User`s Manual - Excella Electronics
Contents
1. mode 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 pulse 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 If a power supply serves several drivers separately connecting 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 9 EXCELLA Controller MD2278 Driver Stepper Motor B R 0 if VCC 5V R 1K Power gt 0 125W if VCC 12V R 2K Power gt 0 125W if VCC 24V R must be connected to control signal terminal Figure 9 Typical connection 10 Sequence Chart of Control Signals In order to avoid some fault operations and deviations PUL DIR and ENA signals shoul2. User s Manual For 22078 High Performance Microstepping Driver Attention Please read this manual carefully before using the driver EXCELLA ELECTRONICS Ghatkopar E Mumbai 400 077 Tel 022 2102 9911 Fax 2102 9922 Contents Table of contents 1 Introduction Features and Applications cccccccccccccceecceceeceeceeaeeeeesseeseesceseeeeeeeeeeees l KUTO UC OT esarion EEE E E E N E EE TEE EN l Eo o E E E I E l PO ICAU ON e a E E E E E l L O a E E E E E l Elecirical Spe CHICATIONG sopari esra aa Eaa e a E Ten EE aara oneey l Mechanical SOCCLICATONS esseere EE 3 Operating Environment and Other Specifications cc cccsesseessesssteeseseeeseesceeeees 3 Elimination of Heata ca cansucasensnvadsiavoncascansendacdusnonmvedenenendouacsinstuectsdsouaduonenoscosnanvabecetdes 4 3 Pin Assignment and DEeSCTIIptiOD csssssssssssssssescesceecesceeceeceecessesseausensenssssseseeecens 4 Connector FIO tito UAL LOTS seei Ei E EEE 4 Connector PZ Oni OU AllOUS seksione nni e E EE Eaa at 4 4 Control Signal Connector P1 Interface cc cicescesseesessesseseeseeesceceeceeceeseeaeaeesenes 5 5 ConnecUne Me Mol asesinan a eenaa raii 6 Connections to 4 lead MOtO0S sa siveindsenascdvarrnastanconscnensusadircanneteccndendiessosiens saicasnadegesaabess 6 Connections to 6 lead MOtomrs cccessssssscsceccecceceeceeceeceeceeceseeseseeseeseeeseseseeeseeeeeeeees 6 Half Coil Configurations cacic2acsseaceaaesataasot
3. acssnataseasersesecdosocectennigemntntutewpenneemeance 6 Full CoilC onfi SU AGiOns esiseina enana iia a EERE Ean 6 Connections to lead MOTI S siecussccesusaieadinasannshcannsessinetesianendsdentocantoedaeetnicxewmnanesduietts 7 Series Connections issiccsacndacaascrancdsnaniametcenedassbodesainanadatadstinesauaetetenetceetedieaveetiaiens 1 Parallel COnneCHONS cascccasacensaudassnusasnegia a ae Eai 7 6 POW CE SUB yee COMO ge crise acca esis erecarsiereiep es eediceauee cnscesee deren eecac E Eaa 8 Cle CUS SONIY VOT iarierease cnet cara rontgsto E 8 7 Selecting Microstep Resolution and Driver Output Current cccceccceceeceeeeeeeenees 8 Microstep Resolution Selection cccccccccccccsesnesnesssesssesesseeseeseeceeceeceeceeeeeaeaeageees 8 Re are aao EEN POEA EE E ore P EE AEA teen A EAE AE 9 Dynamic IIS I Setini age coscerarsrcn cients avis n Tre ira aa 9 SE A a E E ATAA ET T E T 10 Control Signal Mode Setting cccccccccsecseccesecssectsanssesenssseresssessssscescenee 10 Contents 6 Winine NOES acien aa nia E E Aaaa 10 Pc OG A C onne C01 es rst a wredereet setae ocenceueseec E a En 10 10 Sequence hart of Control S1 mals 1c 2isctacicncseneetenspanesinstasiunsnsegaaceevastaesacarsaudeseoeiss 11 11 Protection Functions cs ccascnsasnnsedencaiaeinadennnndon savancmsutmepasaponsaronensuonedopeasadendeswmannenshusiiss 12 Over voltage Pr Ole Cb OM ssiacs5 cai seachchaaterniceseeciuesartinaneehavennesteciamacactaane
