STEPPER DRIVE : E-5042

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1 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S Introduction The E-5042 is a fuy digita stepper drive deveoped with advanced DSP contro agorithm based on the atest motion contro technoogy. It has achieved a unique eve of system smoothness, providing optima torque and nus mid-range instabiity. Its motor auto-identification and parameter auto-configuration feature offers quick setup to optima modes with different motors. Compared with traditiona anaog drives, E-5042 can drive a stepper motor at much ower noise, ower heating, and smoother movement. Its unique features make E-5042 an idea choice for high requirement appications. Features Anti-esonance provides optima torque and nus mid-range instabiity Motor auto-identification and parameter auto-configuration technoogy, offers optima responses with different motors Muti-Stepping aows a ow resoution step input to produce a higher microstep output, thus offers smoother motor movement 15 seectabe microstep resoutions incuding 400, 800, 1600, 3200, 6400, 12800, 25600, 1000, 2000, 4000, 5000, 8000, 10000, 20000, Soft-start with no jump when powered on Input votage 18-50VDC 8 seectabe peak current incuding 1.00A, 1.46A, 1.91A, 2.37A, 2.84A, 3.31A, 3.76A, 4.20A Puse input frequency up to 200 KHz, TTL compatibe and opticay isoated input Automatic ide-current reduction Suitabe for 2-phase and 4-phase motors Support PUL/DI and CW/CCW modes Over-votage, over-current protections Appications 2. Specifications Eectrica Specifications (Tj = 25 /77 ) Parameters DM542 Min Typica Max Unit Output Current (3.0 MS) A Input Votage VDC Logic Signa Current ma Puse input frequency khz Puse Width us Puse Votage 5-24 VDC Isoation resistance 500 MΩ 1 Suitabe 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 tabes, engraving machines, abeing machines, aser cutters, pick-pace devices, and so on. Particuary adapt to the appications desired with ow noise, ow heating, high speed and high precision.

2 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S Operating Environment and other Specifications Cooing Natura Cooing or Forced cooing Avoid dust, oi fog and corrosive gases Environment 0 50 Ambient Temperature Operating Environment Humidity 40%H 90%H 70 Operating Temperature Max 5.9m/s2Max Vibration Storage Temperature Weight Approx. 300g (10.6oz) Figure 1: Mechanica specifications *ecommend use side mounting for better heat dissipation Eimination of Heat Driver s reiabe working temperature shoud be < 70 (158 ),and motor working temperature shoud be <80 (176 ); It is recommended to use automatic ide-current mode, namey current automaticay reduce to 50% when motor stops, so as to reduce driver heating and motor heating; It is recommended to mount the driver verticay to maximize heat sink area. Use forced cooing method to coo the system if necessary. 2 Mechanica Specifications (unit: mm [inch])

3 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S 3. Pin Assignment and Description The DM542 has two connectors, connector P1 for contro signas connections, and connector P2 for power and motor connections. The foowing tabes are brief descriptions of the two connectors. More detaied descriptions of the pins and reated issues are presented in section 4, 5, 9. Connector P1 Configurations Pin Function PUL+ PUL- DI+ DI- ENA+ ENA- Detais Puse signa:in singe puse (puse/direction) mode, this input represents puse signa, each rising or faing edge active (set by inside jumper J3); 5-24V when PUL-HIGH, 0-0.5V when PUL-LOW. In CCW mode (set by inside jumper J1), this input represents cockwise (CW) puse. For reiabe response, puse width shoud be onger than. 2.5μs DI signa: In singe-puse mode, this signa has ow/high votage eves, representing two directions of motor rotation; in CW/CCW mode (set by inside jumper J1), this signa is counter-cock (CCW) puse. For reiabe motion response, DI signa shoud be ahead of PUL signa by 5μs at east. 5-24V when DI-HIGH, 0-0.5V when DI-LOW. Pease note that rotation direction is aso reated to motor-driver wiring match. Exchanging the connection of two wires for a coi to the driver wi reverse motion direction. Enabe signa:this signa is used for enabing/disabing the driver. High eve (NPN contro signa, PNP and differentia contro signas are on the contrary, namey ow eve for enabing.) for enabing the driver and ow eve for disabing the driver. Usuay eft UNCNECTED (ENABLED). Seecting Active Puse Edge or Active Leve and Contro Signa Mode (a) J1, J3 open circuit (b) J1 open circuit, J3 shirt circuit PUL/DI mode and Active at rising edge (NPN) (c) J1 short circuit, J3 open circuit CW/CCW mode PUL/DI mode and active at faing edge (NPN) (d) J1, J3 short circuit CW/CCW mode Figure 2: J1 and J3 jumper Settings 3 There are two jumpers J1 and J3 inside the M860 specificay for seecting active puse edge or effective eve and contro signa mode, as shown in figure 2. Defaut setting is PUL/DI mode and upward-rising edge active. (Note: J2 inside the driver is used to reverse the defaut rotation direction.)

