Leadshine Easy Servo Series Assembly instructions

Hardware InstallationManual
EasyServo Drives
HMN_ES_R20130312
http://www.Leadshine.com
ES-D508 ES-D808/1008 ES-D2306

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SafetyItems
!
Notice
Readthismanualcarefullybeforetryingtoinstall thestepperdriveintoyour
system.Thepeoplewhosetup thestepperdriveshouldhaveabetter
understandingonelectronicsandmechanics. ContactLeadshinetechnicalguys
when youhavequestionson thisdocument.
!
Caution
Makesurethepowersupplyvoltagedosenotexceedthedrivesinputrange.
Doublechecktheconnectionsand makesurethepowerlead polarityiscorrect.
!
Warning
Donotsethighcurrentforsmallsteppermotor.Itispossiblethatthemotorwillbe
damaged.
!
Caution
Disconnectthemotorfromtheloadifyouarenotsurethemovedirection.Adjust
theaxisin thecenterbeforetryingto runthemotor.
!
Warning
Neverdisconnectthemotorlead when thepowersourceisenergized.

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Table ofContents
Introduction to EasyServo ..................................................................................................................1
Getting Start .......................................................................................................................................1
WiringDiagrams..........................................................................................................................2
ConnectingPower Supply.............................................................................................................3
ES-D508,ES-D808...................................................................................................................3
ES-D1008................................................................................................................................4
ES-D2306................................................................................................................................4
ConnectingMotor.........................................................................................................................5
ES-D508 andES-M323XX .......................................................................................................5
ES-D808 andES-M223XX .......................................................................................................5
ES-D808/1008andES-M234XX ..............................................................................................6
ConnectingEncoder......................................................................................................................6
ES-D508 andES-M323XX .......................................................................................................6
ES-D808/1008andES-M223XX/ES-M234XX...........................................................................6
ConnectingControl Signal ............................................................................................................7
Pulse,Direction,EnableInput................................................................................................7
Alarm,In-position Output......................................................................................................9
ConnectingPC...............................................................................................................................9
Configuration....................................................................................................................................10
Configuring ES drivebyDIPSwitches..........................................................................................11
ES-D508................................................................................................................................11
ES-D808/D1008....................................................................................................................12
Configuring ES drivein PCSoftware...........................................................................................13
CalculatingRotation Speedand Angle .......................................................................................13
RotatingtheEasyServoMotorbyMotionController.................................................................14
RotatingtheESMotorin PCSoftware........................................................................................14
Power SupplySelection.....................................................................................................................15
RegulatedorUnregulatedPower Supply....................................................................................15
MultipleDrives...........................................................................................................................15
Selecting SupplyVoltage............................................................................................................15
RecommendedSupplyVoltage...................................................................................................16
WiringNotes.....................................................................................................................................16
Control SignalSetup Timing..............................................................................................................17
Current Control Detail.......................................................................................................................17
FineTuning........................................................................................................................................18
Protection Functions .........................................................................................................................18
Over-current Protection..............................................................................................................18
Over-voltageProtection .............................................................................................................18
PositionFollowingErrorProtection............................................................................................19
FrequentlyAskedQuestions..............................................................................................................19

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ProblemSymptomsand PossibleCauses....................................................................................19
Warranty...........................................................................................................................................20
Exclusions...................................................................................................................................20
ObtainingWarrantyService.......................................................................................................20
WarrantyLimitations..................................................................................................................20
ShippingFailedProduct..............................................................................................................20
ContactUs.........................................................................................................................................21

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IntroductiontoEasyServo
TheES(EasyServo)seriesclose-loopstepperservosofferanalternativeforapplicationsrequiring
high performanceand highreliabilitywhenthetraditionalservo wastheonlychoice,whileitremains
cost-effective.Thesystemincludesaneasyservomotorcombinedwithafullydigital,high
performanceeasyservodrive.Theinternalencoderisusedtoclosetheposition,velocityand current
loopsinrealtime,justlikeservosystems. Itcombinesthebestofservoandsteppermotor
technologies,anddeliversuniquecapabilitiesand enhancementsoverboth,whileatafractionofthe
costof aservo system.
Getting Start
Togetstartyou needoneEasyServo drive,oneEasyServomotor(stepperdrivewith encoder)and a
DC/ACpowersupplyforafirsttimeevaluation.Amotioncontroller-likeindexer,pulsegeneratoror
PLCisrequiredtoo whenyouneedtorotatethemotor.IfyouhaveaPCwithoneserialportorone
PCwithUSB-RS232converter,youcanalsorotatethemotorinthePCsoftware.Howeveritis
recommendedto verifythecompletefunction of theEasyServo usingamotion controller.
EasyServo Drive
EasyServo Motor
StepperMotor
Encoder
Amplifier
Comparator
Comp
Command Position
Measured Position

