Motion DM805-A User manual

Software Operation Manual
For DM805-AI
A Digital Stepper Drive With
Analogue 0-5V Input
V1.0-150324
(March 2015)
Motion Control Products Ltd.
Innovative products for Automation Industry
Tel.: [phone]

DM805-AI Digital Stepper Drives Software Operation Manual
Motion Control Products Ltd. Tel.: [phone]
The contents in this manual have been carefully prepared and are believed to be accurate,
but no responsibility is assumed for inaccuracies.
Motion Control Products Limited reserves the right to make changes without further
notice to any products herein to improve reliability, function or design. Motion Control
Products Limited 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.
Motion Control Product’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 Motion Control Product’s terms and
conditions of sales, the user of Motion Control Product’s products in life support or
aircraft applications assumes all risks of such use and indemnifies Motion Control
Products Limited against all damages.
Copyright © 2015 Motion Control Products Ltd. All rights reserved.
Motion Control Products Ltd
11-15 Francis Avenue
Bournemouth, Dorset, UK BH11 8NX
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
www.motioncontrolproducts.com

DM805-AI Digital Stepper Drives Software Operation Manual
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Contents
1. INTRODUCTION AND THE FUNCTIONS ........................................................ 1
Introduction.......................................................................................................1
Work Platform ...................................................................................................1
Menus and Toolbar............................................................................................2
2. HOW TO USE THE SOFTWARE ..................................................................... 3
Open a file .........................................................................................................3
Save as a file ......................................................................................................3
Connecting Drive ...............................................................................................3
Current Loop Tuning Window............................................................................4
Properties Window ............................................................................................6
Offset.................................................................................................................7
Save to Drive......................................................................................................8
Restore Factory Setting......................................................................................8
3. HOW TO CONFIGURE THE DRIVE................................................................. 8
Set Motor Parameters .......................................................................................8

Table of Contents
Motion Control Products Ltd. Tel.: [phone]
Tuning Current Loop..........................................................................................9
Anti-resonance Tuning ....................................................................................16
Adjusting Electronic Damping..........................................................................18

DM805-AI Digital Stepper Drives Software Operation Manual
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1. INTRODUCTION AND THE FUNCTIONS
Introduction
The ProTuner is a software tool designed to configure and tune our DMD & DM series
digital stepper drives including DM805-AI. The user can tune the current loop and adjust
the anti-resonance parameters via this software.
Work Platform
After installing the software and open it, the software is displayed as follows.
Menu Bar & Toolbar
Properties Window

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Menus and Toolbar
Menus and toolbar are at the top of the workspace. You can click menu bar to view pull-
down menu. The toolbar below offers the most frequency used commands.
Menu
Drop-down Menu
Function
File ->
Open
Open a file
Save As
Save as a file
Exit
Exit the software
View->
Error Log
Check the drive error log.
Drive Information
DM805-AI specification
Drive ->
Connect To Drive
Connect to drive
Current Loop Tuning
Configure current loop parameters
Proportional Gain & Ki and test.
Properties
Set drive properties like I/O logic, motor
parameters.
Offset
Check analog and potentiometer offset.
Save to Drive
Save all data to drive
Restore Factory
Setting
Restore factory settings
Help->
About
Software Information

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!
Notice
2. HOW TO USE THE SOFTWARE
Open a file
If you want to load the configuration data from a file in the PC, click on the File->Open. The
parameters in the software’s workspace will be updated.
Save as a file
Click Drive->Save As to save the data in current workspace to a file and rename it.
Connecting Drive
Connect to Drive window appears every time when you open ProTuner. Select the serial
port, leave the baud rate as default 38400 and click on the Open button. The software will
connect to the drive and read the settings. It may take several minutes.
Before connecting the drive, please make sure:
1) The RS232 cable .has been connected between the drive and PC
serial port;
2) Power has been applied to the drive and the green LED is on.

