Leadshine EM415S User manual

EM415S Digital Stepper Drive User Manual
User Manual
EM415S
Digital Microstepping Drive
Revision 2.0
©2019 Leadshine Technology Co., Ltd.
UK Official Distributor Address:
Motion Control Products Ltd, 11-15 Francis Avenue, Bournemouth, Dorset, BH11 8NX, United Kingdom
Tel: [phone] Fax: [phone]
Web: https://www.motioncontrolproducts.com/ Sales: enqu[email protected]om

EM415S Digital Stepper Drive User Manual
Important Notice
Read this manual carefully before any assembling and using. Incorrect handling of products in this manual can result
in injury and damage to persons and machinery. Strictly adhere to the technical information regarding installation
requirements.
This manual is not for use or disclosure outside of Leadshine except under permission. All rights are reserved. No part
of this manual shall be reproduced, stored in retrieval form, or transmitted by any means, electronic, mechanical,
photocopying, recording, or otherwise without approval from Leadshine. While every precaution has been taken in
the preparation of the book, Leadshine assumes no responsibility for errors or omissions. Neither is any liability
assumed for damages resulting from the use of the information contained herein.
This document is proprietary information of Leadshine that is furnished for customer use ONLY. Information in this
document is subject to change without notice and does not represent a commitment on the part of Leadshine.
Therefore, information contained in this manual may be updated from time-to-time due to product improvements,
etc., and may not conform in every respect to former issues.
Motion Control Products Limited is the official UK distributor of China Leadshine Technology Co. Ltd.
Record of Revisions
Revision
Date
Description of Release
1.0
Oct, 2017
Initial Release
2.0
Jan, 2019
Modify connector, control signal circuit, etc.

EM415S Digital Stepper Drive User Manual
Table of Contents
1.Introduction ......................................................................................................................................................1
1.1 Features ............................................................................................................................................................... 1
1.2 Applications ......................................................................................................................................................... 1
2.Specifications ....................................................................................................................................................2
2.1 Electrical Specifications........................................................................................................................................ 2
2.2 Environment ........................................................................................................................................................ 2
2.3 Mechanical Specifications.................................................................................................................................... 2
2.4 Elimination of Heat .............................................................................................................................................. 3
3. Connection Pin Assignments and LED Indication ................................................................................................3
3.1 P1 - Control Connector Configurations................................................................................................................ 3
3.2 P2 - Fault Output Connector................................................................................................................................ 4
3.3 P3 - Power Connector.......................................................................................................................................... 4
3.4 P4 - Motor Connector.......................................................................................................................................... 4
3.5 P5 - Tuning Port.................................................................................................................................................... 4
3.6 Status LED Lights.................................................................................................................................................. 4
4. Control Signal and Fault Output.........................................................................................................................5
4.1 Control Signal Connection ................................................................................................................................... 5
4.2 Fault output connection ...................................................................................................................................... 5
5. Stepper Motor Connections ..............................................................................................................................5
5.1 4-lead Motor Connection(recommended) .......................................................................................................... 5
5.2 6-lead Motor Connection .................................................................................................................................... 6
5.3 8-lead Motor Connection .................................................................................................................................... 6
6.Power Supply Selection......................................................................................................................................7
6.1 Regulated or Unregulated Power Supply............................................................................................................. 7
6.2 Power Supply Sharing .......................................................................................................................................... 7
6.3 Selecting Supply Voltage...................................................................................................................................... 7
7.DIP Switch Configurations ..................................................................................................................................7
7.1 Output Current Configuration (SW1-3) ................................................................................................ 7
7.2 Micro Step Configuration (SW4-6) ................................................................................................ 8
7.3 Pulse Mode Configuration (SW7)......................................................................................................................... 8
7.4 Self-Test Configuration (SW8) .............................................................................................................................. 8
8. Wiring Notes ....................................................................................................................................................9
9. Typical Connection............................................................................................................................................9
10. Sequence Chart of Control Signals ...................................................................................................................9
11. Protection Functions.....................................................................................................................................10
12. Troubleshooting............................................................................................................................................11
13. Warranty ......................................................................................................................................................12