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Wiring Diagrams
WiringDiagram of ES-D508 and ES-M323XX
WiringDiagram of ES-D808/1008 and ES-M2XXXX
Or
RS232 Cable
USB-232 Converter
Motion Controller
EncoderCable
MotorPowerCable
PowerSupply
Or
RS232 Cable
USB-232 Converter
Motion Controller
EncoderCable
MotorPowerCable
PowerSupply

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WiringDiagram(Continued)
WiringDiagram of ES-D2306andES-MH3XXXX
Connecting Power Supply
ES-D508,ES-D808
TheeasyservodrivesES-D508 and ES-D808 canacceptDCpowerinput.Theyhaveonlytow
wires-positivewireand negativewireforthepowerconnection.Howeveryouneedtopayattention
towirepolarity.A6-pinpluggablescrewconnectorisusedforbothpowersupplyand motor
connection.Lookingatthedrivecoveryoushouldfindtheprinted “+Vdc”and “GND”symbol.
Connectthepositivewireto “+Vdc”terminalandconnectthenegativewireto “GND”terminal.Note
thatthepowershouldbeswitchwhenyoumaketheconnections. Note: Donot exceedtheinput
voltagerangeoftheEasyServodrive.Pleaseconsult Power SupplySelection chapter in themanual
fortherecommendedsupplyvoltage.
DCPowerConnection of ES-D508 andES-D808
Or
RS232 Cable
USB-232 Converter
Motion Controller
EncoderCable
MotorPowerCable
AC Power
+Vdc
GND
High Voltage DCPower
+(Positive)
-
(Negative)

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ConnectingPower Supply(Continued)
ES-D1008
TheES-D1008 can acceptboth DCandACpowerinput.Thereisno powerinputpolarityforit.
DCPowerConnection of ES-D1008
ACPowerConnection ofES-D1008
ES-D2306
TheES-D2306requirestwopowersinputasfollows.Themainpowerisusedtoenergizethemotor
and thecontrolpowerisusedforlogiccircuit.Typicallytheycan sharethesameACpower.
ACPowerConnection ofES-D2306
AC
AC
High Voltage
AC
AC
ACPower
20
-
70VAC
L
N
PE
Main Power
L
N
PE
Control
Power
L
N
ACPower
150
-
230VAC
AC
AC
High Voltage
DCPower
30
-
100VDC
+(Positive)
-
(Negative)

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Connecting Motor
ES-D508 andES-M323XX
TheES-M323XX hasthree wires:U,V and W.Justconnectthemto thecorrespondingterminalsofthe
ES-D508 asfollows.
ConnectES-M323XXto ES-D508
ES-D808 andES-M223XX
TheES-M223XX hasfourwires:A+,A-,B+and B-.Justconnectthemtothecorrespondingterminals
of theES-D808asfollows.
ConnectES-M223XXto ES-D808
A+
A-
B+
B-
ES-D808 A+
A-
B+
B-
ES
-
M223XX
U
V
W
ES
-
D508
U
V
W
ES
-
M323XX

