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
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Fax: [phone]
E-mail: [email protected]
www.motioncontrolproducts.com

DM805-AI Digital Stepper Drive Hardware Operation Manual
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!
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
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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

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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

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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
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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

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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

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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);

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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

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4. OPERATING MODE
Mode
SW7
SW8
Description
0~5V Speed
on
on
Analogue 0-5V Speed Mode
Lo/Hi Speed
off
on
Low and High Speed Mode
External POT
on
off
External Potentiometer Speed Mode
Pulse/Direction
off
off
Pulse and Direction Position Mode
Analogue 0-5V Speed Mode
In this mode motor speed follows the analog 0-5V input voltage. Motor speed is also
proportional to the HiSpeed potentiometer. Direction input controls the motor direction.
The actual motor speed is calculated as follows:
Speed(RPS)=
25±0.5(RPS)
X
Analogue Input
x
Turns of HiSpeed Potentiometer
5V
25Turns
Auto Tuning: Switch SW4 two times in one
second.
RS232 communication port: RJ11,
communicating PC software
Note: It is used to configure and current loop tuning,
anti-resonance tuning with the PC software.
However, the drive can still work properly without it.
The DM805-AI can be fully tuned by the auto-tuning.
DIP switch: 8 bits, current setting, selecting
microstep, operating mode

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Signal Sequence
After power-up, the DM805-AI does not response to the analog 0-5V input immediately.
The Enable and Run signal should be activated prior to the analog 0-5V input. The drive is
enabled when the Enable/Disable input is unconnected and the motor shaft has holding
torque at that time. After Run signal is active, the motor speed follows the analog 0-5V
input.
Ramp Shaping
There are two potentiometers Accel and Decel for adjusting the acceleration ramp and
deceleration ramp, respectively. When the input ramp exceeds the value set by the

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potentiometer, the actual output ramp will be limited by the potentiometer value.
Low/High Speed Mode
In low/high speed mode, motor speed is fixed to the value adjusted by the LoSpeed or
HiSpeed Potentiometer, depending on the level of Speed input. When the Speed input is
LOW level, the maximum motor speed adjusted by the LoSpeed potentiometer is 5rps.
When the Speed input is HIGH level, the maximum motor speed adjusted by the
HighSpeed is 25rps.

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Signal Sequence
After powering up, the DM805-AI does not make the motor run immediately. The Enable
and Run signal should be activated firstly. Drive is enabled when the Enable/Disable input
is unconnected. After Run signal is activated, the Speed can be applied to the drive for
low/high speed selection
Ramp Shaping
When motor speed switches between low and high or changes direction, the
acceleration/deceleration ramp adjusted by the Ramp potentiometer will be inserted
automatically for smooth motion.
Note: Do not adjust too small or too high Ramp. Otherwise the stepper motor may stall
when switching between low and high speed.

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External Potentiometer Mode
In this mode motor speed follows the analog 0-5V input voltage. Motor speed is also
proportional to the HiSpeed potentiometer. When the analog input is 0-2.5V, the motor
runs in negative direction. While the analog input is 2.5-5V, the motor runs in positive
direction.

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Signal Sequence
Ramp Shaping
There are two potentiometers Accel and Decel for adjusting the acceleration ramp and
deceleration ramp, respectively. When the input ramp exceeds the value set by the
potentiometer, the actual output ramp will be limited by the potentiometer value.
Pulse/Direction Mode
In this mode motor speed is the proportional to the pulse input frequency and motor rotary
angle is controlled by the pulse counts. The microstep can be selected by the DIP switch
SW5 and SW6.

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5. CONTROL SIGNAL REQUIREMENT
Pulse/Direction Mode
DM805-AI can support Pulse/Direction and CW/CCW control signal modes. In order to
avoid some fault operations and deviations, PUL, DIR and ENA should abide by some rules,
shown as following diagram:
Remark:
a) ENA must be ahead of DIR by at least 5us. Usually, ENA+ and ENA- are NC (not
connected).
b) DIR must be ahead of PUL active edge by 5us to ensure correct direction;
c) Pulse width not less than2.5us;
d) Low level width not less than 2.5us.

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6. CONNECTING THE MOTOR
The DM805-AI stepper drive can drive any 2-pahse and 4-pahse hybrid stepper motors.
4-lead Motors Connections
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.
6-lead Motors Connections
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 setting the drive output current multiply the specified
per phase (or unipolar) current rating by 1.4 to determine the peak output current.

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Full Coil Configurations
The full coil configuration on a 6-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 issue.
8-lead Motors Connections
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 issue.

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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.
NEVER disconnect or connect the motor while the power source is energized.
7. POWER SUPPLY CONNECTION
The DM805-AI digital stepper drive can match small and medium size stepper motors
(from NEMA frame size 14 to 34) supplied by Motion Control Products Ltd or other motor
manufactures around the world. To achieve good performance, it is important to select
the correct supply voltage and output current. Generally speaking, the supply voltage
determines the high speed performance of the motor, whilst the output current
determines the output torque of the motor (particularly at lower speed). Higher supply
voltage will allow higher motor speeds to be achieved, at the price of more noise and
heating. If the speed requirement is low, it is better to use a 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 power 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 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, with an unregulated supply, a
power supply of lower current rating than that of the motor can be used (typically 50% -
70% of motor current). The reason is that the drive draws current from the power supply