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1. Introduction
The EM415S is a new digital stepper drive based on Leadshine’s widely implemented DM stepper drives (10+ millions
of units in field). While retaining features of simple design, easy setup, high precision and reliability, Leadshine has
also upgraded it by adopting the latest stepper control technology and added additional advanced features for better
performance (10-25%), alarm output, control command smoothing, easy self-test, etc.
The EM415S can power 2 phase (1.8°) and 4 phase (0.9°) stepper motors smoothly with very low motor heating &
noise. It can take 18-36VDC supply voltage and output 0.3 to 1.5A current. Micro step, output current, control type
(step & direction or CW/CCW) and self-test can be easily done via built in DIP switches. It is an ideal choice for many
applications requiring simple step & direction or CW/CCW control of NEMA 8, 11, 14 and 17 stepper motors.
1.1 Features
⚫Step & direction (PUL/DIR) or CW/CCW (double pulse) control
⚫18-36VDC supply voltage
⚫70 KHz max pulse input frequency
⚫8 micro step settings of 200-25,600 via DIP switches, or 200-51,200 via software (increase by 200)
⚫8 output current settings of 0.3 –1.5A via DIP Switches, or via software (increase by 0.1)
⚫Configurable control command smoothing for reducing motor vibration
⚫Automatic idle current reduction to 50%
⚫Convenient self-test for easy diagnosis
⚫Automatic self-configuration to match wide-range NEMA 8, 11, 14 and 17 stepper motors
⚫Anti-Resonance for optimal torque, extra smooth motion, low motor heating and noise
⚫Soft-start with no “jump” when powered on
⚫Optically isolated inputs
⚫Fault output
⚫Over-voltage and over-current protections
⚫CE certified and RoHS compliant
1.2 Applications
The EM415S stepper drive is designed to power 2 phase (1.8°) or 4-phase (0.9°) NEMA 8, 11, 14 and 17 hybrid stepper
motors or Permanent magnetic stepper motor (7.5° or 15°). It can be adopted in many industries (CNC machinery,
electronics, medical, automation, packaging…) for applications such as 3D printer, automation machines, medical
machines, laser cutters, X-Y tables, labeling machines, pick-place devices, etc. Its excellent performance, simple design,
and easy setup features make EM415S ideal for many step & direction control type applications.

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2. Specifications
2.1 Electrical Specifications
Parameters
Min
Typical
Max
Unit
Output Current
0.3
-
1.5 (1.0 RMS)
A
Supply Voltage
18
24
36
VDC
Logic signal current
7
10
16
mA
Pulse input frequency
0
-
70
kHz
Minimal pulse width
72
-
-
μs
Minimal direction setup
150
-
-
μs
Isolation resistance
500
-
-
MΩ
2.2 Environment
Cooling
Natural Cooling or Forced cooling
Operating Environment
Environment
Avoid dust, oil fog and corrosive gases
Ambient Temperature
0 －65°C (32 - 149°F)
Humidity
40 －90%RH
Operating Temperature
0 －50°C (32 - 122°F)
Vibration
10-50Hz / 0.15mm
Storage Temperature
-20°C －65°C (-4°F - 149°F)
Weight
Approx. 150g (5.3 oz)
2.3 Mechanical Specifications
(unit: mm [1inch=25.4mm])
Figure 1 Mechanical specifications
* Side mounting recommended for better heat dissipation
86
72
20
9.25
5
55
25.5
4