4. d abide by some rules shown as following diagram tous t3 ti High Level gt 3 5V PUL l l i PUL CW TF Ca et iH g Level gt 3 5V ee po or eee ereieo Ge it 2ops DIR JIR CCW ti Bus rane Low Level lt 0 5V ENA ENA PUL DIR CW CCW Figure 11 Sequence chart of control signals Remark 1 tl ENA must be ahead of DIR by at least Sus logic HIGH as effective Generally ENA and ENA is NC not connected 2 t2 DIR must be ahead of PUL effective edge by at least Sus to ensure correct EXCELLA direction 3 t3 Pulse width not less than 1 2us 4 t4 Low level width not less than 1 2us 11 Protection Functions To improve reliability the driver incorporates some built in protection features Over voltage Protection When power supply voltage exceeds 250VAC protection will be activated and LED will turn red When power supply voltage is lower than 80VAC the driver will not works properly Short Circuit Protection Protection will be activated in case of short circuit between motor coils or between motor coil and ground Wrong Motor Connection Protection Protection will be activated when the motor is connected in a wrong way 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 12 Frequently Asked Questions In the event that your 22078 doesn t o
5. ed 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 Driver vcc j 2709 R 0 if VCC 5V R 1K Power gt 0 125W if VCC 12V R 2K Power gt 0 125W if VCC 24V R must be connected to control signal terminal Figure 3 Connection to PNP signal common cathode EXCELLA 5 Connecting the Motor The 22078 can drive 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 B B 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
6. eesenenrostaceausevex 12 BMG CU OC a e E E aie auiedauenseeenneres 12 Wrong Motor Connection Protection c cscesessesnenesneeaeeaeeaeseeaeeaeeceeceeeeeeeess 12 12 Frequently Asked Questions cccccccccccceeceeceeceeceseescescessessesseseeseeeesessessesseenesneages 12 Problem Symptoms and Possible Causes c ccccccccccccecceceeceececeeceeceeseeseseeseesenees 12 I Microstepping Driver Manual E 22078 1 Introduction Features and Applications Introduction The 22078 is a high voltage and high performance microstepping driver based on one of the most advanced technologies in the world today Its suitable for driving 2 phase and 4 phase hybrid stepping motors By using advanced bipolar constant current chopping technique the 22078 can output more torque than other drivers at high speed The microstep capability allows stepping motors to run at higher smoothness less vibration and lower noise Its 3 state current control technology allows coil current to be well controlled with relatively small current ripple therefore less motor heating is achieved Features High quality low price Input frequency up to 400KHz Low heating for motor amp driver Supply voltage up to220VAC Suitable for 2 phase and 4 phase stepping Output current up to 7 8A 5 57 ARMS motors TTL compatible and Opto isolated inputs Automatic idle current reduction 16 microstep resolutions selectable DIP switch current sett
7. ing CW CCW mode selectable Applications Suitable for large and medium automation machines and equipments such as engraving machines labeling machines cutting machines laser phototypesetting systems plotting instruments NC machines pick place devices and so on Particularly adapt to the applications desired with low vibration high speed and high precision 2 Specifications Electrical Specifications Tj 2501 A 0 42 0 3A RMS 7 8 80 180 220 VAC 7 10 16 mA 0 400 Khz 500 MQ Mechanical Specifications unit mm 1 inch 25 4 mm bs 143 8 t 162 5 176 Figure 1 Mechanical specifications Operating Environment and Other Specifications Approx 1 16 kg 41 oz Environment Avoid dust oil fog and corrosive gases Humidity 40 RH 90 RH Vibration 5 9m s Max EXCELLA Elimination of Heat Driver s reliable working temperature should be lt 65 motor working temperature should be lt 80 Forced cooling the driver if it s necessary 3 Pin Assignment and Description The 22078 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 of the 22078 More detailed descriptions of the pins and related issues are presented in section 4 5 9 Connector P1 Configurations DIR signa
