Motion DM805-AI Assembly instructions

Hardware Installation Manual
For DM805-AI
A Digital Stepper Drive With
Analogue 0-5V Input
V1.0-150323
(March 2015)
Motion Control Products Ltd.
Innovative products for Automation Industry
Tel.: [phone]

DM805-AI Digital Stepper Drive Hardware Operation Manual
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 Drive Hardware Operation Manual
Motion Control Products Ltd. www.motioncontrolproducts.com
!
Notice
!
Caution
!
Warning
HEALTH AND SAFETY
Read this manual carefully before trying to install the stepper drive into
your system. The person setup the stepper drive should have a better
understanding on electronics and mechanics. Contact us if there is any
question about the products or this manual.
Make sure the power supply voltage does not exceed the drive’s
input range. Double check the connections and make sure the
power lead polarity is correct.
Disconnect the motor from the load if you are not sure the move
direction. Adjust the axis in the middle before trying to run the
motor.
Do NOT set high current on small stepper motor as this may damage
the motor.
Never disconnect the motor wires when the power is on.

DM805-AI Digital Stepper Drive Hardware Operation Manual
Motion Control Products Ltd. Tel.: [phone]
Contents
1. INTRODUCTION, FEATURES AND APPLICATIONS ..........................................1
Introduction.......................................................................................................1
Features.............................................................................................................1
Applications.......................................................................................................2
2. SPECIFICATIONS..........................................................................................2
Electronic Specification Tj = 25℃/77℉.............................................................2
Velocity Control.................................................................................................2
Operating Environment .....................................................................................3
Outline Dimensions ...........................................................................................3
Elimination of Heat............................................................................................3
3. CONNECTORS AND PIN ASSIGNMENT ..........................................................4
4. OPERATING MODE......................................................................................5
Analogue 0-5V Speed Mode ..............................................................................5
Signal Sequence.............................................................................................6
Ramp Shaping................................................................................................6
Low/High Speed Mode ......................................................................................7
Signal Sequence.............................................................................................8
Ramp Shaping................................................................................................8
External Potentiometer Mode...........................................................................9
Signal Sequence...........................................................................................10
Ramp Shaping..............................................................................................10
Pulse/Direction Mode .....................................................................................10
5. CONTROL SIGNAL REQUIREMENT ..............................................................11

DM805-AI Digital Stepper Drive Hardware Operation Manual
Motion Control Products Ltd. www.motioncontrolproducts.com
Pulse/Direction Mode......................................................................................11
6. CONNECTING THE MOTOR........................................................................ 12
4-lead Motors Connections .............................................................................12
6-lead Motors Connections .............................................................................12
Half Coil Configurations ...............................................................................12
Full Coil Configurations ................................................................................13
8-lead Motors Connections .............................................................................13
Series Connections.......................................................................................13
Parallel Connections ....................................................................................14
7. POWER SUPPLY CONNECTION .................................................................. 14
Regulated or Unregulated Power Supply.........................................................14
Multiple Drives ................................................................................................15
Selecting Supply Voltage..................................................................................15
8. TYPICAL CONNECTION .............................................................................. 16
Analogue 0-5V Speed Mode ............................................................................16
Low/High Speed Mode ....................................................................................17
External Potentiometer Mode .........................................................................18
Pulse/Direction Mode......................................................................................19
9. WIRING NOTES......................................................................................... 20
10. DRIVE CONFIGURATION.......................................................................... 20
Auto Configuration by SW4 .............................................................................21
Selecting Operating Mode ...............................................................................21
Microstep Resolution Selection .......................................................................22
Current Settings...............................................................................................22
Dynamic current setting ..............................................................................22
Idle current setting ......................................................................................23

DM805-AI Digital Stepper Drive Hardware Operation Manual
Motion Control Products Ltd. Tel.: [phone]
11. PROTECTION FUNCTIONS ........................................................................23
Over-current Protection ..............................................................................23
Over-voltage Protection ..............................................................................23
Protection Indications .................................................................................24
12. FREQUENTLY ASKED QUESTIONS .............................................................24
Problem Symptoms and Possible Causes ........................................................25
APPENDIX ....................................................................................................26
Twelve Month Limited Warranty.....................................................................26
Exclusions ........................................................................................................26
Shipping Failed Product & Obtaining Warranty Service ..................................26
Warranty Limitations.......................................................................................26