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2.4 Elimination of Heat
⚫EM415S’s working temperature is less than 60℃(140°F)
⚫It is recommended to mount the drive vertically to maximize heat sink area. Use forced cooling method to cool if
necessary.
3. Connection Pin Assignments and LED Indication
S1: DIP Switch
P1: Control Signal
P2: Fault Output
P3: Power Connector
P4: Motor Connector
P5: Tuning Port
Figure 2 Connectors, DIP switches, and LED locations
The EM415S has 5 terminal block connectors P1, P2, P3, P4 and P5, 1 DIP switch selectors S1. P1 is for control signal
connections, P2 is for fault output, P3 is for power connection, P4 is for motor connection and P5 is for fine tuning.
3.1 P1 - Control Connector Configurations
PIN
Details
PUL+ (CW+)
Pulse and Direction Connection: (1) Optically isolated, high level 4.5-5V, low voltage 0-0.5V.
(2) Maximum 70 KHz input frequency. (3) Pulse width of 72μs or longer. (4) Single pulse (step &
direction) control mode or double pulse (CW/CCW) control mode is set by DIP Switch SW7.
(5) DIR signal requires advance PUL signal minimum 150 μs in single pulse mode. (6) When the
control voltage is 24V, 2K resistors are required.
PUL- (CW-)
DIR+ (CCW+)
DIR- (CCW-)
ENA+
Enable Connection: Optional. (1) Optically isolated, differential. (2) Disable the drive by 4.5-5.0V
input connection; enable the drive by 0-0.5 VDC connection(default no connection).
(3) ENA signal requires advance DIR signal minimum 150μs in single pulse mode. (4) When the
control voltage is 24V, a 2K resistor is required. (5) Enable time to be at least 200ms
ENA-
!
Notice
Notes: (1) shield cables are required for P1; (2) don’t tie P1&P2 cables and P3&P4 cables together.

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3.2 P2 - Fault Output Connector
Pin
Details
ALM+
Fault Output Connection: Optional. (1) Maximum 24V/80mA output when over-voltage and
over-current error protections activated. (2) Sinking or sourcing. (3) The resistance between
ALM+ and ALM- is low impedance as default, and will change to high when the drive goes into
error protection.
ALM-
3.3 P3 - Power Connector
Pin
Details
GND
Connect to power supply ground connection.
+VDC
Connect to power supply positive connection. Suggest 18-36VDC power supply voltage
!
Warning
Warning: Don’t plug/unplug P3 or P4 connector to avoid drive damage or injury while powered on.
3.4 P4 - Motor Connector
PIN
Details
A+
Connect to motor A+ wire
A-
Connect to motor A- wire
B+
Connect to motor B+ wire
B-
Connect to motor B- wire
3.5 P5 - Tuning Port
EM415S has a tuning port with RS232 to modify the drive parameters, it’s only for tuning, not for equipment control
because neither precision nor stability is sufficient. If you need a field bus drive, contact Motion Control Products Ltd.
For their range of fieldbus servo drives and stepper drives, ideal for performance network control.
www.motioncontrolproducts.com
The interface definition is as follows:
3.6 Status LED Lights
There are two LED lights for EM415S. The GREEN one is the power indicator which should be always on in normal
circumstance. The RED one is a drive status indication light, which will be OFF while working normally but ON and
flash 1 or 2 times in a 3-second period in the case of enabled over-current or over-voltage protection.

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4. Control Signal and Fault Output
4.1 Control Signal Connection
The EM415S can accept differential or single-ended control signals (pulse, direction, and enable) in open-collector or
PNP connection through the P1 connector (figure 2). It is recommend to add an EMI line filter between the power
supply and the drive to increase noise immunity for the drive in interference environments.
Controller
PUL+ 1
DIR+ 3
PUL-
DIR-
2
4
ENA+ 5
ENA- 6
Step
Direction
Enable
VCC
VCC
VCC
Drive
Controller Drive
PUL+ 1
DIR+ 3
PUL-
DIR-
2
4
ENA+ 5
ENA- 6
VCC
Step
Direction
Enable
Figure 3 Connections to open-collector signals Figure 4 Connections to PNP signals
(Common-anode) (Common-cathode)
4.2 Fault output connection
When over voltage or over current protection happens, EM415S red status LED light will blink and the impedance
state between ALM+ and ALM- will change (from low to high or high to low depending on configuration) and can thus
be detected. Fault output connection is optional, and it can be connected either in sinking or sourcing.
ALM+
Drive
ALM-
Load
5-24VDC
ALM+
Drive
ALM- Load
5-24VDC
Figure 5 Sinking output Figure 6 Sourcing output
5. Stepper Motor Connections
EM415S can drive 2-phase and 4-phase bipolar hybrid stepper motors with 4, 6, or 8 wires, Motion Control Products
also offers easy-to-use and good-performance motors with 4-leads, ideal for running with the EM415S:
https://www.motioncontrolproducts.com/electric-motors/stepper-motors/hybrid-stepper-motors/
5.1 4-lead Motor Connection(recommended)
4-lead motor is easy to use with excellent performance. Refer to figure 7 for how to connect a 4-lead stepper motor.