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Caution
The motor is no need to connect to the drive if you just want to change
the parameters but not tuning.
Do not connect or disconnect serial cable when drive is powered on. The
drive’s communication circuit may be damaged.
Current Loop Tuning Window
It is used to configure current loop parameters according to different motor. In the tuning
window, user can set proportional gain, integral gain and test value.
NOTES: After finishing the input of the number, don’t forget to hit the “Enter” key in the
keyboard to confirm new value.
Red Curve:
Target current
of step test
Green Curve:
Actual current
of step test

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Item
Description
Range
Proportional
Gain
Increase Proportional Gain (Kp) to make current rise
fast. Proportional Gain determines the response of the
drive to current setting command. Low Proportional
Gain provides a stable system (doesn’t oscillate), has
low stiffness, and large current error, causing poor
performances in tracking current setting command in
each step. Too large Proportional Gain values will cause
oscillations and make the system unstable.
1 –65535
Integral Gain
Adjust this parameter to reduce the steady error.
Integral Gain helps the drive to overcome static current
errors. A low or zero value for the Integral Gain may
have current errors at rest. Increasing the Integral Gain
can reduce the error. If the Integral Gain is too large,
the systems may “hunt” (oscillate) about the desired
position.
1 –65535
Test Value
The current amplitude for the step response. T his
value sh o uld not exceed the maximum output
current of the drive.
0.5 –5A
Test Button
Click this button to activate the test. A target curve (red)
and an actual curve (green) will be displayed on the
screen for user’s analysis.
-

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Properties Window
The user can set the drive’s anti-resonance parameters, output current, microstep,
electronic damping and stop mode according the motor and application.
NOTES: Microstep setting is only effective in Pulse/Direction mode.
Item
Description
Range
The 1st
Resonance Area
It is usually between 0.6 to 1.2 RPS.
-
The 2nd
Resonance Area
It is usually between 1.2 to 2.4 RPS.
-
The 3rd
Resonance Area
It is usually between 2.4 to 4.8 RPS.
-
Amplitude
Amplitude adjustment for anti-resonance tuning. 0 - 3500 for the
1st, 2nd resonance area and 0 -256 for the 3rd resonance area.
The user can enter a value directly in the text box or move the
slider bar back and forth to get an optimum value.
0 -3500
or 0- 256

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Phase
Phase adjustment for anti-resonance tuning. The user can enter
a value directly in the text box or move the slider bar back and
forth to get an optimum value.
0-1608 or
0-256
Dynamic Current
Drive’s output current setting according to the motor. It should
be less than the motor’s related current * 1.414
Note: The DIP switch setting must be SW1 = off, SW2 = off, SW3
= off if you want to set this parameter in ProTuner.
0.5 - 7.0 A
MicroStep
Drive’s Microstep setting for the motor.
Note 1: The DIP switch setting must be SW5 = off, SW6 = off,
SW7 = off, SW8 = off if you want to set this parameter in
ProTuner.
Note 2: The microstep is effective only in Pulse/Direction mode.
1 - 512
Electronic
Damping
Adjust this parameter to improve the drive’s high speed
performance. The optimal value depends on the system.
0 - 6000
Stop Mode
The motor stops immediately when a stop command is applied
to the drive if this parameter is immediate stop. Otherwise the
motor stops with acceleration set by the Accel/Ramp or
Decel/LoSpeed potentiometers.
-
Offset
It is used to check the offset of the potentiometers and analog input in factory. The user
can ignore it.

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Notice
Save to Drive
After the drive’s configuration and tuning is done, you need to click Drive->Save To Drive to
save the data to drive’s nonvolatile memory. Otherwise the data will not be lost after
power-off.
Restore Factory Setting
This command is used to restore the factory data when the drive is out of control or the
user want to do that.
3. HOW TO CONFIGURE THE DRIVE
If it is the first time setup, you can follow the steps below to configure the drive.
1) Set motor’s parameters like dynamic current, Microstep and stop mode according
to the motor’s application.
2) Tune the current loop parameters with the connected motor.
3) Tune the anti-resonance parameters if necessary.
4) Adjust the electronic damping when the high speed performance is not good.
1. The motor must be connected to the drive before trying to
configure the drive.
2. After finishing the input of the number, don’t forget to hit the
“Enter” key in the keyboard to confirm new value
Set Motor Parameters
Click Drive->Properties to open the Property window. You can set the motor’s dynamic
current, microstep and stop mode.

