Zapp PM752 User manual

User sManual
For
3M752
HighPerformanceMicrosteppingDriver
Version 1.0
2008 All RightsReserved
Attention: Pleasereadthismanualcarefullybeforeusingthedriver!


The content in this manual has been carefully prepared and is believed to be accurate, but no
responsibility is assumed for inaccuracies.
We reserves the right to make changes without further notice to any products herein to
improve reliability, function or design. We do 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.
Our 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 Zapp Automation Ltd terms and conditions of sales, the user of our products in life
support or aircraft applications assumes all risks of such use and indemnifies Zapp Automation Ltd
against all damages.
2008by=DSS$XWRPDWLRQLimited.

Contents
I
Tableof Contents
1. Introduction, Features and Applications....................................................................1
Introduction...........................................................................................................1
Features.................................................................................................................1
Applications..........................................................................................................1
2. Specifications............................................................................................................1
Electrical Specifications........................................................................................1
Operating Environment and other Specifications..................................................2
Mechanical Specifications.....................................................................................2
Elimination of Heat...............................................................................................2
3. Pin Assignment and Description...............................................................................3
Connector P1 Configurations................................................................................3
Selecting Active Pulse Edge or Active Level and Control Signal Mode...............3
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...............................................................................5
Half Coil Configurations...............................................................................5
Full Coil Configurations................................................................................6
Connections to 8-lead Motors...............................................................................6
Series Connections........................................................................................6
Parallel Connections......................................................................................7
6. Power Supply Selection............................................................................................7
Regulated or Unregulated Power Supply..............................................................7
Multiple Drivers....................................................................................................8
Selecting Supply Voltage.......................................................................................8
7. Selecting Microstep Resolution and Driver Output Current.....................................8
Microstep Resolution Selection............................................................................8
Current Settings.....................................................................................................9
Contents
II
Dynamic current setting................................................................................9
Standstill current setting................................................................................9
8. Wiring Notes...........................................................................................................10
9. Typical Connection..................................................................................................10
10. Sequence Chart of Control Signals.......................................................................11
11. Protection Functions..............................................................................................11
Short-voltage and Over-voltage protection.........................................................11
Over-current Protection.......................................................................................12
Short Circuit Protection.......................................................................................12
12. Frequently Asked Questions..................................................................................12
Problem Symptoms and Possible Causes............................................................13
APPENDIX.................................................................................................................14
Twelve Month Limited Warranty........................................................................14
Exclusions...........................................................................................................14
Obtaining Warranty Service................................................................................14
Warranty Limitations...........................................................................................14

PM752 Microstepping Driver Manual V1.0
Tel: [phone]
1. Introduction, Features and Applications
Introduction
The PM752 is a high performance microstepping driver based on pure-sinusoidal current control
technology. Owing to the above technology and the self-adjustment technology (self-adjust current
control parameters) according to different motors, the driven motors can run with smaller noise,
lower heating, smoother movement and have better performances at higher speed than most of the
drivers in the markets. It is suitable for driving 2-phase and 4-phase hybrid stepping motors.
Features
lHigh performance, cost-effective
lSupply voltage up to +75 VDC
lOutput current up to 5.2A
lSelf-adjustment technology
lPure-sinusoidal current control technology
lPulse input frequency up to 300 KHz
lTTL compatible and optically isolated input
lAutomatic idle-current reduction
l16 selectable resolutions in decimal and
binary, up to 51,200 steps/rev
lSuitable for 2-phase and 4-phase motors
lSupport PUL/DIR and CW/CCW modes
lShort-voltage, over-voltage, over-current
protections
Applications
Suitable for a wide range of stepping motors, from NEMA size 17 to 34. It can be used in various
kinds of machines, such as X-Y tables, labeling machines, laser cutters, engraving machines,
pick-place devices, and so on. Particularly adapt to the applications desired with low noise, low
heating, high speed and high precision.
2. Specifications
Electrical Specifications (Tj = 25 /77℉)
PM752
Parameters
Min Typical Max Unit
Output current 1.8 - 5.2 (3.7 RMS) A
Supply voltage +20 +48 +75 VDC
Logic signal current 7 10 16 mA
Pulse input frequency 0 - 300 kHz
Isolation resistance 500 MΩ
PM752 Microstepping Driver Manual V1.0
Tel: [phone]
Operating Environment and other Specifications
Cooling Natural Cooling or Forced cooling
Environment Avoid dust, oil fog and corrosive gases
Ambient Temperature 050 (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. 280g (10 oz)
Mechanical Specifications (unit: mm [inch])
Figure 1: Mechanical specifications
*Recommend use side mounting for better heat dissipation
Elimination of Heat
lDriver s reliable working temperature should be <70 (158℉), and motor working temperature
should be <80 (176℉);
lIt 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;