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ConnectingMotor(Continued)
ES-D808/1008andES-M234XX
TheES-M234XX hasfourwires:A+,A-,B+and B-.Justconnectthemtothecorrespondingterminals
of theES-D808/1008asfollows.
ConnectES-M234XXto ES-D808/1008
Connecting Encoder
AstheEasyServoDriveworksinclose-loopmode,itneedstoknowtheactualmotorposition.The
encodermountedinthemotorofferssuchinformation.PleasenotethattheEasyServo Drivecan not
workwithoutencoderfeedback.
ES-D508 andES-M323XX
TheencoderoutputoftheES-M323XX isaHDD15 maleconnector.JustplugittotheES-D508s
feedback(encoder)connector.
Encoderconnectionbetween ES-D508 and ES-M323XX
ES-D808/1008andES-M223XX/ES-M234XX
TheencoderoutputoftheES-M223XX/ES-M234XX isaHDD15connectorbutthedrivesencoder
inputisascrewterminal,anextensioncableisneededtoconnectthemotor sencodersignaltothe
drive.Theextension cableoutputsare6 flyingwires.
Feedback
ES-D508
ES
-
M323XX
1
65 10
11 15
EncoderSignals
A+
A-
B+
B-
E
S
-
D
808
ES
-
D1008
A+
A-
B+
B-
ES
-
M234XX

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Encoderconnectionbetween ES-D808/1008and ES-M223XX/ES-M234XX
Connecting ControlSignal
Pulse,Direction,EnableInput
Thepulse,directionandenableinputoftheEasyServodriveisdifferential.Itcanalsobeconnected
toPNP(sourcing)orNPN(sinking)typecontroller. Fortheenablesignal,apply0VbetweenENA+
and ENA-orleavethemunconnectedtoenablethedrivel. Ifit isneedn ttodisablethedrive,just
leaveit unconnected.
In aNPN (sourcing)typeoutput,thecontrolsignals sharethesamepositiveterminal.
ES-DXXX
PUL+ 1
DIR+ 3
PUL-
DIR-
2
4
ENA+ 5
ENA- 6
VCC
Step
Direction
Enable
Controller
R
R
R
ES-D508
R=0if VCC=5V;
R=1K(Power>0.125W)if VCC=12V;
R=2K(Power>0.125W)if VCC=24V;
Rmust beconnectedtocontrolsignalterminal.
Control Signal
Connector
ES-D808/1008
VCC=5~24V. Rcanberemoved.
ConnectES-DXXX to NPN (sinking)typecontroller
EB+
EB-
EA+
EA-
VCC
EGND
ES
-
D808/
ES
-
D1008
ES-M223XX
ES-M234XX
EncoderSignals
EncoderCable
Color Name
Red VCC
White GND
Yellow EB+
Green EB-
Black EA+
Blue
E
A
-
1
65 10
11 15

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Pulse, Direction, EnableInput(Continued)
In aPNP(sinking)typeoutput,thecontrolsignalsarereferto thesameground terminal.
ES-DXXXController
Control Signal
Connector
PUL+ 1
DIR+ 3
PUL-
DIR-
2
4
ENA+ 5
ENA- 6
Step
Direction
Enable
VCC
VCC
VCC
R
R
R
ES-D508
R=0ifVCC=5V;
R=1K(Power>0.125W)ifVCC=12V;
R=2K(Power>0.125W)ifVCC=24V;
Rmust beconnectedtocontrolsignalterminal.
ES-D808/1008
VCC=5~24V.Rcanberemoved.
ConnectES-DXXX to PNP(sourcing)typecontroller
ES-DXXXController
Control Signal
Connector
PUL+ 1
DIR+ 3
PUL-
DIR-
2
4
ENA+ 5
ENA- 6
5V
Step
Direction
Enable
ConnectES-DXXX to differentialtypecontroller

