SOPROLEC DMD4022 User manual

User’s Manual
For
DMD4022
Fully Digital Stepping Driver
Version 1.0
©2009 All Rights Reserved
Attention: Please read this manual carefully before using the driver!
18 bis, rue du vert buisson
95470 VEMARS
France
Phone : [phone] Fax : [phone]
Internet : www.soprolec.com E-Mail:cont[email protected]
Contents
II
The content in this manual has been carefully prepared and is believed to be accurate, but no
responsibility is assumed for inaccuracies.
Soprolec reserves the right to make changes without further notice to any products herein to
improve reliability, function or design. Soprolec 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.
Soprolec’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 Soprolec’s terms and conditions of sales, the user of Soprolec’s products in life
support or aircraft applications assumes all risks of such use and indemnifies Soprolec against all
damages.
©2009 by Soprolec
All Rights Reserved

Contents
I
Table of Contents
1. Introduction, Features and Applications.................................................................... 1
Introduction ........................................................................................................... 1
Features ................................................................................................................. 1
Applications........................................................................................................... 1
2. Specifications ............................................................................................................ 2
Electrical Specifications (Tj =25/77) .............................................................. 2
Mechanical Specifications ( unit: mm [inch] ) ...................................................... 2
Elimination of Heat ............................................................................................... 2
Operating Environment and other Specifications.................................................. 3
3. Pin Assignment and Description ............................................................................... 3
Connector P1 Configurations ................................................................................ 3
Selecting Active Pulse Edge and Control Signal Mode......................................... 4
Connector P2 Configurations ................................................................................ 4
4. Control Signal Connector (P1) Interface ................................................................... 4
5. Connecting the Motor................................................................................................ 5
Connections to 4-lead Motors................................................................................ 5
Connections to 6-lead Motors................................................................................ 6
Half Coil Configurations ............................................................................... 6
Full Coil Configurations................................................................................ 6
Connections to 8-lead Motors................................................................................ 7
Series Connections ........................................................................................ 7
Parallel Connections...................................................................................... 7
6. Power Supply Selection............................................................................................. 7
Regulated or Unregulated Power Supply .............................................................. 8
Multiple Drivers .................................................................................................... 8
Selecting Supply Voltage....................................................................................... 8
7. Selecting Microstep Resolution and Driver Output Current .....................................9
Microstep Resolution Selection.............................................................................9
Current Settings ..................................................................................................... 9
Contents
II
Dynamic current setting ..............................................................................10
Standstill current setting .............................................................................. 10
8. Wiring Notes............................................................................................................ 10
9. Typical Connection.................................................................................................. 11
10. Sequence Chart of Control Signals........................................................................ 11
11. Protection Functions .............................................................................................. 12
Over-current Protection ............................................................................... 12
Over-voltage Protection............................................................................... 12
Phase Error Protection.................................................................................13
Protection Indications.................................................................................. 13
12. Frequently Asked Questions.................................................................................. 13
Problem Symptoms and Possible Causes ............................................................ 14
13. Professional Tuning Software ProTuner................................................................ 15
Introduction ......................................................................................................... 15
Software Installation............................................................................................ 15
Connections and Testing...................................................................................... 19
RS232 Interface Connection................................................................................ 20
Testing the Stepping System................................................................................ 20
Software Introduction.......................................................................................... 20
Com Config Window................................................................................... 21
Tuning.......................................................................................................... 21
Anti-Resonance Introduction....................................................................... 24
Procedure for Achieving Optimum Performance ........................................ 25
APPENDIX ................................................................................................................. 29
Twelve Month Limited Warranty ........................................................................ 29
Exclusions ........................................................................................................... 29
Obtaining Warranty Service ................................................................................ 29
Warranty Limitations........................................................................................... 29