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P4
Figure 7 4-lead Motor Connection
5.2 6-lead Motor Connection
EM415S can power 6-lead stepper motors through half coil connection (half chopper) or full coil (full copper)
connection. The half coil connection only uses one half of the motor’s winding and is usually selected in applications
requiring high speed but lower torque. The full coil connection uses the full coil winding and is usually selected in
high-torque required applications. Refer to figure 8 and 9 for those two connections.
P4
P4
Figure 8 6-lead motor half coil connection Figure 9 6-lead motor full coil connection
5.3 8-lead Motor Connection
EM415S can power 8-lead in series or parallel connection in series or parallel.
Series connected 8-lead stepper motors are typically implemented in applications which higher torque at lower speed
movement is required. Because a stepper motors under series connection has the most inductance, the performance
will start to degrade when the motor runs at higher speed. For this connection, it is suggested to set an EM415S’s
output RMS current to no more than 70% of the stepper motor’s phase current to prevent overheating. See the figure
10 for how to connect an 8-lead stepper motor for series connection.
Parallel connected 8-lead stepper motors are typically implemented in applications which higher torque at high speed
movement is required. Compared with series connection, a parallel connected stepper motor has lower inductance
and therefore have better torque performance at higher speed movement. Although setting the drive output current
to 1.4 times of driven motor phase current will get the most torque, it is suggested to set an EM415S’s output current
(peak of sinusoidal) to no more than 1.2 times the stepper motor’s phase current to prevent overheating. Refer to the
figure 11 for how to connect an 8-lead stepper motor for parallel connection.
P4
P4
Figure 10 8-lead motor series connection Figure 11 8-lead motor parallel connection

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6. Power Supply Selection
EM415S is designed to power small size stepping motors (frame sizes NEMA 8 to 17) made by Leadshine or other
motor manufacturers. To get optimal performances, it is important to select proper power supply type, voltage, and
supply output current. In general power supply voltage determines the high speed performance of a stepper motor,
while drive output current determines the driven motor torque output. Higher supply voltage can increases motor
speed torque performance, but at the same time result in more noise and motor heating. For low motor speed
applications, it is suggested to use lower supply voltage power supplies.
6.1 Regulated or Unregulated Power Supply
Both regulated and unregulated power supplies can be used to power an EM415S. Theoretically unregulated power
supplies are preferred due to their ability to withstand back EMF current surge and faster response for current change.
If you prefer to use a regulated power supply instead, it is suggested to choose one specially designed for stepper or
servo controls such as one Leadshine RPS series power supply:
http://www.leadshine.com/ProductSubType.aspx?type=products&category=other-products&producttype=power-sup
plies&subtype=regulated-switching-power-supplies.In the case when only general purpose switching power supplies
are available, choose one with “OVERSIZED” current output rating (for example, using a 4A power supply for 3A
stepper motor) to avoid current clamp. 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 phase current). The reason is that the drive
only draws current from an unregulated power supply during the ON duration of the PWM cycle, but not during the
OFF duration.
6.2 Power Supply Sharing
Multiple EM415S drives can share the same power supply, if that power supply has enough capacity. To avoid cross
interference, connect each EM415S DIRECTLY to that shared power supply separately instead of connecting those
power connectors of drives in daisy-chain connection.
6.3 Selecting Supply Voltage
EM415S’s operating voltage is 18–36 VDC. Because of voltage increasing from potential power line voltage fluctuation
and back EMF voltage generated during motor deceleration, it is suggested to use a 24 VDC power supply.
7. DIP Switch Configurations
The EM415S has 8-bit DIP Switch to configure output current, microstep resolution, pulse mode and self-test as
shown below, the factory setting of SW1-SW8 is ON, ON, ON, OFF, OFF, ON, OFF, OFF. Default means that parameters
can be modified by Leadshine ProTuner software.
SW1
SW2
SW3
SW4
SW5
SW6
SW7
SW8
7.1 Output Current Configuration (SW1-3)
The EM415S has 8 output current settings which can be configured through DIP switch SW1, SW2 and SW3.
Pulse Mode
Self Test
Output Current
Microstep