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Alarm,In-position Output
Theoutputsareisolatedandyou cantakethemaselectronicswitch.Anupperresistorisused tolimit
thecurrent.Itsresistanceisdependingon theinputcurrentrequirementofthecontroller.Thesource
voltageforthoseoutputscanalsobe24V.TheresistorRisdependingontheinputcurrentofthe
controller.
ES-DXXX
ALM+
ALM-
Alarm
Controller
5V
Pend+
Pend-
In-Position
ControlSignal
Connector
RR
Alarm,in-position signalconnectionof ES-DXXX
(Note:thereisnoin-position outputin ES-D508)
Connecting PC
Abuilt-inRS232 communicationportintheEasyServodriveisusedforcommunicationand
configuration.ConnectthisporttothePC sserialport.ThenyoucanturnthemotorinPCsoftware.
Thissoftware-ProTuner,isdesignedtoconfiguretheEasyServodrive.Youcandefinethecontrol
mode,microstepresolution,currentrate,activelevelof inputs/outputsin ProTuner.
TheProTunercanbedownloadedfromourwebsite: http://www.leadshine.com oryoumayalso getit
fromourCD.Itisrecommendedtogetitfromthewebsitebecauseitisalwaysthelatest.Install itin
yourPCand makeitreadyforuselater.
ConnectEX-D808 toRS232 connection
ARS232cableisneededforthecommunicationbetweenthedrivesRS232 portandthePC sserial
port.Itwill beshippedwiththekitifyouincludeitintheorder.Itisalsopossibletomakethiscable
yourself.OneendofthiscableisaRJ-11 headerand theotherendofcableisa9pinD-Subfemale
connector.IfyourPCdoesnothaveaserialport,aUSB-to-Serialconverterwhich simulatestheserial
portisrequired. Thepowershouldbeturnedoff whenyou performanyconnections!
Or
RS232 Cable
USB-232 Converter
ProTuner

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WhenyouopenProTuner,a “Connecttodrive”windowappears. The “BaudRate”and “Device
Address”arefixed.Youonlyneedtoselectthe “ComPort”regardingtotheactualserialportorthe
mappingportofaUSB-232 converter.Checkthe DeviceManager forthemappingportnumberof
theUSB-232 converter.
Configuration
WhenthedefaultsettingoftheEasyServodriveis notsuitableforyourapplication,itisnecessaryto
configureitviatheDIPswitchorProTuner.Otherwiseyoumayencounterproblemslikehighmotor
heating,bigmotornoiseorevenmotorstall duetoweaktorque.ForaquickstartoftheEasyServo
drive,therearenotmuchparametersneedtobeconfigured.Thefollowingtablegivesthemost
significantsettings of theEasyServo drive.
MostSignificantSettingsoftheEasy Servodrive
Parameters ES-D508 / ES-D2306 ES-D808, ES-D1008
MicroStepResolution (PPR) Default4000, SoftwareAdjustable Default1600,DIPSwitchorSoftware
Adjustable
HoldingCurrent(%) Default60%, SoftwareAdjustable Default60%, SoftwareAdjustable
Close-loop CurrentLimit(%) Default100%, SoftwareAdjustable Default100%, SoftwareAdjustable
CurrentLoopKp AutoTuningatPower-up Default1500, SoftwareAdjustable
CurrentLoopKi AutoTuningatPower-up Default200, SoftwareAdjustable
Theholdingcurrentaffectstheholdingtorquewhenthemotorisstop.Theclose-loopcurrentlimit
affectsthedynamictorque.Increasethemifthetorqueisnotenough.Bydefault,the
ES-D808/ES-D1008 isconfigured forES-M234XX (NEMA34 motor,4Nmor8Nm)on 60VDC. Ifyouuse
themtodriveES-M223XX(NEMA23motor,1Nmor2Nm),itisrecommendedtotunethecurrent
loopKpand Kito fortheoptimizingperformance. Refertothesoftwaremanual formoredetail.
TheES-D508/ES-D2306 isconfiguredautomaticallyatpower-up regardingtomotorand supply
voltage.Forothercombinations, itisrecommendedtomodifythesesettings togettheoptimizing
performanceasshown inthefollowingtables.

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RecommendedHolding/Close-loop Current Percentage
ES-M32309 ES-M32320 ES-M22310 ES-M22320 ES-M23440 ES-M23480
Holding
Current(%) 60% 60% 40% 60% 60% 60%
Close-loop
CurrentLimit(%)
100% 100% 100% 100% 100% 100%
Easy servodrive ES-D508 ES-D508 ES-D808 ES-D808 ES-D808 ES-D808
Recommended CurrentLoop Kp/ KiofDifferentSupply Voltage
ESMotor ESdrive 24VDC 36VDC 48VDC 60VDC
ES-M22310 ES-D808 1500 / 200 1000 / 300 800 / 250 N/A
ES-M22320 ES-D808 3700 / 200 2000 / 300 1500 / 200 N/A
ES-M23440 ES-D1008 N/A 4400 / 200 3000 / 200 2300 / 200
ES-M23480 ES-D1008 N/A 4400 / 200 3000 / 200 2300 / 200
TherearepossibletwomethodstoconfiguretheEasyServodriveasfollows,dependingonthe
specificdrive.
Configuring ES drivebyDIPSwitches
ES-D508
Thereisa2-bitDIPswitchon theES-D508 whichcan beusedto reversethemotiondirection.
SW1isusedtoreverse
themotion direction.
SW2hasnofunction.

