NANOTEC PD4-N5918X4204 User manual

Technical Manual
Plug & Drive Motors
PD4-N
NANOTEC ELECTRONIC GmbH & Co. KG
Kapellenstraße 6
D-85622 Feldkirchen b. Munich, Germany
Tel. [phone]
Fax [phone]
[email protected]

Technical Manual
PD4-N5918
Editorial
2 Issue: V 1.4
Editorial
©2011
Nanotec®Electronic GmbH & Co. KG
Kapellenstraße 6
D-85622 Feldkirchen b. Munich, Germany
Tel.: [phone]
Fax: [phone]
Internet: www.nanotec.com
All rights reserved!
MS-Windows 2000/XP/Vista are registered trademarks of Microsoft Corporation.
Translation of the original operation manual
Version/Change overview
Version Date Changes
1.0 11/16/2009 New issue C+P
1.1 04/12/2010 Operating voltage; CANopen firmware
1.2 04/23/2010 Wire colors ZK-PD4N
1.3 11/02/2010 Revision RS485/CANopen
1.4 11/03/2011 Revision C+P

Technical Manual
PD4-N5918
About this manual
Issue: V 1.4 3
About this manual
Target group
This technical manual is aimed at designers and developers who need to operate a
Nanotec®stepper motor without much experience in stepper motor technology.
Important information
This technical manual must be carefully read before installation and commissioning of
the Plug & Drive motor.
Nanotec®reserves the right to make technical alterations and further develop
hardware and software in the interests of its customers to improve the function of this
product without prior notice.
This manual was created with due care. It is exclusively intended as a technical
description of the product and as commissioning instructions. The warranty is
exclusively for repair or replacement of defective equipment, according to our general
terms and conditions; liability for subsequent damage or errors is excluded. Applicable
standards and regulations must be complied with during installation of the device.
For criticisms, proposals and suggestions for improvement, please contact the above
address or send an email to: [e-mail]
Additional manuals
Please also note the following manuals from Nanotec:
NanoPro
User Manual
Configuration of controllers with the
NanoPro software
NanoCAN User Manual Configuration of the CAN
communication for CANopen-
capable controllers with the
NanoCAN software
Nanotec CANopen
reference
Detailed documentation of the
CANopen functions
Programming manual
Controller programming
•Command reference
•NanoJ
•COM interface
The manuals are available for download at www.nanotec.com.

Technical Manual
PD4-N5918
Contents
4 Issue: V 1.4
Contents
1Overview ............................................................................................................................... 5
2Connection and commissioning ........................................................................................ 8
2.1 Overview ................................................................................................................................ 8
2.2 Connection diagram............................................................................................................... 9
2.3 Commissioning..................................................................................................................... 10
3Connections and circuits .................................................................................................. 14
3.1 Inputs and outputs (JST PHD-12)........................................................................................ 14
3.2 Power supply (Phoenix connector) ...................................................................................... 16
3.3 RS485 network/CANopen (JST PHD-8) .............................................................................. 17
4Operating modes................................................................................................................ 21
4.1 Serial operating modes ........................................................................................................ 21
4.2 CANopen operating modes.................................................................................................. 23
5Troubleshooting.................................................................................................................24
6Technical data .................................................................................................................... 26
Index...................................................................................................................................................... 31