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For a given stepper motor, as normal setting the output current to 1.4 times of motor phase current, will make it
output larger torque, but at the same time cause more heating for both the motor and drive. Therefore, it is
suggested to set a output current (peak of sinusoidal) to no more than 1.2 times the stepper motor’s (for 4-lead
motor) phase current to prevent overheating .
The SW1, SW2 and SW3 are used to set the dynamic current. Select a setting closest to your motor’s required current.
When they are set to ON, ON, ON, the output current can be set by Leadshine ProTuner.
Peak Current
RMS Current
SW1
SW2
SW3
0.3A
0.21A (default)
ON
ON
ON
0.5A
0.35A
OFF
ON
ON
0.6A
0.42A
ON
OFF
ON
0.7A
0.49A
OFF
OFF
ON
0.8A
0.57A
ON
ON
OFF
1.0A
0.71A
OFF
ON
OFF
1.2A
0.85A
ON
OFF
OFF
1.5A
1.06A
OFF
OFF
OFF
7.2 Micro Step Configuration(SW4-6)
Each EM415S has 8 micro step settings which can be configured through DIP switch SW4, SW5, SW6. See the
following table for detail. When they are set to ON, ON, ON, the microstep can be set via Leadshine ProTuner.
Micro step
Pulses/Rev. (for 1.8°motor)
SW4
SW5
SW6
1
200 (default)
ON
ON
ON
2
400
OFF
ON
ON
4
800
ON
OFF
ON
8
1600
OFF
OFF
ON
16
3200
ON
ON
OFF
32
6400
OFF
ON
OFF
64
12800
ON
OFF
OFF
128
25600
OFF
OFF
OFF
7.3 Pulse Mode Configuration (SW7)
DIP switch SW7 is used to configure the control mode. Factory setting is single pulse (step & direction, or pulse &
direction) control. Setting to ON to change the control model to double pulse (CW/CCW) control type.
7.4 Self-Test Configuration (SW8)
For test and system diagnosis purpose, EM442S is featured with Self-Test. Anytime DIP switch SW8 is switched to ON
position, the drive will automatically rotate the driven stepper motor back and forth for one round in each direction.
Set this switch position to OFF for normal operation.

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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 only one power supply serves multiple EM415S drives, separately connecting the drives to the power supply is
recommended instead of daisy-chaining.
⚫It is prohibited to pull and plug connector P3&P4 while the drive is powered ON, because there is high current
flowing through motor coils (even when motor is at standstill), which 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 12.
GND
A+
A-
+Vdc
1
5
6
Power &
Motor Connector
Controller
Control Signal
Connector
4
PUL+ 1
DIR+ 3
PUL-
DIR-
2
4
ENA+ 5
ENA- 6
Step
Direction
Enable
Fault
5-24VDC
ALM+ 1
2
ALM-
Status Signal
Connector
18-36VDC recommended,
leaving rooms for voltage fluctuation
and back EMF of the motor
2
3B+
B-
Drive
Figure 12 Typical connection
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:

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Figure 13 Sequence chart of control signals
Remark:
a) t1: ENA must be ahead of DIR by at least 150 s. Usually, ENA+ and ENA- are NC (not connected). See
“Connector P1 Configurations” for more information
b) t2: DIR must be ahead of PUL effective edge by 150 s to ensure correct direction
c) t3: Pulse width not less than 72 s, duty cycle recommend 50%
d) t4: Low level width not less than 72 s
e) For control signals, both PUL,DIR and ENA are activated by rising edges in default
11. Protection Functions
EM415S incorporates are built with over-voltage and over-current error protections. When it is under error
protection, the red LED light will blink for 1 or 2 or 4 times in a period of 3 seconds. If fault output connection is
connected, the impedance mode between ALM+ and ALM- will be changed (See “Fault Output Configuration”
section for detail).
Priority
Time(s) of
Blink
Sequence wave of red LED
Description
1st
Always on
The drive was short-circuited or burned out.
1st
1
Over-current protection activated when peak
current exceeds the limit.
2nd
2
Over-voltage protection activated when drive
working voltage is greater than 42VDC
3rd
4
Motor cable error or not connected to the motor.
Figure 14 Error Protections
When over-current and over-voltage protections are activated, the motor shaft will be free or the red LED blinks.
Reset the drive by restart it to make it function properly after removing above problems.

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12. Troubleshooting
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.
Problem Symptoms and Possible Causes
Trouble
Solution Measures
Motor is not rotating
No power, to start power supply
Pulse/revolution setting is wrong
DIP switch current setting is wrong
Fault condition exists or the drive is disabled
Motor rotates in the wrong
direction
Motor phases may be connected in reverse
Pulse mode may be wrong
Red light blinking
Red light blinks 1 time or always on, try not to connect the motor and restart the
power supply
Red light blinks 2 times, check the power voltage and restart the power supply
Red light blink 4 times, the motor is not connected or has broken circuit.
Erratic motor motion
Current setting is too small, losing steps
Wrong motor connection or has broken circuit in motor coil.
The current of the control signals is not in the range of 7-15mA
Control signals don’t meet the requirements of chapter 10 , check the waveform
of the control signals
Motor stalls or loss steps
Output current of the drive is too small or motor torque is not enough
Acceleration is set too high
Power supply voltage too low
Modify the activated edge value in the ProTuner or the control signal is
interfered with.
Excessive motor and drive
heating
Inadequate heat sinking / cooling
Automatic current reduction function not being utilized
Reduce output current

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13. Warranty
TWELVE MONTH LIMITED WARRANTY
Motion Control Products Ltd warrants its products against defects in materials and workmanship for a period of 12 months
from the shipping/purchasing date. During the warranty period Motion Control Products, at their discretion, will repair or
replace products that are proved to be defective.
EXCLUSIONS
The above warranty shall not apply to defects resulting from: improper or inadequate handling by the customer; improper
or inadequate customer wiring; unauthorised modification or misuse; or operation beyond the electrical specifications of
the product and/or operation beyond environmental specifications for the product.
SHIPPING FAILED PRODUCT & OBTAINING WARRANTY SERVICE
If your product should fail during the warranty and you want to obtain warranty service, a RMA (returned material
authorisation number) request form must be filled in on our website https://www.motioncontrolproducts.co.uk/returns/
before returning the product for service. Please include a written description of the problem along with contact name and
address. Customer shall prepay shipping charges returned to Motion Control Products for warranty service, and Motion
Control Products shall pay for return of products to the customer, providing the fault is not customer caused. Send the
failed product to your distributor for your area or to Motion Control Products Limited, 11-15 Francis Avenue, Bournemouth,
Dorset BH11 8NX, UK. Also enclose information regarding the circumstances prior to the product failure. For full terms and
conditions of Warranty and Returns Policy, please refer to our website https://www.motioncontrolproducts.co.uk/returns/
WARRANTY LIMITATIONS
Motion Control Products makes no other warranty, either expressed or implied, with respect to the product. Motion
Control Products specifically disclaims the implied warranties for a particular purpose. Some jurisdictions do not allow
limitations on how long the implied warranty lasts, so the above limitation or exclusion may not apply to you. However, any
implied warranty is limited to the 12-month duration of this written warranty.
Copyright © 2019 Motion Control Products Ltd. All rights reserved.
All data subject to change without notice in advance [V2019-08]