however
the selection also depends on leads and connections.
When it’s not in software configured mode, the first three bits (SW1, 2, 3) of the DIP switch are used
to set the dynamic current. Select a setting closest to your motor’s required current.
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Dynamic current setting
Peak Current RMS Current SW1 SW2 SW3
Default/Software configured (0.5 to 4.2A) ON ON ON
1.46A 1.04A OFF ON ON
1.91A 1.36A ON OFF ON
2.37A 1.69A OFF OFF ON
2.84A 2.03A ON ON OFF
3.31A 2.36A OFF ON OFF
3.76A 2.69A ON OFF OFF
4.20A 3.00A OFF OFF OFF
Notes: Due to motor inductance, the actual current in the coil may be smaller than the dynamic
current setting, particularly under high speed condition.
Standstill current setting
SW4 is used for this purpose. OFF meaning that the standstill current is software configured, and ON
meaning that standstill current is set to be the same as the selected dynamic current.
By default, the current automatically reduced to 60% of the selected dynamic current two second
after the last pulse. Theoretically, this will reduce motor heating to 36% (due to P=I2*R) of the
original value. Reduction rate and idle time can be configured in the PC software ProTuner. See
more information in section 13.
8. Wiring Notes
In order to improve anti-interference performance of the drive, it is recommended to use twisted
pair shield cable.
To prevent noise incurred in PUL/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
disturbing signals generated by motor will easily disturb pulse direction signals, causing motor
position error, system instability and other failures.
If a power supply serves several drives, separately connecting the drives is recommended
instead of daisy-chaining.
It is prohibited to pull and plug connector P2 while the drive is powered ON, because there is
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high current flowing through motor coils (even when motor is at standstill). Pulling or plugging
connector P2 with power on will cause extremely high back-EMF voltage surge, which may
damage the drive.
9. Typical Connection
A complete stepping system should include stepping motor, stepping drive, power supply and
controller (pulse generator). A typical connection is shown as figure 9.
Figure 9: Typicalconnection
10. Sequence Chart of Control Signals
In order to avoid some fault operations and deviations, PUL, DIR and ENA should abide by some
rules, shown as following diagram:
Figure 10: Sequence chart of control signals
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Remark:
a) t1: ENA must be ahead of DIR by at least 5µs. Usually, ENA+ and ENA- are NC (not
connected). See “Connector P1 Configurations”for more information.
b) t2: DIR must be ahead of PUL active edge by 5µsto ensure correct direction;
c) t3: Pulse width not less than 2.5µs;
d) t4: Low level width not less than 2.5µs.
11. Protection Functions
To improve reliability, the drive incorporates some built-in protection functions. The DM442 uses
one RED LED to indicate what protection has been activated. The periodic time of RED is 5 s
(seconds), and how many times the RED turns on indicates what protection has been activated.
Because only one protection can be displayed by RED LED, so the drive will decide what error to
display according to their priorities. See the following Protection Indications table for displaying
priorities.
Over-current Protection
Over-current protection will be activated when continuous current exceeds the limit or in case of
short circuit between motor coils or between motor coil and ground, and RED LED will turn on once
within each periodic time (5 s).
Over-voltage Protection
When power supply voltage exceeds 50±1 VDC, protection will be activated and RED LED will
turn on twice within each periodic time (5 s).
Phase Error Protection
Motor power lines wrong & not connected will activate this protection. RED LED will turn on four
times within each periodic time (5 s).
Attention: When above protections are active, the motor shaft will be free or the LED will blink.
Reset the drive by repowering it to make it function properly after removing above problems. Since
there is no protection against power leads (﹢,﹣) reversal, it is critical to make sure that power
supply leads correctly connected to drive. Otherwise, the drive will be damaged instantly.
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Protection Indications
Priority
Time(s) of ON Sequence wave of RED LED Description
1st 1 Over-current protection
2nd 2
Over-voltage protection
3rd 4 Phase error protection
12. Frequently Asked Questions
In the event that your drive doesn’t operate properly, the first step is to identify whether the problem
is electrical or mechanical in nature. The next step is to isolate the system component that is causing
the problem. As part of this process you may have to disconnect the individual components that make
up your system and verify that they operate independently. It is important to document each step in
the troubleshooting process. You may need this documentation to refer back to at a later date, and
these details will greatly assist our Technical Support staff in determining the problem should you
need assistance.
Many of the problems that affect motion control systems can be traced to electrical noise, controller
software errors, or mistake in wiring.
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Problem Symptoms and Possible Causes
Symptoms Possible Problems
No power
Microstep resolution setting is wrong
DIP switch current setting is wrong
Fault condition exists
Motor is not rotating
The drive is disabled
Motor rotates in the wrong direction
Motor phases may be connected in reverse
DIP switch current setting is wrong
The drive in fault Something wrong with motor coil
Control signal is too weak
Control signal is interfered
Wrong motor connection
Something wrong with motor coil
Erratic motor motion
Current setting is too small, losing steps
Current setting is too small
Motor is undersized for the application
Acceleration is set too high
Motor stalls during acceleration
Power supply voltage too low
Inadequate heat sinking / cooling
Automatic current reduction function not being utilized
Excessive motor and drive heating
Current is set too high
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13. Professional Tuning Software ProTuner
Introduction
This section will provide an overview of connection and basic setup instructions for Leadshine’s
digital stepping drive DM442 using the ProTuner software. These instructions will walk you through
the following steps necessary to start up your drive and motor. This section is intended for setting up
the drive with the ProTuner.
Software Installation
The ProTuner is windows based setup software for tuning Leadshine’s digital stepper drive DM442.
It can run in windows systems, including Win95/Win98/WindowsNT/ Windows 2000/Windows XP.
And the selected PC should have 1 serial port at least for communicating with the drive.
Double click “ProTuner_DM442_V2.0.exe”to begin installing the ProTuner. See Figure 11. Click
Next to enter the “License Agreement”window. See Figure 12.
Figure 11:Begin to install the ProTuner
Note: The user can get it from either Leadshine CD or website. Please get the latest version
from http://www.leadshine.com.
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