Technical Manual
PD4-N5918
Overview
Issue: V 1.4 5
1 Overview
Introduction
The PD4-N Plug & Drive motor includes, in addition to the integrated power end stage,
a complete, network-capable closed-loop speed and positioning control.
The PD4-N not only significantly reduces development and installation outlay, but also
space and component requirements. It also increases flexibility, system properties and
the availability of a complete drive unit. Replacement of existing drive solutions is easy
with the mechanical and electrical compatibility with standard motors.
Variants
The PD4-N is available in the following variants that differ in holding torque, weight
and length (see Section 6 “Technical data"):
•PD4-N5918X4204
•PD4-N5918M4204
•PD4-N5918L4204
•PD4-N6018L4204
Firmware variants
The Plug & Drive motor can be operated with the following firmware variants:
•RS485 firmware
•CANopen firmware
Functions of the PD4-N
The PD4-N Plug & Drive motor has the following functions:
•Microstep 1/1 – 1/64 Final output stage (0.014° step resolution)
•Closed-Loop current control (sinusoidal commutation via the encoder)
•Powerful DSP microprocessor for flexible I/O
•Sequence programs with NanoJ (RS485)
•Integrated encoder for rotation monitoring and Closed-Loop current control
•RS485/CANopen interface for parameterization and control (USB connection
possible via converter cable ZK-RS485-USB)
•Network capability with up to 254 motors (RS485) or 127 motors (CANopen)
•Easy programming with Windows software NanoPro (RS485) or NanoCAN
(CANopen)

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Overview
6 Issue: V 1.4
Closed-Loop current control (sinusoidal commutation via the encoder):
In contrast to conventional stepper motor positioning controls where only the motor is
actuated or the position adjusted via the encoder, sinusoidal commutation controls the
stator magnetic field via the rotary encoder as in a servomotor. The stepper motor acts
in this operating mode as nothing more than a high pole servomotor, i.e. the classic
stepper motor noises and resonances vanish. As the current is controlled, the motor
can no longer lose any steps up to its maximum torque.
If the controller recognizes that the rotor is falling behind the stator field due to
overload, adjustments are made with optimal field angle and increased current. In the
opposite case, i.e. if the rotor is running forward due to the torque, the current is
automatically reduced so that current consumption and heat development in the motor
and controller are much lower compared to normal controlled operation.
With dspDrive®, the motor current is controlled directly by a digital signal processor.
Unlike conventional ICs, which resolve the winding current measurement and the
target current value with only 6 or 8 bit, the new dspDrive®performs the entire control
with a resolution of 12 bit. The parameters of the PI current controller can be adjusted
to the motor and by the user as a function of the rpm.
This has the following application advantages:
•Very smooth, low-resonance operation with a sinusoidal current in the windings,
even at low speeds.
•Very good step angle accuracy and synchronization, even in open-loop operation.
The integrated programming language NanoJ, based on the Java standard, means
complete application programs can be realized on the drivers that can be executed
independently without a higher-order controller.
The programs can be created, compiled directly and written to the controller with the
free NanoJEasy editor.
NanoJ is only supported by the RS485 firmware.
More detailed information can be found in the separate programming manual.

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PD4-N5918
Overview
Issue: V 1.4 7
Activation via CANopen
It is possible to include the stepper motor control in a CANopen environment with the
PD4-N. The connection can be established either via 2 wires of the I/O connection
cable or in a customer-specific version also via an M12 connector (5-pole).
More detailed information on this can be found in the CANopen reference and in the
NanoCAN user manual.
In addition, the Plug & Drive motor via CANopen has another safety function: Even
when the voltage supply of the PD4-N is interrupted, the processor continues to be
supplied with power via the communication line and the position data cannot be lost so
that the machine does not need to be referenced after being switched on.
Settings
The operating behavior of the motor can be set and optimized according to individual
requirements by setting the motor-related parameters. The parameters can be set
using the NanoPro or NanoCAN software and significantly reduce commissioning
time.
More detailed information on this can be found in the separate NanoPro or NanoCAN
user manual.
Rotation monitoring
Even if stepper motors do not lose steps during normal operation, the integrated
speed control provides additional security in all operating modes, e.g. against motor
stalling or other external sources of error. The monitoring function detects a stalled
motor or step loss after tenth of a step at the most (for 1.8° stepper motors with 500
pulses/rotation).
Automatic error correction is possible after the drive profile is ended or during the
drive.

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Connection and commissioning
8 Issue: V 1.4
2 Connection and commissioning
2.1 Overview
Plug connections
The PD4-N Plug & Drive motor is equipped with the following plug connections:
•JST PHD-12: inputs and outputs
•JST PHD-8: RS485/CANopen
•Phoenix connector: power supply
Configuration
The following figure shows the configuration of the connectors:
Connection cable
For making the connection, you need the PD4-N cable set (order number: ZK-PD4-N).

