User`s Manual - American Motion Technology LLC
Contents
1. 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 Problem Symptoms and Possible Causes Microstep resolution setting is wrong Fault condition exists Motor phases may be connected in reverse Something wrong with motor coil Control signal is interfered Something wrong with motor coil Current setting is too small Acceleration is set too high Inadequate heat sinking cooling Current is set too high 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 APPENDIX Twelve Month Limited Warranty Leadshine Technology Co 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 Leadshine will either at it2. Drive Controller Drive EN NL PUL 3 gt VCC l DIR O DIR TIT y vcce eS gt PuL PUL a x d L PUL d l PUL DIR 7 l DIR pe A ENA a L gt ENABLE 1 ENA Al YA C XX T P Q _ Y ENABLE V ly ENA L AN Ns Figure 3 Connections to open collector Figure 4 Connection to PNP signal common cathode signal common anode 5 Connecting the Motor The DM5342 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 P2 A A B p Figure 5 4 lead Motor Connections 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 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 co
3. 24V VCC a O ee ee V Recommended Power Suppl pply GND 20 45VDC Figure 10 Typical connection e Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 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 ts ta wl High Level gt 3 5V PUL PUL CW High Level gt 3 5V Low Level lt 0 5V DIR JIR CCW Low Level lt 0 5V ENA ENA PUL DIR CW CCW Figure 11 Sequence chart of control signals Remark a tl ENA must be ahead of DIR by at least 5us 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 Sus to ensure correct direction c t3 Pulse width not less than 2 5us d t4 Low level width not less than 2 5us 11 Protection Functions To improve reliability the driver incorporates some built in protections features i Over current protection activated when peak current exceeds the limit Over voltage protection activated when drive working voltage is greater than 52VDC When above protections are active the motor shaft will be free or the red LED blinks Reset the driver by repowering it to make it function properly after removing above problems 10 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 12 Frequently Asked Questions
4. 96 75 5 2 972 47 8 1 882 112 4 409 Figure 1 Mechanical specifications Recommend use side mounting for better heat dissipation Elimination of Heat Driver s reliable working temperature should be lt 70 C 158F and motor working temperature should be lt 80C 176F y It is recommended to use automatic idle current mode namely current automatically reduce to 50 when motor stops so as to reduce driver heating and motor heating It is recommended to mount the driver vertically to maximize heat sink area Use forced cooling method to cool the system if necessary 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 3 Pin Assignment and Description The DM542 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 DIR signal In single pulse mode this signal has low high voltage levels representing two directions of motor rotation in CW CCW mode set by inside jumper J1 this signal is counter clock CCW pulse For reliable motion response DIR signal should be ahead of PUL signal by 5us at least 5 24V 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
5. A Cr nee Tn hr natn e oe ene tere tetany 9 10 Sequence Chart OC Onnok ona A 10 A neces ceensdeateane ter NANENANE AEAEE TEE 10 2 Frequently Asked Ques MOMS yaiccescncsssscssensisasranccacecencenevareetes A RA 11 Probl m Symptomis a a Possible Cass AA A E 11 APPENDIX eaer ae a SS IO ISA ISO ONIS ROA aii SS oido 12 Twelve Month Limited Warrants 12 EXCUSAS A 12 Obtamino Wairanty SEVEN A A A A R 12 e Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 Nc ny TPE EAT ONG POSE ON PROC OPE E N E NE 12 Contact Us II 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 1 Introduction Features and Applications Introduction The DM5342 is a fully digital stepper drive developed with advanced DSP control algorithm based on the latest motion control technology It has achieved a unique level of system smoothness providing optimal torque and nulls mid range instability Its motor auto identification and parameter auto configuration feature offers quick setup to optimal modes with different motors Compared with traditional analog drives DM542 can drive a stepper motor at much lower noise lower heating and smoother movement Its unique features make DM542 an ideal choice for high requirement applications Features Anti Resonance provides optimal torque and nulls mid range instability Motor auto identification and parameter auto configuration technology offers optimal responses with different motors Multi Steppin
