G203V STEPPER DRIVE
Contents
1. GECKODRIVE INC GECKODRIVE G203V STEPPER DRIVE 14662 FRANKLIN AVE SUITE E MOTOR CONTROLS REV 7 January 7 2010 TUSTIN CA 92780 714 832 8874 Thank you for purchasing the G203V drive The G203V is Geckodrive s new generation CPLD based microstep drive It has short circuit protection for the motor outputs over voltage and under voltage protection over temperature protection reversed power supply polarity protection and will survive accidental motor disconnects while powered up The V in G203V stands for Vampire as it is an unkillable drive The G203V uses a synchronous PWM design that is absolutely silent when the motor is stopped or turning slowly It virtually eliminates stopped motor heating regardless of power supply voltage The G203V is a jumper free drive There are no internal user settings at all so there is no need to ever remove the drive cover at all The STEP DIRECTION and DISABLE inputs are opto isolated All three inputs work with 2 5V 3 3V or 5V logic drive signals The input drive current is now 2 5mA at 2 5V so almost all logic family 74LS 74HC etc can be used to drive these inputs The COMMON return for the signals is controller ground referenced instead of 5VDC This greatly eases the drive to controller interface There are no unusual STEP to DIRECTION timing restrictions Stepping occurs on the positive edge of the STEP pulse The DIRECTION input must be true 200nS before and after this STEP2. RED and GREEN indicator LEDs are lit then the motor is miswired the motor has a wire shorted to ground is shorted to another motor wire or the motor is bad Secondarily Everything GECKODRIVE INC GECKODRIVE G203V STEPPER DRIVE 14662 FRANKLIN AVE MOTOR CONTROLS REV 7 January 7 2010 Sas cea 714 832 8874 ran OK but the RED LED lit a while later Check the drive temperature it may have overheated because of inadequate heatsinking Also see that the DISABLE input isn t being activated 5VDC on DISABLE MOTOR HAS NO HOLDING TORQUE If the RED LED is off and the GREEN LED is on check the CURRENT SET resistor with a multimeter Re calculate the resistor value Check to see if the motor is connected to the G203V MOTOR HAS HOLDING TORQUE BUT WON T MOVE Check your STEP DIRECTION DISABLE if used and COMMON interface Verify COMMON goes to your controller GND MY MOTOR RUNS ROUGH AT LOW SPEEDs Try adjusting the ADJUST trimpot setting Verify you are using the correct CURRENT SET resistor A round stepper motor will not operate as well as a square stepper motor as they were not designed for microstepping MY YELLOW LED NEVER LIGHTS You are not going fast enough to get full power from your motor If you don t need to go any faster use a lower power supply voltage This indicator is a good application diagnostic for motor gearing and power supply voltage choice Using it correctly will help you to optimize your system
3. Connect the DIRECTION line to this terminal TERMINAL 9 Step Connect the STEP line to this terminal TERMINAL 10 Common Connect this terminal to the controller GROUND These 3 inputs are optically isolated from the rest of the drive They will operate with 2 5V 3 3V or 5V logic outputs with 2 5mA minimum source drive current The STEP input s maximum rated frequency is 350kHz with a 50 duty cycle waveform The G203V steps the motor on the 0 to 1 logic positive edge of the STEP signal TERMINAL 11 Current Set Connect the current set resistor to this terminal TERMINAL 12 Current Set Connect the other end of the current set resistor to this terminal This input matches the G203V s current output to the motor windings The G203V will accommodate motor winding currents from 0 to 7A Use the following equation to calculate the value in kilo Ohms of the current set resistor R in kilo ohms 47 I 7 I Use the nearest standard value 5 tolerance 1 4W resistor for this setting Here are the current set resistor values for motor current in 5A increments Round the appropriate answer to the nearest 5 resistor value 1A 7 8K 1 5A 12 8K 2A 18 8K 2 5A 26 1K 3A 35 25K 3 5A 47K 4A 62 67K 4 5A 84 6K 5A 117 5K 5 5A 172 33K 6A 282K 6 5A 611K 7A OPEN Zarra moan 3 OTHER CONSIDERATIONS HEATSINKING The G203V needs heatsinking for current settings greater than 3 amps
4. DISCLAIMER CERTAIN APPLICATIONS USING POWER PRODUCTS MAY INVOLVE POTENTIAL RISKS OF DEATH PERSONAL INJURY OR SEVERE DAMAGE TO PROPERTY GECKODRIVE INC PRODUCTS ARE NOT DESIGNED AUTHORIZED OR WARRANTED TO BE SUITABLE FOR USE IN LIFE SUPPORT DEVICES OR OTHER CRITICAL APPLICATIONS INCLUSION OF GECKODRIVE INC PRODUCTS IN SUCH APPLICATIONS IS UNDERSTOOD TO BE FULLY AT THE PURCHASER S OWN RISK In order to minimize risks associated with the purchaser s application adequate design and operating safeguards must be provided by the purchaser to minimize inherent or procedural hazards GECKODRIVE INC assumes no liability for applications assistance or the purchaser s product design GECKODRIVE INC does not warrant or represent that any license either express or implied is granted under any patent right copyright or other intellectual property right of GECKODRIVE INC GECKODRIVE G203V STEPPER DRIVE MOTOR CONTROLS REV 7 January 7 2010 SPECIFICATIONS Supply Voltage 15 to 80 VDC Phase Current 0 to 7 Amps Auto Current Reduction 71 of set current 1 second after last Step Pulse Size 2 5 W 2 5 D 85 H 63 5mm 63 5mm 21 5mm Mounting Pattern 4 6 32 screws 1 75 by 2 375 44 5 mm 60 mm Weight 3 6 oz 100 gm Quiescent Current 20 Ma or less drive disabled Short circuit trip current 10A 3uS response time Step Frequency 0 to 333 kHz Step Pulse 0 Time 2uS min Step on rising edge Temp Oto 70C Step P