DM805-AI Digital Stepper Drive Hardware Operation Manual
Motion Control Products Ltd. P a g e | 1www.motioncontrolproduts.com
1. INTRODUCTION, FEATURES AND APPLICATIONS
Introduction
Motion Control Products Ltd (MCP)’s digital stepper drive DM805-AI is a digital stepper
drive with built-in oscillator, featured in supporting 0-5V analogue signal for speed
controls. Using the latest digital control algorithm, it brings a unique level of system
smoothness, providing optimum torque and nulls mid-range instability. The self-test and
auto-configuration 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 drivers on the markets.
The three built-in potentiometers are used to pre-set and adjust the velocity, acceleration
and deceleration. In 0-5V speed mode, the motor speed is controllable and follows the
analogue 0-5V input. In high/low speed mode, the motor speed is selected by digital input
and adjusted by the high/low speed potentiometers. The user can run the motor with the
least configuration and connection. In position mode, the DM805-AI digital stepper drive
can be used as a traditional stepper drive. There is a 5V power supply output for
customer’s use.
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
Command Source: 0-5V, built-in potentiometer and pulse
Two preset velocity and adjust by built-in potentiometer
Preset acceleration/deceleration and adjust by built-in potentiometer
Velocity control mode via 0-5V and position control mode via pulse Built-in pulse
generator nulls external motion controller
Supply voltage up to +80 VDC
Output current programmable, from 0.3A -5.0A (RMS)
TTL compatible and optically isolated digital input
Automatic current reduction
Over-voltage, over-current, phase-error protections

DM805-AI Digital Stepper Drive Hardware Operation Manual
Motion Control Products Ltd. P a g e | 2Tel.: [phone]
Applications
DM805-AI stepper drive is suitable for the application which needs to adjust the velocity
via the potentiometer or analogue 0-5V command. It can work with the size NEMA
17/23/34 stepper motors to replace the brushless motor with gearbox, due to the nature
of its high torque and less motor noise at low speed. It can be used in various kinds of
machines, such as rotary heat exchange, conveyor belts, transport vehicle, laser cutters,
laser markers, high precision X-Y tables, labeling machines and so on.
2. SPECIFICATIONS
Electronic Specification Tj = 25℃/77℉
Parameters
DM805-AI
Minimum
Typical
Maximum
Input voltage (VDC)
+ 18
+ 60
+80
Logic signal current (mA)
7
10
16
Pulse input frequency (kHz)
0
-
200
Isolation resistance ( M Ω)
500
-
-
Velocity Control
Item
Specification
Dead Band
Resolution
Min
Max
Analogue
input
0-5V Speed
Mode
0-5 V
10 mV
10 mV
0 Rev/s
25 ±0.5
Rev/s
External POT
Mode
20 mV
Accel / Decel / Ramp
Potentiometer
0-25 turns
10 mV
10 mV
0.5 Rev/s2
250 ±1
Rev/s2
Low-Speed
Potentiometer
0-25 turns
10 mV
10 mV
0 Rev/s
5 ±0.01
Rev/s
High-Speed
Potentiometer
0-25 turns
10 mV
10 mV
0 Rev/s
25 ±0.5
Rev/s

DM805-AI Digital Stepper Drive Hardware Operation Manual
Motion Control Products Ltd. P a g e | 3www.motioncontrolproduts.com
Operating Environment
Cooling
Natural Cooling or Forced cooling
Operating Environment
Environment
Avoid dust, oil fog and corrosive
gases
Ambient Temperature
0ºC－50ºC (32ºF－122ºF)
Humidity
40%RH－90%RH
Operating Temperature
70˚C (158˚F) Max
Vibration
5.9m/s2 Max
Storage Temperature
-20ºC －65ºC (-4ºF －149ºF)
Weight
Approx. 350g (12.34 oz)
Outline Dimensions
Elimination of Heat
Drive’s reliable working temperature (heat sink) should be <70°C (158°F), and
motor working temperature (surface) should be <80°C (176°F);

DM805-AI Digital Stepper Drive Hardware Operation Manual
Motion Control Products Ltd. P a g e | 4Tel.: [phone]
It is recommended to use automatic idle-current mode, namely current
automatically reduce to 60% when motor stops, so as to reduce driver heating
and motor heating;
It is recommended to mount the driver vertically to maximize heat sink area.
Use forced cooling method to cool the system if necessary.
3. CONNECTORS AND PIN ASSIGNMENT
The DM805-AI has three connectors, connector for digital I/O signals connections,
connector for analog 0-5V signal connections and connector for power and motor
connections. The three parameters are used to preset or adjust the speed, acceleration
and deceleration ramp. They have different functions in different modes. The green
indicator turns on when the drive is powered on. When error happens, the red indicator
flashes periodicity to indicate the error type.
Indicator in Green: Power on, In Red: Faulty
Potentiometers Adjusting Speed: Acceleration and
Deceleration
Digital I/O Signal Connector: 6-pin screw terminal, 3.81
mm space
Analogue Signal Connector: 6-pin screw terminal, 3.81
mm space
Power Connector: 6-pin screw terminal, 3.81 mm space