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!
Notice
!
Notice
The motor’s dynamic current is related to the RMS current. Usually, the motor
manufacturer states the RMS (root mean square) current in the datasheet. Please refer to
the hardware installation manual for how to set the dynamic current.
The DIP switch setting must be put as SW1 = off, SW2 = off, SW3 = off, if
you want to set Default/software configured current parameter in
ProTuner Properties Window
The microstep is so important and is ONLY effective in Pulse and Direction command mode.
High resolution microstep makes the motor move more smoothly. Low microstep
resolution reduces the high frequency requirement to the controller.
1. The DIP switch setting must be put as SW5= off, SW6= off, SW7= off,
SW8= off, if you want to set Default/software configured microstep
parameter in ProTuner Properties Window
2. The microstep is effective only in Pulse/Direction mode
The motor stops in the acceleration set by the potentiometer. If the application needs fast
stop, please click Immediate Stop.
Tuning Current Loop
The current loop parameter on DM805-AI stepper drive needs to be tuned before normal
operation in order to optimise the responses with different motors. Otherwise motor will
be easily stalled or howls WHEN it is powered up. Below example is the tuning process of
DM805-AI with a NEMA 23 motor at 24VDC supply voltage.

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Step 1: Set Test Current 1 and start the tuning with small Proportional Gain and “zero”
Integral Gain. Here we set Proportional Gain=500.
Step 2: Click the Test button and the plot window will show two curves. The red curve is
“target current”and the green curve is “actual current”. There is a big gap
between them in the scope. It indicates that a larger Proportional Gain needs to be
introduced.
Initial Value:
Proportional
Gain =500
Integral Gain
=1
Start Test:
Proportional
Gain = 500
Integral Gain=
1

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Step 3: Increase Proportional Gain to 1000 and click Start. The gap between target value
and actual value is smaller but a higher Proportional Gain is still needed.
Step 3: Give Proportional Gain 2000, 3000, 4000 and click Test button, respectively. The
green curve is getting closer and closer to the red curve. Over-shoot is obvious
when we increase Proportional Gain to 4000. It indicates that you need to stop
increasing Proportional Gain and back off. Our purpose is to make the green
curve (the actual current) a little higher than the red curve (the target). So we
decrease Proportional Gain to 3700 until the actual value is exactly over the
target value.
Proportional
Gain= 1000
Integral Gain = 1
Proportional
Gain= 2000
Integral Gain =1

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Over -shoot
Proportional
Gain= 3000
Integral Gain =1
Proportional
Gain= 4000
Integral Gain =1

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Step 4: Now the Proportional Gain is relatively good enough. But there is still some gap
between the green curve and the red curve when we use the mouse to zoom in
the green curve. So we need to introduce Integral Gain to reduce the “gap”
or steady error at the constant part. It follows the same procedure as
Proportional Gain. High Proportional Gain causes big vibration, system lag and
makes the performance worse. The following figures show how to tune the
Integral gain.
Drag a triangle to zoom in
Proportional
Gain= 3700
Integral Gain =1

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Zero Integral Gain:
Proportional Gain
=3700
Integral Gain =1
↑Integral Gain:
Proportional Gain
=3700
Integral Gain =200

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Step 5: The current loop tuning is basically finished. You can continue to adjust
Proportional Gain and Integral Gain for better performance. Now the updated
Proportional Gain and Integral Gain is just stored in the drive’s RAM. The data will
be lost when we power off the drive. Don’t forget to click Drive->Save To Drive
to store the changed value to the drive’s EEPROM.
Further
adjustment:
Proportional Gain
=3500
Integral Gain =300
↑Integral Gain:
Proportional Gain
=3700
Integral Gain =400

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Notice
Anti-resonance Tuning
Stepper motors are highly resonant, which results in vibration and ringing. The ringing
utilizes a large fraction of the motor's available torque –thereby wasting performance.
Furthermore, at mid-range velocities, the resonance can become so severe that the motor
looses synchronisation and stalls. The DM805-AI digital stepper drive provides robust anti-
resonance control to stop the vibrations and maintain equilibrium. This feature requires
that the drive be configured with respect to the total inertia in the system. If it is set
improperly, the effectiveness of the feature may be diminished.
1. For most of the application, it is not needed to tune DM805-AI
stepper drive’s anti-resonance parameters. We only recommend
the advance user to use this function as it is a boring process.
2. In most of the case, only the tuning of the 1st and 2nd anti-resonance
area has the obvious effects
Step 1: Connect the drive as follows and configure it in Low/High Speed mode by set SW7
= OFF and SW8 = ON. As the Speed input is connected to Signal GND, the motor
speed is determined by the LoSpeed potentiometer and it can be adjusted from
0RPS to 5RPS.
Save all the changes to
the drive’s non-violated,
non-volatile memory.