PM752 Microstepping Driver Manual V1.0
Tel: [phone]
lIt is recommended to mount the driver vertically to maximize heat sink area. Use forced cooling
method to cool the system if necessary.
3. Pin Assignment and Description
The PM752 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+
PUL-
Pulse signal: In single pulse (pulse/direction) mode, this input represents pulse
signal, each rising or falling edge active (set by inside jumper J3); 4-5V when
PUL-HIGH, 0-0.5V when PUL-LOW. In double pulse mode (pulse/pulse) ,
this input represents clockwise (CW) pulse，active at high level or low level
(set by inside jumper J3). For reliable response, pulse width should be longer
than 1.5μs. Series connect resistors for current-limiting when +12V or +24V
used. The same as DIR and ENA signals.
DIR+
DIR-
DIR signal: In single-pulse mode, this signal has low/high voltage levels,
representing two directions of motor rotation; in double-pulse mode (set by
inside jumper J1), this signal is counter-clock (CCW) pulse，active at high
level or low level (set by inside jumper J3). 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. The default rotation direction can be
reverse by inside jumper J2.
ENA+
ENA-
Enable signal: This signal is used for enabling/disabling the driver. High level
(NPN control signal, PNP and Differential control signals are on the contrary,
namely Low level for enabling.) for enabling the driver and low level for
disabling the driver. Usually left UNCONNECTED (ENABLED).
Selecting Active Pulse Edge or Active Level and Control Signal Mode
There are two jumpers J1 and J3 inside the PM752 specifically for selecting active pulse edge or
effective level and control signal mode, as shown in figure 2. Default setting is PUL/DIR mode and
rising edge active (NPN, and PNP control signal is on the contrary).
J2 inside the driver is used to reverse the default rotation direction. 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.
PM752 Microstepping Driver Manual V1.0
Tel: [phone]
(a) J1, J3 open circuit (b) J1 open circuit, J3 shirt circuit
PUL/DIR mode and Active at rising edge (NPN) PUL/DIR mode and active at falling edge (NPN)
(c) J1 short circuit, J3 open circuit (d) J1, J3short circuit
CW/CCW mode and active CW/CCW mode and active
at low level (The fixed level) at high level (The fixed level)
Figure 2: J1 and J3 jumpers
Connector P2 Configurations
Pin Function Details
+V Power supply, 20~75 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 PM752 can accept differential and single-ended inputs (including open-collector and PNP output).
The PM752 has 3 optically isolated logic inputs which are located on connector P1 to accept line
driver control signals. These inputs are isolated to minimize or eliminate electrical noises coupled
onto the drive control signals. Recommend use line driver control signals to increase noise immunity
of the driver in interference environments. In the following figures, connections to open-collector and
PNP signals are illustrated.
Figure 3: Connections to open-collector signal (common-anode)

PM752 Microstepping Driver Manual V1.0
Tel: [phone]
Figure 4: Connection to PNP signal (common-cathode)
5. Connecting the Motor
The M752 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.
Figure 5: 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
PM752 Microstepping Driver Manual V1.0
Tel: [phone]
setting the driver output current multiply the specified per phase (or unipolar) current rating by 1.4 to
determine the peak output current.
Figure 6: 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 7: 6-lead motor full coil (higher torque) connections
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 8: 8-lead motor series connections