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1. Introduction, Features and Applications
Introduction
The DMD4022 is a versatility fully digital stepping driver based on a DSP with advanced control
algorithm. The DMD4022 is the next generation of digital stepping motor controls. It brings a
unique level of system smoothness, providing optimum torque and nulls mid-range instability.
Motor self-test and parameter auto-setup 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 in the markets. Its unique features make the
DMD4022 an ideal solution for applications that require low-speed smoothness. Compared to the
DM432C, the DMD4022 has smaller size and lower cost.
Features
zAnti-Resonance, provides optimum torque
and nulls mid-range instability
zMotor self-test and parameter auto-setup
technology, offers optimum responses with
different motors
zMulti-Stepping allows a low resolution step
input to produce a higher microstep output
for smooth system performance
zMicrostep resolutions programmable, from
full-step to 102,400 steps/rev
zSupply voltage up to +40 VDC
zOutput current programmable, from 0.3A to
2.2A
zPulse input frequency up to 75 KHz
zTTL compatible and optically isolated input
zAutomatic idle-current reduction
zSuitable for 2-phase and 4-phase motors
zSupport PUL/DIR and CW/CCW modes
zOver-voltage, over-current, phase-error
protections
Applications
Suitable for a wide range of stepping motors, from NEMA frame size 14 to 23. It can be used in
various kinds of machines, such as laser cutters, laser markers, high precision X-Y tables, labeling
machines, and so on. Its unique features make the DMD4022 an ideal solution for applications that
require low-speed smoothness.
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2. Specifications
Electrical Specifications (Tj =25℃/77℉)
DMD4022
Parameters
Min Typical Max Unit
Output current 0.3 - 2.2 (1.6 RMS) A
Supply voltage +20 - +40 VDC
Logic signal current 7 10 16 mA
Pulse input frequency 0 - 75 kHz
Isolation resistance 500 MΩ
Mechanical Specifications ( unit: mm [inch] )
Figure 1: Mechanical specifications
Elimination of Heat
zDriver’s reliable working temperature should be <70(158 ℉), and motor working
temperature should be <80(176℉);
zIt 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;
zIt is recommended to mount the driver vertically to maximize heat sink area. Use forced

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cooling method to cool the system if necessary.
Operating Environment and other Specifications
Cooling Natural Cooling or Forced cooling
Environment Avoid dust, oil fog and corrosive gases
Ambient Temperature 0－50 (32℉－122℉)
Humidity 40%RH－90%RH
Operating Temperature 70 (158℉) Max
Operating
Environment
Vibration 5.9m/s2 Max
Storage Temperature -20－65 (-4℉－149℉)
Weight Approx. 100g (3.5274oz)
3. Pin Assignment and Description
The DMD4022 has two connectors, connector P1 for control signals connections, and connector
P2 for power and motor connections. The following tables are brief descriptions of the two
connectors. More detailed descriptions of the pins and related issues are presented in section 4, 5,
9.
Connector P1 Configurations
Pin Function Details
PUL
Pulse signal: In single pulse (pulse/direction) mode, this input represents pulse
signal, each rising or falling edge active (software configurable); 4-5V when
PUL-HIGH, 0-0.5V when PUL-LOW. In double pulse mode (pulse/pulse) ,
this input represents clockwise (CW) pulse，active both at high level and low
level (software configurable). For reliable response, pulse width should be
longer than 7.5µs. Series connect resistors for current-limiting when +12V or
+24V used. The same as DIR and ENA signals.
DIR
DIR signal: In single-pulse mode, this signal has low/high voltage levels,
representing two directions of motor rotation; in double-pulse mode (software
configurable), this signal is counter-clock (CCW) pulse，active both at high
level and low level (software configurable). For reliable motion response, DIR
signal should be ahead of PUL signal by 5µs at least. 4-5V when DIR-HIGH,
0-0.5V when DIR-LOW. Please note that rotation direction is also related to
motor-driver wiring match. Exchanging the connection of two wires for a coil
to the driver will reverse motion direction.
OPTO Opto-coupler power supply, and the typical voltage is +5V. Series connect
resistors (at the PUL, DIR, ENA terminals) for current-limiting when +12V or
+24V used.
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ENA Enable signal: This signal is used for enabling/disabling driver. High level for
enabling the driver and low level for disabling the driver. Usually left
UNCONNECTED (ENABLED).
Selecting Active Pulse Edge and Control Signal Mode
The DMD4022 supports PUL/DIR and CW/CCW modes and pulse active at rising or falling edge.
See more information about these settings in Section 13. Default setting is PUL/DIR mode and
rising edge active.
Connector P2 Configurations
Pin Function Details
+Vdc Power supply, 20~40 VDC, Including voltage fluctuation and EMF voltage.
GND Power Ground.
A+, A- Motor Phase A
B+, B- Motor Phase B
4. Control Signal Connector (P1) Interface
The DMD4022 uses opto-couplers to increase noise immunity and interface flexibility. If the
opto-couplers’ supply voltage is higher than +5V, a current-limiting resistor needs to be
connected at each command signal terminal to prevent overheating the opto-couplers. In the
following figures, connections to open-collector and differential controller are illustrated.

