phytron SINCOS User manual

Manual 2066-A006 GB
Linear
Stepper Motor Power Stage
SINCOS

phytron
Manual 2066-A006 GB
SINCOS
Linear Stepper Motor Power Stage
for Bipolar Control Mode

Manual SINCOS
2MA 2066-A006 GB
©2002
All rights with:
Phytron-Elektronik GmbH
Industriestraße 12
82194 Gröbenzell, Germany
Tel.: [phone]
Fax: [phone]
Every possible care has been taken to ensure the accuracy of this technical manual. All
information contained in this manual is correct to the best of our knowledge and belief but
cannot be guaranteed. Furthermore we reserve the right to make improvements and
enhancements to the manual and / or the devices described herein without prior
notification.
We appreciate suggestions and criticisms for further improvement. Please send your
comments to the following
E-mail address: [e-mail]

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Manual 2066-A006 GB 3
Contents
1SINCOS Stepper Motor Power Stage.................................................................................... 4
1.1 Step Resolution/Current Shapes .....................................................................................5
1.2 Motor Currents.................................................................................................................6
1.3 LED Display .....................................................................................................................6
2Technical Data.......................................................................................................................7
2.1 Dimensions ......................................................................................................................8
2.2 Pin Assignment................................................................................................................9
3Principle of Operation ............................................................................................................10
4Inputs.....................................................................................................................................12
4.1 Control Pulses .................................................................................................................12
4.2 Direction +/–.....................................................................................................................12
4.3 Motor Stop .......................................................................................................................13
4.4 Reset ...............................................................................................................................13
4.5 Motor Current OFF .......................................................................................................... 13
4.6 Select A, B, C, D..............................................................................................................14
4.6.1 Table Step Resolution and Current Shape ........................................................... 14
4.7 Overtemperature Output..................................................................................................15
5Supply Voltage.......................................................................................................................15
5.1 Power Supply Unit ........................................................................................................... 15
5.2 Phase Current Setting .....................................................................................................16
5.2.1 Stop Current.......................................................................................................... 16
5.2.2 Drive Current......................................................................................................... 16
6Motor Wiring Schemes ..........................................................................................................17
7To Consider before Installation.............................................................................................. 18
7.1 Qualified Personnel .........................................................................................................18
7.2 Safety Instructions ...........................................................................................................18
8Warranty ................................................................................................................................19
9ESD Protective Measures......................................................................................................19
Index...........................................................................................................................................20

Manual SINCOS
4MA 2066-A006 GB
1 SINCOS Stepper Motor Power Stage
SINCOS is a linear stepper motor power stage particularly developed for applications
which require very high step resolution, such as: measuring tables, machine tools, graphic
instruments, etc.
SINCOS is specially recommended for applications where chopping is not acceptable.
• Designed to drive 2-phase, 8, 6 or 4 lead stepper motors
• Resolution up to 10,000 steps/rev. (for a 500-step motor)
• Front panel or external setting of step resolution and current shape
• Drive and stop currents are continuously adjustable independently of one another
• Overheat monitoring with safety cut-out and LED display
• Voltage monitoring with LED display
• No stabilized power supply required
• Compact Europe size plug-in board (100 * 160 mm)
Fig. 1: Front view

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1.1 Step Resolution/Current Shapes
SINCOS enables 15 different operating modes: Six step resolutions from full step up to
1/20 step and four different current shapes. So you can always select an adapted
operating mode for each motor type and application.
The operating mode can be set with the selector switch at the front panel.
For external programming the SELECT inputs can be used.
Fig. 2: Current shapes

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6MA 2066-A006 GB
1.2 Motor Currents
Drive current and stop current are adjustable in a range from 0 to 100 % of the maximum
current.
The maximum current for each phase is 2.5 A (cooled), or 1.5 A (without cooling).
1.3 LED Display
Green LED +VB/ –VB
SINCOS requires a dual power supply of maximum 21V / 5A. The green LEDs show that
both supply voltages are OK.
Red LED > 85 °C
The power stage is short-circuit proof. A temperature monitoring circuit cuts off the current
if the heat sink temperature is above 85 °C. This will be displayed by the red front panel
LED. An error output will also be set.
When the temperature falls below 75 °C the unit can be reactivated by RESET.
Alternatively the supply voltage can be switched OFF and ON again. This automatically
generates a RESET signal.