8. ing 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 80 180 VAC leaving room for power fluctuation and back EMF If the motion speed requirement is low it s better to use lower supply voltage to decrease noise heating and improve reliability 7 Selecting Microstep Resolution and Driver Output Current This driver uses a 9 bit DIP switch to set microstep resolution motor operating current and control signal mode as shown in the following figure Microstep Dynamic Resolution Current en 11213 14 5 6 7 819 PUL DIR or CW CCW selection Microstep Resolution Selection Microstep resolution is set by SW1 2 3 4 of the DIP switch as shown in the following table Steps rev for 1 8 motor SWl SWw2 SW3 SWw4 400 ON ON ON ON EXCELLA 500 FF ON ON ON ee ON COFF ON ON 800 CFF OFF ON ON lo ON ON CF ON 1200s ON OFF ON o lo ON CFF COFF Y ON o 200 OF OFF OFF ON O o ON CON ONCE o 30 O ON ON OFF 40000 ON O YON COFF o 500 OF OFF ON OFF Oo a i 6400 OFF ON OFF OFF o w N CFF OFF COFFE 10000 OF OFF OFF OFF Current Settings For a given motor higher driver current will make the motor to output more tor
9. l In single pulse mode this signal has low high voltage levels representing two directions of motor rotation in double pulse mode set by SWS this signal is counter clock CCW pulse effective for high level For reliable motion response DIR signal should be ahead of PUL signal by 5ps at least 4 5V when DIR HIGH 0 0 5V when DIR LOW Please note that motion 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 nabl s signal is use bl sabling the dr High level Alarm signal positive READY is a photocouper output from open collector circuit effectively output when driver operate normally maximum permitted input voltage is 30VDC maximum output current 20mA It generally can be serial connected to PLC input terminal zZ a n n O Z F o Z Q x Q Q T z Q S amp z So 5 a n n Q T F o Z o z 3 a 9 Connector P2 Configurations EXCELLA theoretical output voltage of 80 180 VAC leaving room for power at fluctuation and back EMF A A Motor phase A B B Motor phase B PE Ground terminal Recommend connect this port to the ground for better safety 4 Control Signal Connector P1 Interface The 22078 can accept differential and single ended inputs including open collector and PNP output The 22078 has 3 optically isolated logic inputs which are locat
10. nections 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 EXCELLA 6 Power Supply Selection The 22078 can match large and medium size stepping motors from NEMA size 34 to 43 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 Attention For safety and to improve reliability it is recommended to use isolation transformer instead of directly use network source to supply the 22078 Recommend use isolation transformers with theoretical output voltage of 80 I180VAC leaving room for power fluctuation and back EMF And the power of the isolation transformer should larger than 500 watts Selecting Supply Voltage The 22078 can actually operate within 80V 220VAC 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 los
11. perate 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 Symptoms Possible Problems Motor is not rotating No power EXCELLA 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
12. que 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 SW6 7 8 9 of the DIP switch are used to set the dynamic current Select a setting closest to your motor s required current Dynamic Current Setting 045 OFF OFF OFF ON EXCELLA 555 3 96 ON 660 4 71 ON 780 5 57 ON Notes Due to motor inductance the actual current in the coil may be smaller than the dynamic current settings particularly under high speed condition Standstill Current The 22078 has automatic idle current reduction function The current automatically be reduced to 60 of dynamic current setting 0 2 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 us Control Signal Mode Setting SW5 is used for this purpose SW5 ON means CW CCW pulse pulse mode and SW5 OFF means PUL DIR
13. 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 A A NC B B NC 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 EXCELLA 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 r NC B B Figure 6 6 lead motor full coil hi gher 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 P2 Figure 7 8 lead motor series con
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