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Figure 2: Connections to open-collector signal (common-anode)
Figure 3: Connections to differential control signal
5. Connecting the Motor
The DMD4022 can drive any 2-pahse and 4-pahse hybrid stepping motors.
Connections to 4-lead Motors
4 lead motors are the least flexible but easiest to wire. Speed and torque will depend on winding
inductance. In setting the driver output current, multiply the specified phase current by 1.4 to
determine the peak output current.
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Figure 4: 4-lead Motor Connections
Connections to 6-lead Motors
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 driver output current multiply the specified per phase (or unipolar) current
rating by 1.4 to determine the peak output current.
Figure 5: 6-lead motor half coil (higher speed) connections
Full Coil Configurations
The full coil configuration on a six 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.
Figure 6: 6-lead motor full coil (higher torque) connections

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Connections to 8-lead Motors
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.
Figure 7: 8-lead motor series connections
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.
Figure 8: 8-lead motor parallel connections
NEVER disconnect or connect the motor while the power source is energized.
6. Power Supply Selection
The DMD4022 can match medium and small size stepping motors (from NEMA frame size 14 to
23) made by Soprolec or other motor manufactures around the world. To achieve good driving
performances, it is important to select supply voltage and output current properly. Generally
speaking, supply voltage determines the high speed performance of the motor, while output current
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determines the output torque of the driven motor (particularly at lower speed). Higher supply
voltage will allow higher motor speed to be achieved, at the price of more noise and heating. If the
motion speed requirement is low, it’s better to use 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 supply the driver. However,
unregulated power supplies are preferred due to their ability to withstand current surge. If
regulated power supplies (such as most switching supplies.) are indeed used, it is important to
have large current output rating to avoid problems like current clamp, for example using 4A
supply for 3A motor-driver operation. On the other hand, if unregulated supply is used, one may
use a power supply of lower current rating than that of motor (typically 50%～70% of motor
current). The reason is that the driver draws current from the power supply capacitor of the
unregulated supply only during the ON duration of the PWM cycle, but not during the OFF
duration. Therefore, the average current withdrawn from power supply is considerably less than
motor current. For example, two 3A motors can be well supplied by one power supply of 4A
rating.
Multiple Drivers
It is recommended to have multiple drivers to share one power supply to reduce cost, if the supply
has enough capacity. To avoid cross interference, DO NOT daisy-chain the power supply input
pins of the drivers. Instead, please connect them to power supply separately.
Selecting Supply Voltage
The power MOSFETs inside the DMD4022 can actually operate within +20 ~ +40VDC, including
power input fluctuation and back EMF voltage generated by motor coils during motor shaft
deceleration. Higher supply voltage can increase motor torque at higher speeds, thus helpful for
avoiding losing steps. However, higher voltage may cause bigger motor vibration at lower speed,
and it may also cause over-voltage protection or even driver damage. Therefore, it is suggested to
choose only sufficiently high supply voltage for intended applications, and it is suggested to use
power supplies with theoretical output voltage of +20 ~ +36VDC, leaving room for power
fluctuation and back-EMF.