PM752 Microstepping Driver Manual V1.0
Tel: [phone]
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 9: 8-lead motor parallel connections
6. Power Supply Selection
The PM752 can match medium and small size stepping motors (from NEMA frame size 17 to 43)
Supplied by Zapp Automation Ltd 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 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.
PM752 Microstepping Driver Manual V1.0
Tel: [phone]
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 PM752 can actually operate within +20 ~ +75VDC, 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 ~ +68VDC, leaving room for power fluctuation and back-EMF.
7. Selecting Microstep Resolution and Driver Output Current
This driver uses an 8-bit DIP switch to set microstep resolution, and motor operating current, as
shown below:
Microstep Resolution Selection
Microstep resolution is set by SW5, 6, 7, 8 of the DIP switch as shown in the following table:
Microstep Steps/rev.(for 1.8°motor) SW5 SW6 SW7 SW8
2 400 ON ON ON ON
4 800 OFF ON ON ON
8 1600 OFF OFF ON ON
16 3200 ON OFF ON ON
32 6400 ON ON OFF ON
64 12800 OFF ON OFF ON
128 25600 OFF OFF OFF ON
256 51200 ON OFF OFF ON
5 1000 ON ON ON OFF
10 2000 OFF ON ON OFF

PM752 Microstepping Driver Manual V1.0
Tel: [phone]
20 4000 OFF OFF ON OFF
25 5000 ON OFF ON OFF
40 8000 ON ON OFF OFF
50 10000 OFF ON OFF OFF
100 20000 ON OFF OFF OFF
200 40000 OFF OFF 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.
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
1.26A 0.90A ON ON ON
1.80A 1.29A OFF ON ON
2.36A 1.68A ON OFF ON
2.92A 2.09A OFF OFF ON
3.51A 2.51A ON ON OFF
4.09A 2.92A OFF ON OFF
4.64A 3.32A ON OFF OFF
5.20A 3.71A 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.
PM752 Microstepping Driver Manual V1.0
Tel: [phone]
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 Zapp Automation Ltd.
8. Wiring Notes
lIn order to improve anti-interference performance of the driver, it is recommended to use
twisted pair shield cable.
lTo 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.
lIf a power supply serves several drivers, separately connecting the drivers is recommended
instead of daisy-chaining.
lIt 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 10.
Figure 10: Typical connection

PM752 Microstepping Driver Manual V1.0
Tel: [phone]
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:
Figure 11: 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 1.5µs;
d) t4: Low level width not less than 1.5µs.
11. Protection Functions
To improve reliability, the driver incorporates some built-in protections features.
Short-voltage and Over-voltage protection
When power supply voltage is lower than +17VDC, short-voltage protection will be activated and the
power indicator LED will turn off. When the power supply voltage is back to normal operation range,
the driver will automatically reset and power indicator LED will turn on.
When power supply voltage exceeds +95VDC, over-voltage protection will be activated and power
indicator LED will turn red.
PM752 Microstepping Driver Manual V1.0
Tel: [phone]
Over-current Protection
Protection will be activated when continuous current reaches to 16A.
Short Circuit Protection
Protection will be activated in case of short circuit between motor coils or between motor coil and
ground.
When above protections are active, the motor shaft will be free or the LED will turn red (except
short-voltage protection). Reset the driver by repowering it to make it function properly after
removing above problems.
12. Frequently Asked 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.

PM752 Microstepping Driver Manual V1.0
Tel: [phone]
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
Wrong motor connection
Something wrong with motor coil
Erratic motor motion
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
PM752 Microstepping Driver Manual V1.0
Tel: [phone]
APPENDIX
Twelve Month Limited Warranty
Zapp Automations Ltd. warrants its products against defects in materials and
workmanship for a period of 12 months from shipment out of factory. During the warranty period,
we will either, at its option, repair or replace products which proved to be defective.
Exclusions
The above warranty does not extend to any product damaged by reasons of improper or inadequate
handlings by customer, improper or inadequate customer wirings, unauthorized modification or
misuse, or operation beyond the electrical specifications of the product and/or operation beyond
environmental specifications for the product.
Obtaining Warranty Service
To obtain warranty service, a returned material authorization number (RMA) must be obtained
from customer service before returning product for service.
Customer shall prepay shipping charges for products returned to Zapp Automation Ltd for warranty
service and Zapp Automation Ltd shall pay for return of products to customer.
Warranty Limitations
Zapp Automation Ltd makes no other warranty, either expressed or implied, with respect to the
product. Zapp Automation Ltd specifically disclaims the implied warranties of merchantability
and fitness for a particular purpose. Some jurisdictions do not allow limitations on how long and
implied warranty lasts, so the above limitation or exclusion may not apply to you. However, any implied
warranty of merchantability or fitness is limited to the 12-month duration of this written warranty.