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ES-D808/D1008
Thereisa6-bitDIPswitch in theES-D808 andES-D1008 drive.SW1to SW4 areused tosetthemicro
step resolution and SW5 areused to setthedirectionpolarity.
ES-D808 and ES-D1008 MicroStepResolution Setting
Steps/Revolution SW1 SW2 SW3 SW4
SoftwareConfigured
(Default 200) on on on on
800 off on on on
1600 (Factory Setting) on off on on
3200 off off on on
6400 on on off on
12800 off on off on
25600 on off off on
51200 off off off on
1000 on on on off
2000 off on on off
4000 on off on off
5000 off off on off
8000 on on off off
10000 off on off off
20000 on off off off
40000 off off off off
6-bitDIPSwitchesin ES-D808/ES-D1008
SW1-SW4
MicrostepResolution
SW5isusedtoreverse
themotion direction.
SW6hasnofunction

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Configuring ES drivein PCSoftware
Consultthe “ConnectingtoPCSoftware”chapterforhowtoconnecttheEasyServodrivetoPC.
Supposethetuningsoftwarehasbeenopen,clickthe “Drive->Parameters”toopenthe Tool->Drive
Parameters window.Doubleclickthe Value columntomodifytheparameter.Don tforgettoclick
“DownloadtoDrive”to storethechangeto drivesNVM.Consultthe “Configuration”chapterforthe
recommendedsettings ofdifferentEasyServokit.Refertothesoftwaremanualformoreinformation
abouttheparameters.
Calculating Rotation Speed and Angle
Youmayalsowanttocalculatethemotorrotation speedand rotationangle,beforecommandingany
motion.If thepulsefrequencyand countsareknown,theycan becalculated asfollows:
Rotation Speed (RPM)=60 *Pulse(Step)Frequency/ Micro Step Resolution
Rotation Angle(°)=360 *Pulse(Step)Counts/ Micro Step Resolution

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Rotating theEasyServo Motor byMotion Controller
Noweverythingisready.You canstartthecontrollerorpulsegeneratortorotatethemotor.Actually,
anydevicewhichgiveshigh-to-loworlow-to-highlevelchangescanbeusedtomovethemotor.Ifit
isyourfirsttimeinstallation,itisrecommendedtodisconnectthemotorshaftfromtheloadincase
ofaccident.Youcanstartfromlowpulsefrequencythengoingtohigh.Onetriggerededgeofthe
pulsemakesthemotormoveonemicroangle.ThereisnominimumspeedlimitforESservo however
themaximumrunningspeedwillbedetermined bytheinputvoltageand currentsetting.
Rotating theESMotor in PCSoftware
Thereisasimpleemulatingcontrollerthatisusedforself-testintheESdrive.Itisnotafull
functionalitycontrollerbutitdoeliminatesthetroublestosetup arealmotioncontrollerwhenyou
wanttotesttheESdrivesorverifytheconnectionincaseofproblem. However,theperformancein
theemulatingcontrollerofthePCsoftwareCANNOTrepresent theactual motion controller.
Click DriveSetting->CurrentLoop /Motion Test toopen thetestwindow.Then clickthe Motion Test
tabtoopentheemulatingcontroller.Editthetrapezoidvelocityprofileand clickthe Start buttonto
issuethemotion.