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Connection and commissioning
Issue: V 1.4 9
2.2 Connection diagram
To operate the Plug & Drive motor, you must implement the wiring according to the
following connection diagram.

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Connection and commissioning
10 Issue: V 1.4
2.3 Commissioning
Introduction
The connection and commissioning of the PD4-N Plug & Drive motor are described
below.
This section describes the main first steps you need to take to be able to quickly begin
working with the PD4-N if you want to work with the NanoPro (RS485) or NanoCAN
(CANopen) software from a PC. You will find more detailed information in the separate
NanoPro and NanoCAN manuals.
If you want to work at a later time with a PLC or your own program, you will find the
necessary information in the separate "Command Reference".
Familiarize yourself with the PD4-N Plug & Drive motor and the relevant NanoPro or
NanoCAN control software before configuring the Plug & Drive motor for your
application.
Selecting the firmware
The Plug & Drive motor is always delivered with a firmware that is optimized for
RS485. For the operation and configuration of the Plug & Drive motor with a CANopen
interface and NanoCAN, you first need to perform a firmware update.
Proceed as follows:
Step Action Note
1 Install the NanoPro control software on your PC.
See the NanoPro separate manual.
Download of
www.nanotec.com
2 Connect the PC to the RS485 interface of the Plug
& Drive motor according to the connection diagram.
Connection diagram,
see Section 2.2.
3 Öffnen Sie in NanoPro das Menü
<System / Firmware ändern / wähle Firmware>
The following window appears:
4 Select the desired firmware and click on "Open".

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Connection and commissioning
Issue: V 1.4 11
Commissioning with NanoPro (RS485 firmware)
Proceed as follows to commission the Plug & Drive motor with the RS485 firmware:
Step Action Note
1 Install the NanoPro control software on your PC.
See the NanoPro separate manual.
Download of
www.nanotec.com
2 Connect the Plug & Drive motor according to the
connection diagram.
Connection diagram, see
Section 2.2.
Detailed information on
connections can be found
in Section 3.
3 Apply the operating voltage
(12 V DC ... 48 V DC).
CAUTION!
An operating voltage > 50 V will destroy the
output stage!
•Follow the information in Section 3.2.
4 If necessary, install the driver for the converter
cable ZK-RS485-USB.
Download
www.nanotec.com
in the
Accessories/Converter
menu item
5 Connect the Plug & Drive motor with the USB
port of your PC.
Use the converter cable
ZK-RS485-USB.
Connection via the RS232 interface is not
possible.
Order number:
•ZK-RS485-USB
6 Start the NanoPro software.
The NanoPro main menu
appears.
7 Select the <Communication> tab.
8 In the "Port" field, select the COM port to which
the PD4-N is connected.
The number of the COM
port to which the Plug &
Drive motor is connected
can be found in the device
manager of your Windows
PC (System
Supervision/System/Hard
ware).
9 Select the "115200 bps" entry in the "Baudrate"
selection field.

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Connection and commissioning
12 Issue: V 1.4
Step Action Note
10 Check the current setting using the motor data
sheet on the <Motor Settings> tab.
Under no circumstances
may the current be set to
a value higher than the
rated current of the motor.
11 Select the "Movement" tab.
12 Click on the <Test Record> button to carry out
the pre-set travel profile.
The connected motor
operates with the pre-set
travel profile (default travel
profile after new
installation).
13 You can now enter your required settings.
For instance, you can enter a new travel profile.
See the NanoPro separate
manual.