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Manual 2066-A006 GB 7
2 Technical Data
Stepper motor for 2-phase stepper motors, wired as 8-, 6- or 4-lead
motor
selectable by front panel switch RESOLUTION
or external binary setting by the SELECT inputs
Steps/revolution
for a 200-steps motor:
200, 400, 800, 1000, 2000, 4000 steps/rev.
for a 500-steps motor:
500, 1000, 2000, 2500, 5000, 10.000 steps/rev.
Selectable by front panel switch RESOLUTION or
external binary setting by the SELECT inputs
Current shapes
Conventional full step and half step mode, triangular,
sine-shaped or trapezoidal current shapes
Drive current
Stop current
Front panel setting switches IDRIVE and ISTOP
Separate adjustment (continuously) from 0 to 100% of
each current
Admissible supply voltage ranges –8 to –21 V
+8 to +21 V
Maximum current/phase 1.5 A without cooling
2.5 A cooled
Maximum heat sink temperature +85 °C
Maximum control pulse frequency 200 kHz
Inputs TTL and open collector
Control pulses
Direction +/–
Stop / Run
Motor current OFF
Step resolution, current shape
Overtemperature output Open collector 45 V / 100 mA
Front panel LED displays +VB+ supply monitoring
–VB– supply monitoring
> 85 °C overtemperature monitoring
Front panel width 50,5 mm (10 TE)

Manual SINCOS
8MA 2066-A006 GB
Dimensions Europe size 100*160 mm
Connector 32-pole acc. to DIN 41612, model D
Accessories Front panel (10 TE) with handle
NTS 10 power supply unit
NBS SINCOS power supply kit
Mating connector
2.1 Dimensions
Fig. 3: Dimensions

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2.2 Pin Assignment
Fig. 4: Pin assigment of the 32-pole connector

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10 MA 2066-A006 GB
3 Principle of Operation
To reach all intermediate positions between two full steps, both phase currents of a 2-
phase stepper motor have to be controlled and phase-shifted by 90 degrees. This control
is effected by an EPLD: By each control pulse a counter will be incremented or decrement-
ed in function of the direction of rotation. The counter value will be decoded equivalent to
the step resolution.
The actual transient current value is transmitted to two bipolar output stages. By applicat-
ing the constant current principle, the phase currents are in a wide range independent of
the supply voltage.
Microsteps can be programmed by dividing each full step into 1, 2, 4, 5, 10 or 20 micro-
steps. For step divisions of 2, a conventional half step or triangular phase current shape
can be selected. For step divisions of 4, 5, 10 or 20 triangular, sine-shaped or trapezoidal
phase current shapes can be selected.

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Manual 2066-A006 GB 11
Fig. 5: Schematic diagram

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12 MA 2066-A006 GB
4 Inputs
The inputs include internal 4.7 kΩpull-up resistors and are designed for open collector
control signals.
Fig. 6: Input wiring
4.1 Control Pulses
One control pulse provokes one motor step. With the falling signal edge the direction input
signal is stored and the drive current switched ON. The effective motor step is executed
with the rising edge of the control pulse signal.
An internal logic circuit will detect failing control pulses and switch back to the stop current
after 100 ms delay time. If the control pulse signal remains on the low-level, the drive
current remains ON.
4.2 Direction +/–
This determines the rotational direction of the motor. The corresponding signal level must
only be changed when the motor stands still or is driven within the start/stop frequency
range.
Switching at higher speeds provokes "loosing" of steps or will stop the motor.
If the motor rotates – in function of the logic level – in the undesired direction, the motor
connecting wires of one phase should be inverted (e.g. 24ac and 26ac).

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Fig. 7: Time diagram: control pulses and motor direction
The control pulse signal width should be at least 2 µs (maximum frequency 200 kHz).
The direction input must not be changed within 1 µs before and 1 µs after the falling edge
of the control pulse signal (see time diagram).
4.3 Motor Stop
This signal stops the motor independently of the control pulse signal.
Warning:
Using this input is not a safe interruption in case of emergency.
For safe cut-off the unit, the supply voltage has to be interrupted.
4.4 Reset
This signal resets the internal counter (asynchronous to the control pulse signal). With the
rising edge of the clock signal, an overtemperature error message will be reset, too. Both
functions are automatically initiated when the supply voltages are switched ON.
Warning:
Using this input is not a safe interruption in case of emergency.
For safe cut-off the unit, the supply voltage has to be interrupted.
4.5 Motor Current OFF
This signal switches the motor current off independently of other input signals.
Warning:
Using this input is not a safe interruption in case of emergency.
For safe cut-off the unit, the supply voltage has to be interrupted.

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4.6 Select A, B, C, D
Via four external data lines, step resolution and current shapes can be set instead of using
the selection switch.
For enabling setting by the inputs, the upper front panel selection switch has to be set to
position F.
Programming is indicated in the following table.
4.6.1Table Step Resolution and Current Shape
How to set step resolution and current shape
External programming:
SELECT inputs
D C B A
RESOLUTION
selection switch
Step resolution and current shape
L L L L 0 Conventional full step
L L L H 1 Conventional half step
L L H L 2 Half step triangular
L L H H 3 1/4 step sine-shaped
L H L L 4 1/5 step sine-shaped
L H L H 5 1/10 step sine-shaped
L H H L 6 1/20 step sine-shaped
L H H H 7 1/4 step triangular
H L L L 8 1/5 step triangular
H L L H 9 1/10 step triangular
H L H L A 1/20 step triangular
H L H H B 1/4 step trapezoidal
H H L L C 1/5 step trapezoidal
H H L H D 1/10 step trapezoidal
H H H L E 1/20 step trapezoidal
H H H H F External programming