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7. Selecting Microstep Resolution and Driver Output Current
Microstep resolutions and output current are programmable, the former can be set from full-step to
102,400 steps/rev and the latter can be set from 0.3A to 2.2A. See more information about
Microstep and Output Current Setting in Section 13.
However, when it’s not in software configured mode, this driver uses a 6-bit DIP switch to set
microstep resolution, and motor operating current, as shown below:
Microstep Resolution Selection
When it’s not in software configured mode, microstep resolution is set by SW5, 6 of the DIP
switch as shown in the following table:
Microstep Steps/rev.(for 1.8°motor) SW5 SW6
1 to 512 Default/Software configured ON ON
8 1600 OFF ON
16 3200 ON OFF
32 6400 OFF OFF
Current Settings
For a given motor, higher driver current will make the motor to output more torque, but at the
same time causes more heating in the motor and driver. Therefore, output current is generally set
to be such that the motor will not overheat for long time operation. Since parallel and serial
connections of motor coils will significantly change resulting inductance and resistance, it is
therefore important to set driver output current depending on motor phase current, motor leads and
connection methods. Phase current rating supplied by motor manufacturer is important in selecting
driver current, however the selection also depends on leads and connections.
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When it’s not in software configured mode, the first three bits (SW1, 2, 3) of the DIP switch are
used to set the dynamic current. Select a setting closest to your motor’s required current.
Dynamic current setting
Peak Current RMS Current SW1 SW2 SW3
Default/Software configured (0.3 to 2.2A) ON ON ON
0.5A 0.35 A OFF ON ON
0.7A 0.50 A ON OFF ON
1.0A 0.71 A OFF OFF ON
1.3A 0.92 A ON ON OFF
1.6A 1.13 A OFF ON OFF
1.9A 1.34 A ON OFF OFF
2.2A 1.56 A OFF OFF OFF
Notes: Due to motor inductance, the actual current in the coil may be smaller than the dynamic
current setting, particularly under high speed condition.
Standstill current setting
SW4 is used for this purpose. OFF meaning that the standstill current is set to be half of the
selected dynamic current, and ON meaning that standstill current is set to be the same as the
selected dynamic current.
The current automatically reduced to 60% of the selected dynamic current one second after the last
pulse. Theoretically, this will reduce motor heating to 36% (due to P=I2*R) of the original value. If
the application needs a different standstill current, please contact Soprolec.
8. Wiring Notes
zIn order to improve anti-interference performance of the driver, it is recommended to use
twisted pair shield cable.
zTo prevent noise incurred in PUL/DIR signal, pulse/direction signal wires and motor wires
should not be tied up together. It is better to separate them by at least 10 cm, otherwise the
disturbing signals generated by motor will easily disturb pulse direction signals, causing
motor position error, system instability and other failures.
zIf a power supply serves several drivers, separately connecting the drivers is recommended