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Connection and commissioning
Issue: V 1.4 13
Commissioning with NanoCAN (CANopen firmware)
Proceed as follows to commission the Plug & Drive motor with the CANopen firmware.
More detailed information can be found in the separate NanoCAN manual.
Step Action Note
1 Install the NanoCAN control software on your
PC.
Download of
www.nanotec.com
2 Connect the Plug & Drive motor to the stepper
motor according to the connection diagram.
Connection diagram, see
Section 2.2.
Detailed information on
connections can be found
in Section 3.
3 Apply the operating voltage
(12 V DC ... 48 V DC).
CAUTION!
An operating voltage > 50 V will destroy the
output stage!
•Follow the information in Section 3.2.
4 Install and configure your CANopen adapter. Details can be obtained
from the manufacturer of
the CANopen adapter.
5 Start the NanoCAN software.
6 Select the desired node ID, the baud rate and, if
necessary, the CAN card in the <Configuration &
NMT> tab.
7 Select the desired operating mode (e.g. PP
mode) in the <Drive Modes> tab.
8 Click on the <Power on> button.
9 Enter the desired target position in the "target"
field.
10 Click on the <Start> button.

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Connections and circuits
14 Issue: V 1.4
3 Connections and circuits
3.1 Inputs and outputs (JST PHD-12)
Introduction
An overview of the assignments can be found in the connection diagram in Section
2.2. This section looks in detail at the assignment, functions and circuits of the
connections.
Pin assignment
Pin no. Name Wire color ZK-PD4N
1 Signal GND (Com) GY/BN
2 GND RD
3 Input 1 BK
4 Input 2 VT
5 Input 3 GY/PK
6 Input 4 RD/BU
7 Input 5 WH/GN
8 Input 6 BN/GN
9 Analog input WH/BU
10 Output 1 WH/YE
11 Output 2 YE/BN
12 Output 3 WH/GY
Input circuits
All inputs (apart from the "Analog In" input) are electrically isolated by optocouplers
from the voltage supply of the PD4-N and designed for 5-24 V input signals at an input
current of 8 mA.
Note:
The voltage must not exceed 24 V. It should drop below 2 V for safe switching off and
be at least 4.5 V for safe switching on.

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Connections and circuits
Issue: V 1.4 15
Function of the inputs
All digital inputs – with the exception of the "Clock" input in the clock directional mode
– can be freely programmed using the NanoPro software (RS485) (e.g. as a limit
position switch, enable, etc.) and can be used for sequential control with NanoJ.
All inputs can be configured for “active-high" (PNP) or “active-low" (NPN) with
NanoPro.
Output circuits
The outputs are MosFET outputs in an Open-Drain circuit (0 switching, max. 24 V/2
A). An LED can be integrated to test the output. The LED lights up when the output is
active.
Signal states at the outputs (RS485)
Note:
In the CANopen firmware, the status of the controller is not displayed at the outputs.
The following table shows the possible signal states at the outputs 1 to 3:
Signal states Meaning
Output 3 Output 2 Output 1
0 0 Rotation monitoring (error) or limit switch
0 1 Motor idle (waiting for new command)
1 0 Busy (control processing last command)
1 1 Reference point or zero point reached
1 Overtemperature
The outputs can be freely programmed using the NanoPro software.
Note:
Output 3 is also used to display errors and when switching on the controller.

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Connections and circuits
16 Issue: V 1.4
3.2 Power supply (Phoenix connector)
Permissible operating voltage
The permissible operating voltage of the Plug & Drive motor PD4-N lies within the
range +12 to +48 V DC and must not exceed 50 V or undershoot 11 V.
A charging condenser with minimum 4700 µF (10000 µF) must be provided for the
operating voltage to prevent exceeding the permissible operating voltage (e.g. during
braking).
Danger of electrical surges
Connect charging condensor with minimum 4700 µF!
An operating voltage > 50 V will destroy the output stage!
Mixing up the connections can destroy the output stage!
Never disconnect the motor when operating voltage is applied!
Never disconnect lines when live!
Voltage supply connection diagram
Note:
Complete connection diagram, see Section 2.2.
Pin assignment
Pin no. Name Wire no. ZK-PD4N
1 GND 1
2 Vcc 2
Accessories for voltage supply
Appropriate power packs and charging condensers are available as accessories:
Name Order identifier
Power pack NTS-xxV-yA
(xx=voltage: 12, 24 or 48 V, y=current: 2.5, 5 or 10 A)
Information on the selection of the required power supply unit
can be found in our FAQ on www.nanotec.com.
Charging
condenser
Z-K4700 or Z-K10000
Note:
Further information about accessories can be found on the Nanotec website:
www.nanotec.com