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PowerSupplySelection
Toachievegooddrivingperformances,itisimportanttochooseasuitablesupplyvoltageandusea
matchingcurrentvalue.Generallyspeaking,supplyvoltagedeterminesthehighspeedperformance
ofthemotor,whileoutputcurrentdeterminestheoutputtorqueof thedriven motor(particularlyat
lowerspeed).Highersupplyvoltagewillallowhighermotorspeedtobeachieved,atthepriceof
morenoiseand heating. Ifthemotionspeedrequirementislow,it sbettertouselowersupply
voltageto decreasenoise,heatingand improvereliability.
Regulated or Unregulated Power Supply
Bothregulatedandunregulatedpowersuppliescanbeusedtosupplythedrive.Ifregulatedpower
supplies(suchasmostswitchingsupplies.)areindeedused,itisimportanttohavelargecurrent
outputratingtoavoidproblemslikecurrentclamp,forexampleusing4Asupplyfor3Amotor-drive
operation.Ontheotherhand,ifunregulatedsupplyisused,onemayuseapowersupplyoflower
currentratingthan thatofmotor(typically50% 70%of motorcurrent).Thereasonisthatthedrive
drawscurrentfromthepowersupplycapacitoroftheunregulatedsupplyonlyduringtheON
durationofthePWMcycle,butnotduringtheOFF duration.Therefore,theaveragecurrent
withdrawnfrompowersupplyisconsiderablyless thanmotorcurrent.Forexample,two3Amotors
can bewell supplied byonepowersupplyof 4Arating.
MultipleDrives
Itisrecommendedtohavemultipledrivestoshareonepowersupplytoreducecost,ifthesupply
hasenoughcapacity.Toavoidcross interference,DONOTdaisy-chainthepowersupplyinputpinsof
thedrives. Instead,pleaseconnectthemto powersupplyseparately.
Selecting SupplyVoltage
Highersupplyvoltagecanincreasemotortorqueathigherspeeds,thushelpfulforavoidinglosing
steps. However,highervoltagemaycausebiggermotorvibrationatlowerspeed,anditmayalso
causeover-voltageprotectionorevendrivedamage.Therefore,itissuggestedtochooseonly
sufficientlyhighsupplyvoltageforintendedapplications,and itissuggestedtousepowersupplies
withtheoreticaloutputvoltageofdrivesminimum+10%todrivesmaximum –10%,leavingroom
forpowerfluctuation and back-EMF.

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SelectPowerSupplyVoltage
DriverInputVoltage
DriverUpperInput limit
PowerSupplyVoltage
Heating
Vibration
MaximumSafeRating
DriverUpperInput limit 10%
DriverLowerInputlimit +10%
DriverLowerInputlimit
MinimumSafeRating
Torque
Speed
SafeRegion
DriverInputVoltage
DriverUpperInput limit
PowerSupplyVoltage
Heating
Vibration
MaximumSafeRating
DriverUpperInput limit 10%
DriverLowerInputlimit +10%
DriverLowerInputlimit
MinimumSafeRating
Torque
Speed
SafeRegion
Recommended SupplyVoltage
BothLeadshinesregulatedand unregulatedpowersupplyhasbeendesignedspeciallyformotion
control.
Motor Drive VoltageRange TypicalVoltage LeadshinePowerSupply
ES-M32309 ES-D508 DC(20-50)V DC24V RPS2410(-L)
ES-M32320 ES-D508 DC(20-50)V DC36V RPS369
ES-M22310 ES-D808 DC(30-80)V DC36V RPS369
ES-M22320 ES-D808 DC(30-80)V DC36V RPS369
ES-M23440 ES-D808 DC(30-80)V DC60V RPS608
ES-M23480 ES-D808 DC(30-80)V DC60V RPS608
Wiring Notes
lIn orderto improveanti-interferenceperformanceof thedrive,itisrecommendedto usetwisted
pair shield cable.
lTopreventnoiseincurredinPUL/DIRsignal,pulse/directionsignalwiresand motorwiresshould
notbetiedup together.Itisbettertoseparatethembyatleast10 cm,otherwisethedisturbing
signalsgeneratedbymotorwilleasilydisturbpulsedirectionsignals, causingmotorposition
error,systeminstabilityand otherfailures.
lIfapowersupplyservesseveraldrives,separatelyconnectingthedrivesisrecommendedinstead
of daisy-chaining.
lItisprohibitedtopull and plugpowerconnectorwhilethedriveispoweredON,becausethereis
highcurrentflowingthroughmotorcoils(evenwhenmotorisatstandstill).Pullingorplugging
powerconnectorwithpoweronwill causeextremelyhighback-EMFvoltagesurge,whichmay
damagethedrive.