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instead of daisy-chaining.
zIt is prohibited to pull and plug connector P2 while the driver is powered ON, because there
is high current flowing through motor coils (even when motor is at standstill). Pulling or
plugging connector P2 with power on will cause extremely high back-EMF voltage surge,
which may damage the driver.
9. Typical Connection
A complete stepping system should include stepping motor, stepping driver, power supply and
controller (pulse generator). A typical connection is shown as figure 9.
Figure 9: Typical connection
10. Sequence Chart of Control Signals
In order to avoid some fault operations and deviations, PUL, DIR and ENA should abide by some
rules, shown as following diagram:
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Figure 10: Sequence chart of control signals
Remark:
a) t1: ENA must be ahead of DIR by at least 5µs. Usually, ENA+ and ENA- are NC (not
connected). See “Connector P1 Configurations” for more information.
b) t2: DIR must be ahead of PUL effective edge by 5µs to ensure correct direction;
c) t3: Pulse width not less than 7.5µs;
d) t4: Low level width not less than 7.5µs.
11. Protection Functions
To improve reliability, the driver incorporates some built-in protection functions. The DMD4022
uses one RED LED to indicate what protection has been activated. The periodic time of RED is 3
s (seconds), and how many times the RED turns on indicates what protection has been activated.
Because only one protection can be displayed by RED LED, so the driver will decide what error to
display according to their priorities. See the following Protection Indications table for displaying
priorities.
Over-current Protection
Over-current protection will be activated when continuous current exceeds 16A or in case of short
circuit between motor coils or between motor coil and ground, and RED LED will turn on once
within each periodic time (3 s).
Over-voltage Protection
When power supply voltage exceeds 42±1 VDC, protection will be activated and RED LED will

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turn on twice within each periodic time (3 s).
Phase Error Protection
Motor power lines wrong & not connected will activate this protection. RED LED will turn on
four times within each periodic time (3 s).
Attention: When above protections are active, the motor shaft will be free or the LED will turn
red. Reset the driver by repowering it to make it function properly after removing above problems.
Since there is no protection against power leads (﹢,﹣) reversal, it is critical to make sure that power
supply leads correctly connected to driver. Otherwise, the driver will be damaged instantly.
Protection Indications
Priority Time(s) of ON Sequence wave of RED LED Description
1st 1 Over-current protection
2nd 2
Over-voltage protection
3rd 4 Phase error protection
12. FrequentlyAsked Questions
In the event that your driver doesn’t operate properly, the first step is to identify whether the
problem is electrical or mechanical in nature. The next step is to isolate the system component that
is causing the problem. As part of this process you may have to disconnect the individual
components that make up your system and verify that they operate independently. It is important to
document each step in the troubleshooting process. You may need this documentation to refer back
to at a later date, and these details will greatly assist our Technical Support staff in determining the
problem should you need assistance.
Many of the problems that affect motion control systems can be traced to electrical noise,
controller software errors, or mistake in wiring.
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Problem Symptoms and Possible Causes
Symptoms Possible Problems
No power
Microstep resolution setting is wrong
DIP switch current setting is wrong
Fault condition exists
Motor is not rotating
The driver is disabled
Motor rotates in the wrong direction Motor phases may be connected in reverse
DIP switch current setting is wrong
The driver in fault Something wrong with motor coil
Control signal is too weak
Control signal is interfered
Erratic motor motion
Wrong motor connection

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Something wrong with motor coil
Current setting is too small, losing steps
Current setting is too small
Motor is undersized for the application
Acceleration is set too high
Motor stalls during acceleration
Power supply voltage too low
Inadequate heat sinking / cooling
Automatic current reduction function not being utilized
Excessive motor and driver heating
Current is set too high
13. Professional Tuning Software ProTuner
Introduction
This section will provide an overview of connection and basic setup instructions for Soprolec’s
digital stepping driver DMD4022 using the ProTuner software. These instructions will walk you
through the following steps necessary to start up your driver and motor. This section is intended for
setting up the driver with the ProTuner.
Software Installation
The ProTuner is windows based setup software for tuning Soprolec’s digital stepper driver
DMD4022. It can run in windows systems, including Win95/Win98/WindowsNT/ Windows
2000/Windows XP. And the selected PC should have 1 serial port at least for communicating with
the driver.
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Double click “ProTuner_DMD4022.exe” to begin installing the ProTuner. See Figure 11. Click
Next to enter the “License Agreement” window. See Figure 12.
Figure 11: Begin to install the ProTuner
Figure 12: License agreement
Choose “I agree to the terms of this license agreement” and click Next to continue installation. The
user can enter user’s information in the following window. See Figure 13. After entering the user’s
information, click Next to select installation folder, where you would like to install the ProTuner.
See Figure 14.