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Connections and circuits
Issue: V 1.4 17
3.3 RS485 network/CANopen (JST PHD-8)
PD4-N in a network
Generally, up to 254 (RS485) or 127 (CANopen) Plug & Drive motors can be actuated
in a network from a PC or PLC.
The number of PD4-N controllers in an RS485 network is limited to 32 by the
hardware.
These network connections are set up via the RS485/CANopen interface.
Pin assignment
Pin no. Name Wire color ZK-PD4N
1 GND BU
2 +Vb external WH/PK
3 RS485 Rx– YE
4 RS485 Rx+ GN
5 RS485 Tx– PK
6 RS485 Tx+ GY
7 CAN+ BN
8 CAN– WH
CANopen
With the PD4-N it is also possible to control the motor via CANopen.
If you use the Plug & Drive motor with CANopen, you can use the additional safety
function of the separate logic supply: Even when the voltage supply of the PD4-N is
interrupted, the processor continues to be supplied with power via the communication
line and the position data cannot be lost so that the machine does not need to be
referenced after being switched on.
More detailed information on this can be found in the CANopen reference and in the
NanoCAN user manual.
CANopen connection
A suitable CAN interface adapter (e.g. USB adapter from IXXAT or PEAK) is required
for connecting with a PC.
CANopen standard connector assignment (on the adapter)
Pin-
No.
Name
2 CAN low
3 CAN GND
7 CAN high
CANopen connection assignments on the controller
Circuitry according to the "Pin assignment" table (see above on this page)

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Connections and circuits
18 Issue: V 1.4
Notes on the baud rate
It is important to note that both the controller and the CAN master use the same baud
rate. Only this way can communication be established.
The baud rate has a direct influence on the maximum possible bus length. The
following list shows the possible baud rates as well as their maximum permissible bus
lengths:
Baud rate Bus length
1 MBaud 40 m
500 kBaud 130 m
250 kBaud 270 m
125 kBaud 530 m
50 kBaud 1300 m
20 kBaud 3300 m
Notes on the bus termination
With CAN, the bus termination is handled by two 120 ohm resistors on both ends of
the bus.
Two-wire operation RS485
To enable RS485 two-wire transmission capability, all bus stations must have a
direction control.
An intelligent converter, which automatically switches to transmission mode when a
start bit is received at the RS232 interface and returns to reception mode at the end of
the stop bit, enables two-wire operation of the PD4-N. This solution requires no
software support.
We can recommend the ICP-7520 converter, for example, that is available from
Schuricht.
Talk to our Technical Hotline if you require support for this.

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Connections and circuits
Issue: V 1.4 19
Circuit diagram RS485 network

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Connections and circuits
20 Issue: V 1.4
Setting the RS485/CANopen module address
Max. 127 addresses can be set which can, however, only be used to the full extent via
CANopen as the maximum number of PD4-N controllers in an RS485 network is
limited to 32 by the hardware.
A rotary switch on the board can be used to adjust the module addresses 1 to 7 in the
hardware.
With RS485, the baud rate is read out from the EEPROM. Depending on the position
of the rotary switch, it is either set for 1 MBaud (CANopen) or is read out from the
EEPROM; see table:
Rotary switch value
dec
(hex)
Node ID Baud rate
0
(0x00) From EEPROM
1 - 7
(0x01 - 0x07) = rotary switch value
= from EEPROM (RS485)
or 1 MBaud (CANopen)
8
(0x08) From EEPROM
9 - 15
(0x09 - 0x0F)
= rotary switch value
minus 8
From EEPROM
If the rotary switch is in position 0 or 8, the module address can be set in the software
and read out from the EEPROM.
When the power supply is applied, the controller checks which address is set with the
rotary switch on the hardware. This hardware address is then adopted. After the
address is changed, the power supply must be briefly switched off and on again.