5. The case temperature measured on the bottom plate should not exceed 70 degrees C and for best life should be kept at 50C degrees or less Use heatsink compound between the G203V and your heatsink CAUTION Current settings above 3A without a heatsink may result in the G203V entering thermal shutdown AUTO CURRENT REDUCTION The G203V reduces motor phase current to 71 of the set current value 1 second after the last step pulse is sent The G203V also changes to a special recirculating current mode to nearly eliminate motor heating GECKODRIVE INC GECKODRIVE G203V STEPPER DRIVE 14662 FRANKLIN AVE SUITE E MOTOR CONTROLS REV 7 January 7 2010 TUSTIN CA 92780 714 832 8874 ADJUST This trimpot adjusts the motor for the smoothest possible low speed operation Set the motor speed to about 1 2 revolution per second and then turn the trimpot until a distinct null is noted in the motor s vibration This will result in the most even microstep placement for a given motor and power supply voltage The default setting for this trimpot is at turn and the setting for your motor will be within 4 turn of the default setting MAIN CONNECTOR The G203V uses a 2 piece modular main connector The connector is split in two pieces terminals 1 thru 6 power supply and motor leads and terminals 7 thru 12 control interface Each can be removed separately by pulling the connector body up and away from the top surface of the G203V Remove th
6. e connectors to access the G203V front mounting screw locations in order to mount it to a heatsink or chassis G203V INDICATORS POWER LED The GREEN POWER indicator is lit wnenever the G203V has power supply voltage applied FULL POWER LED The YELLOW FULL POWER indicator is lit when the motor is turning fast enough to generate maximum possible mechanical power Power is torque times RPM and power output reaches its maximum value when this indicator is lit Use this indicator to verify your motor is optimally geared to the load ERROR LED The RED ERROR indicator is lit when 1 During power on reset for 1 second when power is first applied to the G203V 2 While the DISABLE input is active 3 When there is a short circuit on any motor output Momentarily activate the DISABLE input to reset 4 During over temperature shutdown The LED automatically resets when the drive temperature drops INTERNAL FUSE The G203V uses a socketed user replaceable internally mounted fuse Littlefuse Inc part 0251005 MXL Reversing the power supply polarity or a power supply voltage over 114VDC will cause the internal fuse to blow CAUTION Do not use any other type of fuse do not bridge a blown fuse with wire and do not solder the fuse in place Doing so will void the drive s warranty REMOVING AND REPLACING THE COVER REMOVING THE COVER 1 Remove the two 2 56 phillips head screws on the bottom of the drive 2 Slide the cover backwards until it clea
7. end of the winding to this terminal One motor winding connects to terminals 3 and 4 and the other winding connects to terminals 5 and 6 Turn the power supply off when connecting or disconnecting the motor If the motor turns in the wrong direction reverse the motor winding connections to terminals 3 and 4 CAUTION Avoid shorting the motor leads to each other or to ground or the G203V will enter protective shut down 4 wire 6 wire and 8 wire motor may be used If 6 wire motors are used they may be connected in half winding or full winding This is equivalent to an 8 wire motor connected in parallel or series If a motor is connected in series or full winding the motor s GECKODRIVE INC GECKODRIVE G203V STEPPER DRIVE a AVE MOTOR CONTROLS REV 7 January 7 2010 TUSTIN CA 92780 714 832 8874 phase current rating is half of its parallel or unipolar rating The choice depends on the high speed performance required a parallel connected motor will provide twice the power of a series connected motor at the same power supply voltage DISABLE PIN TERMINAL 7 Disable This terminal will force the winding currents to zero when tied to the step and direction controller 5V The DISABLE input on the G203V is optically isolated and requires logic 1 to DISABLE and logic 0 to ENABLE the drive Once it is disabled the motor windings are unergenized and the motor freewheels STEP AND DIRECTION INPUTS TERMINAL 8 Direction