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4.7 Overtemperature Output
This output is switched to GND when the temperature monitoring circuit is activated (open
collector).
Max. admissible load: 45 V; 0.1 A; max. 0.3 W (BC 547B).
Remark:
The losses can be reduced as well as the heat sink temperature, by applying a lower
supply voltage.
5 Supply Voltage
The SINCOS unit requires a dual supply voltage in the ranges of –8 to –21 V and +8 to
+21 V.
The voltage value depends on the desired run frequency.
A low supply voltage will reduce the losses as well as the heat sink temperature.
5.1 Power Supply Unit
Fig. 8: Power supply unit for SINCOS (ED = duty cycle)
The mains transformer and bridge rectifier size depend on the adjusted maximum current.
Within each half part of the power supply the maximum current is twice the value of the
adjusted motor current.
The SINCOS unit includes internal fuses in the supply leads: 2 * 5 A fast-blow.
The supply leads from power supply unit to SINCOS should have a cross section of at
least
1 mm².

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5.2 Phase Current Setting
With the IDRIVE and ISTOP potentiometers, drive current and stop current can be adjusted
indepently from another to values from 0 to 100% of the maximum value.
As the following figure shows, the true values can be measured with instruments.
The SINCOS has to be set to the full step mode!
Fig. 9: Phase current measuring
5.2.1Stop Current
In general, the stop current should be adjusted to approx. 50 % of the drive current, in
order to avoid excessive heating of motor and power stage. With the potentiometer ISTOP
the motor current during motor standstill can be adjusted.
5.2.2Drive Current
The drive current (run current or operating current) IDRIVE should be adjusted as low as
possible (empirical determination). To measure the current please proceed as follows:
1. Wire measuring instruments as shown in the figure above.
2. Set full step mode.
3. Activate a STOP input signal.
4. Apply a control pulse signal (approx. 20 to 50 Hz).
5. Adjust the required drive current by means of potentiometer IDRIVE.
Warning:
If the STOP input signal would not be activated during current adjustment, the current flow
direction would change after each control pulse and the instruments might be damaged.

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Manual 2066-A006 GB 17
6 Motor Wiring Schemes
Fig. 10: Motor Connection
The letters correspond to the connector pin assignment and refer to Phytron stepper
motors (see motor connection leaflet).

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7 To Consider before Installation
Read this manual very carefully before installing and operating this unit.
Observe the safety instructions in the following chapter.
7.1 Qualified Personnel
Design, installation and service may only be performed by qualified and trained
personnel.
This personnel should be able to recognize and handle risks emerging from
electrical, mechanical or electronic system parts.
WARNING !
By persons without proper training and qualification serious damages to devices
and persons might result!
7.2 Safety Instructions
1. Check the output voltages of the supply unit before connecting the SINCOS
rear connector.
Inverted supply voltage leads would immediately cause damage of the
power stage.
2. Do not unplug the SINCOS when powered !
3. Check correct wiring of the motor leads.
4. Always switch off the supply voltage if you connect or disconnect any wires or
connector.
Most important:
Do not unplug the motor connector while powered !
Danger of electric arcing.
5. Voltages connected to the signal inputs and outputs should be safely
separated from mains.
The maximum voltage against protective ground must not exceed 60 VDC or
25 VAC.
6. The inputs STOP and MOTOR CURRENT OFF must only be switched during
motor standstill.

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7. Setting the inputs MOTOR CURRENT OFF, MOTOR STOP or RESET is no
sure separation in the emergency case.
The voltage supply has to be interrupted for safely switching off the drive.
8. For high stepping frequencies, the control pulse frequency should not be
interrupted suddenly. Also avoid maintaining the control pulse input at the low-
level (L).
9. If the stepper motor misses steps, decrease the acceleration or the maximum
frequency values.
10. The motor should not be driven externally, because it would operate as a
generator and deliver energy to the SINCOS.
11. If the SINCOS power stage switches to overtemperature, make sure that
sufficient cooling measures are installed.
Perhaps the supply voltage could be reduced in order to get lower losses. The
stop current should not be set to more than 50% of the drive current (check
potentiometer ISTOP setting).
12. The SINCOS surface may reach temperatures of 70 °C.
Danger of injury if touching the surface !
8 Warranty
The SINCOS stepper motor power stages are subject to Phytron's legal warranty. Phytron
will repair or exchange units which show a failure due to defects in material or caused by
the production process. This warranty does not include damages which are caused by the
customer, as there are, for example, not intended use, unauthorized modifications, wrong
treatment or wrong wiring.
9 ESD Protective Measures
All the products which we deliver have been carefully checked and submitted to a longterm
test. To avoid the failure of components sensitive to electrostatic discharge (ESD), we
apply a great number of protective measures during manufacturing, from the component
input check until the delivery of the finished products.
Warning:
Manipulation of ESD sensitive devices must be effected by respecting special protective
measures (EN 61340 – 5). Only return the devices in adapted packaging.
Phytron's warranty is cancelled in case of damages arising from improper
manipulation or transportation of ESD sensitive modules and components.