6. User s Manual For DM542 Fully Digital Stepper Drive Version 1 0 2012 All Rights Reserved Attention Please read this manual carefully before using the drive eh Leadshine Technology Co Ltd 3 F Block 2 Nanyou Tianan Industrial Park Nanshan Dist Shenzhen China T 86 755 26409254 F 86 755 26402718 Web site www leadshine com E Mail sales leadshine com Leadshine reserves the right to make changes without further notice to any products herein to improve reliability function or design Leadshine does not assume any liability arising out of the application or use of any product or circuit described herein neither does 1t convey any license under its patent rights of others Leadshine 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 Leadshine s terms and conditions of sales the user of Leadshine s products in life support or aircraft applications assumes all risks of such use and indemnifies Leadshine against all damages 2012 by Leadshine Technology Company Limited All Rights Reserved Contents Table of Contents Introduction Eeatires and Applications dido l Inroddu OMe aE a ina l Eater O i A ON l Electricals Pe Ci CAOS ica iaa l Operating Environment and other Specifications sssesccesecccccccccnceensssssseesscesececccccasccene
7. cedure 3 1 Motor is connected to drive SW4 Swa 2 Power is connected to drive 3 Turn on the power esp 4 Make sure there is no pulse applied to drive 5 Switch SW4 two times in one second That is iii ii OFF ON OFF or ON OFF ON ee ee ee ee eee ee et 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 8 Wiring Notes In order to improve anti interference performance of the driver it is recommended to use twisted pair shield cable To prevent noise incurred in PUL DIR signal pulse direction signal wires and motor wires should not be tied up together It 1s 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 If a power supply serves several drivers separately connecting the drivers is recommended instead of daisy chaining It 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 Controller VCC 5
8. cssessesseseaeccecccsaaaens 2 Mechanical SPECINCAONS iria SS oneness 2 El rmimnmation ore 2 YE ASS AMEN ANA DESTA UI EA A AAA EE AAA 3 Connector Pil OMNES UTA asas 3 Selecting Active Pulse Edge or Active Level and Control Signal Mode oooooooooonnncccncnnnononnnonnnnnnnnnnnonccncnnnnnnnnnnnnos 3 Connector PZ COmb Sur anon ose io 4 4 Control renal Connector El Inter kace a aren aleeaiaects sas avanti ia leaie S Aen 4 De GOmMee ete VOL Olite 4 COMME CTIONS TO IEA Motors A o o e o dl dee eee 4 Connections too lead MOOS aai E E E E E A E E E 5 Half Col Grav Uralon NA A A A id ha halen achat 5 FUNE OEE Ome 0121 6 0 hpemeeretre a e e de a Teen tes 5 COMME CTLOMS1Oi 5 I AC MOTOTS acess ae RARE PPP PO o a O PE O O deeds acer sen endcedee nace deco ande es 5 MELISS E OMC MOMS ia 5 PAELLA a eee 6 A POW Cl SOD ya CCC Ul OM iio inn E E A EI 6 Resulated or Unreculated Power Supply ia inane a nie eae ee eens 6 MUS DUES oa 6 Sel cuina Supply Volize AAA AAA aa ice 7 7 Selecting Microstep Resolution and Driver Output CurTONt oocccccncccncnnnoncnnnnnoonnnnnnnnnnnnnnnnnnnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 7 Microst p RESOLUTION Select Olsena A ace 7 Current ELIAS A A a a ee a sacacaaeaeeaneeicecst 7 Dynamic Curent SEUS a rasa 8 Stanastill Current cintia diodes 8 23 DAMOS DS WE diets dic 8 5 WIEN NOE N a escioas ke erie cai seats na sae roca A E E uae an ode E se aaah season nateeeenenemaae 9 DS bai PLE AE OA EOI A A E A
9. eds 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 45VDC 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 Dynamic Current Microstep Resolution 1p2 3 4 5 6 7 8 Standstill Current half full Microstep Resolution Selection Microstep resolution is set by SW5 6 7 8 of the DIP switch as shown in the following table 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 7 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 connection methods Phase current rating supplied by motor manufacturer is imp
10. es mode the motors should also be run at only 70 of their rated current to prevent over heating 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 P2 A B B Figure 8 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 P2 A B B Figure 9 8 lead motor parallel connections 6 Power Supply Selection The DM542 can match medium and small size stepping motors from NEMA frame size 17 to 34 made by Leadshine 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 Ho