8. ied limits keep the power supply ripple voltage to 10 or less for best results CAUTION Power supply voltage in excess of 80 VDC will blow the G203V internal fuse CAUTION Reversed power supply polarity will blow the G203V internal fuse CAUTION Never put a switch on the DC side of the power supply This will damage if not destroy your drive The choice of power supply voltage depends on the required high speed performance from the motor doubling the voltage doubles the motor s high speed power In all cases the power supply voltage should be no less than 4 times or no more than 20 times the motor s rated voltage The motor may not run as smoothly as possible if the power supply voltage is less than 4 times or more than 20 times the motor s rated voltage A power supply voltage greater than 20 times the motor s rated voltage may overheat and damage the motor Motor winding inductance should be 500uH or greater A more accurate calculation of power supply voltage is to find your motor s inductance and put it into the following equation 32 mH inductance Power Supply Voltage If your motor has 2mH of inductance the equation would look as follows 32 V2 45 12V MOTOR CONNECTION TERMINAL 3 Phase A Connect one motor winding to this terminal TERMINAL 4 Phase A Connect the other end of the winding to this terminal TERMINAL 5 Phase B Connect the other motor winding to this terminal TERMINAL 6 Phase B Connect the other
9. pulse edge The G203V microstep drive is warranted to be free of manufacturing defects for 1 year from the date of purchase Anyone who is dissatisfied with it or is unable to make it work to their satisfaction for any reason will be cheerfully refunded the purchase price if the G203V is returned within 15 days of the purchase date in a cosmetically and electrically undamaged condition PLEASE READ FIRST BEFORE USING THE G203V Before you start you must have a 2 phase hybrid PM step motor ordinary 1 8 or 0 9 degree per step motor a DC power supply suitable for the motor and a current set resistor The motor s rated phase current must not be more than 7 Amps The power supply voltage must be between 15VDC and 80VDC unregulated The current set resistor may be a 1 4 Watt 5 part Finally have a STEP DIRECTION and DISABLE if needed source available G203V TERMINAL WIRING The G203V uses a 2 piece modular main connector The connector is split in two pieces terminals 1 through 6 power supply and motor leads and terminals 7 through 12 control interface Each can be removed separately by pulling the connector body upwards and off of the mating header pins on the G203V The connectors must initially be removed to mount the G203V to a heatsink or chassis TERMINAL 1 Power Ground Connect the negative black lead of your power supply to this terminal TERMINAL 2 Power Connect the positive red lead of your power supply to this terminal I
10. rs the drive REPLACING THE COVER 1 Slide the cover forward over the drive while lifting the back of the cover 2 Replace the screws on the bottom of the drive It is recommended to use small needle nose pliers or tweezers to move the jumpers on the internal headers MAIN CONNECTOR The G203V uses a 2 piece modular main connector The connector is split in two pieces terminals 1 thru 6 power supply and motor leads and terminals 7 thru 12 control interface Each can be removed separately by pulling the connector body upwards and off of the mating header pins on the G203V The connectors must initially be removed to mount the G203V to a heatsink or chassis TROUBLESHOOTING EVERYTHING IS CONNECTED NOTHING HAPPENS Is the GREEN LED lit If not either the G203V has no power supply voltage connected or something very bad caused its internal fuse to blow Check the power supply voltage using a multimeter set to DC VOLTS on terminal screw heads 1 2 of the drive The internal fuse is the G203V s final line of protection It blows only under the most extreme circumstances Those are reversed power supply polarity AC voltage instead of DC voltage on terminals 1 and 2 and power supply voltages in excess of 114VDC Correct the problem and replace the fuse with the only approved type It is the only kind that blows fast enough to protect the G203V Anything else voids the warranty EVERYTHING IS CONNECTED RED INDICATOR STAYS LIT If the
11. t must be between 18VDC to 80VDC TERMINAL 3 Motor Phase A Connect one end of your Phase A motor winding here TERMINAL 4 Motor Phase A Connect the other end of your Phase A motor winding here TERMINAL 5 Motor Phase B Connect one end of your Phase B motor winding here TERMINAL 6 Motor Phase B Connect the other end of your Phase B motor winding here TERMINAL 7 Disable This terminal will force the winding currents to zero when tied to the step and direction controller 5V TERMINAL 8 Direction Connect the DIRECTION signal to this terminal TERMINAL 9 Step Connect the STEP signal to this terminal TERMINAL 10 Common GECKODRIVE INC GECKODRIVE G203V STEPPER DRIVE 14662 FRANKLIN AVE SUITE E MOTOR CONTROLS REV 7 January 7 2010 TUSTIN CA 92780 714 832 8874 Connect the controller s GROUND to this terminal TERMINAL 11 Current Set Connect one end of your current set resistor to this terminal TERMINAL 12 Current Set Connect the other end of your current set resistor to this terminal POWER SUPPLY WIRING TERMINAL 1 Power Ground Connect the power supply ground to term 1 TERMINAL 2 Power Connect the power supply to this terminal The power supply voltage must be between 15 VDC and 80 VDC The maximum power supply current required is equal to the motor s rated phase current An unregulated power supply may be used so long as the voltage stays between the specif
12. ulse 1 Time 1 uS min Humidity 0 to 95 non condensing Direction Setup 200nS before step pulse rising edge 200nS hold after step pulse rising edge Power Dissipation 1 to 13 W 0 to 7 Amps GECKODRIVE INC 14662 FRANKLIN AVE SUITE E TUSTIN CA 92780 714 832 8874
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