11. g allows a low resolution step input to produce a higher microstep output thus offers smoother motor movement 15 selectable microstep resolutions including 400 800 1600 3200 6400 12800 25600 1000 2000 4000 5000 8000 10000 20000 25000 Soft start with no jump when powered on Input voltage 18 50VDC 8 selectable peak current including 1 00A 1 46A 1 91A 2 37A 2 84A 3 31A 3 76A 4 20A Pulse input frequency up to 200 KHz TTL compatible and optically isolated input Automatic idle current reduction Suitable for 2 phase and 4 phase motors Support PUL DIR and CW CCW modes 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 engraving machines labeling machines laser cutters 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 C 77FT 5 0 Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 Operating Environment and other Specifications Environment Avoid dust oil fog and corrosive gases Humidity 40 RH 90 RH Vibration 5 9m s Max Mechanical Specifications unit mm inch 118 4 646 112 4 409 A A ct D g9 i LN i o gt E Lu gt To co 25 3 0 9
12. nfiguration 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 P2 B NC 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 P2 A ENE B B 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 seri
13. of two wires for a coil to the driver will reverse motion direction Selecting Active Pulse Edge or Active Level and Control Signal Mode There are two jumpers J1 and J3 inside the M860 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 upward rising edge active Note J2 inside the driver is used to reverse the default rotation direction nal e n f Y 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 H E Ma c J1 short circuit J3 open circuit d J1 J3 short circuit CW CCW mode CW CCW mode Figure 2 J1 and J3 jumper Settings e Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 Connector P2 Configurations Motor Phase B 4 Control Signal Connector P1 Interface The DM542 can accept differential and single ended inputs including open collector and PNP output The DM542 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 Controller
14. ortant 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 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 50 of the selected dynamic current one second after the last pulse Theoretically this will reduce motor heating to 36 due to P I R of the original value If the application needs a different standstill current please contact Leadshine Auto Tuning by SW4 To get the optimized performance switch SW4 two times in one second to identify the motor parameter after power up if it is the first time installation The motor parameter is identified and the drive s current loop parameters are calculated automatically when SW4 is activated The motor shaft will have a little vibration during auto configuration If the user changes the motor or the power supply don t forget to toggle SW4 once again Auto Tuning Requirement and Pro
15. s 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 at e mail tech leadshine com before returning product for service Customer shall prepay shipping charges for products returned to Leadshine for warranty service and Leadshine shall pay for return of products to customer Warranty Limitations Leadshine makes no other warranty either expressed or implied with respect to the product Leadshine 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 Shipping Failed Product If your product fail during the warranty period e mail customer service at tech leadshine com to obtain a returned material authorization number RMA before returning produc
16. t for service Please include a written description of the problem along with contact name and address Send failed product to distributor in your area or Leadshine Technology Co Ltd 3 F Block 2 Nanyou Tianan Industrial Park Nanshan Dist Shenzhen China Also enclose information regarding the circumstances prior to product failure 12 e Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 Contact Us China Headquarters Address 3 F Block 2 Nanyou Tianan Industrial Park Nanshan District Shenzhen China Web http www leadshine com Sales Hot Line Tel 86 755 2643 4369 for All 86 755 2641 7674 for Asia Australia Africa areas 86 755 2640 9254 for Europe America areas Fax 86 755 2640 2718 Email sales O leadshine com Technical Support Tel 86 755 2641 8447 and 86 755 2647 1129 Fax 86 755 2640 2718 Email tech leadshine com Leadshine U S A Address 25 Mauchly Suite 318 Irvine California 92618 Tel 1 949 608 7270 Fax 1 949 608 7298 Web http www leadshineUSA com Email sales OleadshineUSA com and support leadshineUSA com Leadshine Hong Kong Address Rm 3 9 F Block E Wah Lok Industrial Center 31 41 Shan Mei St Fo Tan Shatin Hong Kong Tel 852 2952 9114 Fax 852 2952 9395 Email hk _salesOleadshine com 13
17. wever 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 e Leadshine DM542 Fully Digital Stepper Drive Manual V1 0 Selecting Supply Voltage The power MOSFETS inside the DM542 can actually operate within 20 50VDC 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 spe
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