4 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S Connector P2 Configurations Pin Function +V Detais Power suppy, 20~50 VDC, Incuding votage fuctuation and EMF votage. GND Power Ground. A+, A- Motor Phase A B+, B- Motor Phase B 4. Contro Signa Connector (P1) Interface The E-5042 can accept differentia and singe-ended inputs (incuding open-coector and PNP output). The E-5042 has 3 opticay isoated ogic inputs which are ocated on connector P1 to accept ine driver contro signas. These inputs are isoated to minimize or eiminate eectrica noises couped onto the drive contro signas. ecommend use ine driver contro signas to increase noise immunity of the driver in interference environments. In the foowing figures, connections to open-coector and PNP signas are iustrated. Drive Controer VCC PUL+ Controer PUL PULPUL PUL+ VCC DI+ Drive DI PULDI+ DIDI DIENA+ ENABLE ENA+ ENAENA- ENABLE Figure 3: Connections to open-coector signa (common-anode) Figure 4: Connection to PNP signa (common-cathode) The E-5042 can drive any 2-pahse and 4-pahse hybrid stepping motors. Connections to 4-ead Motors 4 ead motors are the east fexibe but easiest to wire. Speed and torque wi depend on winding inductance. In setting the driver output current, mutipy the specified phase current by 1.4 to determine the peak output current. Figure 5: 4-ead Motor Connections 4 5. Connecting the Motor

5 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S Connections to 6-ead Motors Like 8 ead stepping motors, 6 ead motors have two configurations avaiabe for high speed or high torque operation. The higher speed configuration, or haf coi, is so described because it uses one haf of the motor s inductor windings. The higher torque configuration, or fu coi, uses the fu windings of the phases. Haf Coi Configurations As previousy stated, the haf coi configuration uses 50% of the motor phase windings. This gives ower inductance, hence, ower torque output. Like the parae connection of 8 ead motor, the torque output wi be more stabe at higher speeds. This configuration is aso referred to as haf chopper. In setting the driver output current mutipy the specified per phase (or unipoar) current rating by 1.4 to determine the peak output current. Figure 6: 6-ead motor haf coi (higher speed) connections Fu Coi Configurations Figure 7: 6-ead motor fu coi (higher torque) connections Connections to 8-ead Motors 8 ead motors offer a high degree of fexibiity to the system designer in that they may be connected in series or parae, thus satisfying a wide range of appications. Series Connections A series motor configuration woud typicay be used in appications where a higher torque at ower speeds is. this configuration has the most inductance, the performance wi start to degrade at higher required Because speeds. In series mode, the motors shoud aso be run at ony 70% of their rated current to prevent over heating. 5 The fu coi configuration on a six ead motor shoud be used in appications where higher torque at ower speeds is desired. This configuration is aso referred to as fu copper. In fu coi mode, the motors shoud be run at ony 70% of their rated current to prevent over heating.

6 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S Figure 8: 8-ead motor series connections Parae Connections An 8 ead motor in a parae configuration offers a more stabe, but ower torque at ower speeds. But because of the ower inductance, there wi be higher torque at higher speeds. Mutipy the per phase (or unipoar) current rating by 1.96, or the bipoar current rating by 1.4, to determine the peak output current. Figure 9: 8-ead motor parae connections 6. Power Suppy Seection The E-5042 can match medium and sma size stepping motors (from NEMA frame size 17 to 34) made by us or other motor manufactures around the word. To achieve good driving performances, it is important to seect suppy votage and output current propery. Generay speaking, suppy votage determines the high speed performance of the motor, whie output current determines the output torque of the driven motor (particuary at ower speed). Higher suppy votage wi aow higher motor speed to be achieved, at the price of more noise and heating. If the motion speed requirement is ow, it s better to use ower suppy votage to decrease noise, heating and improve reiabiity. Both reguated and unreguated power suppies can be used to suppy the driver. However, unreguated power suppies are preferred due to their abiity to withstand current surge. If reguated power suppies (such as most switching suppies.) are indeed used, it is important to have arge current output rating to avoid probems ike current camp, for exampe using 4A suppy for 3A motor-driver operation. On the other hand, if unreguated suppy is used, one may use a power suppy of ower current rating than that of motor (typicay 50% 70% of motor current). The reason is that the driver draws current from the power suppy capacitor of the unreguated suppy ony during the duration of the PWM cyce, but not during the duration. Therefore, the average current withdrawn from power suppy is consideraby ess than motor current. For exampe, two 3A motors can be we suppied by one power suppy of 4A rating. Mutipe Drivers It is recommended to have mutipe drivers to share one power suppy to reduce cost, if the suppy has enough capacity. To avoid cross interference, DO NOT daisy-chain the power suppy input pins of the drivers. (Instead, pease connect them to power suppy separatey.) 6 eguated or Unreguated Power Suppy

7 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S Seecting Suppy Votage The power MOSFETS inside the E-5042 can actuay operate within +20 ~ +50VDC, incuding power input fuctuation and back EMF votage generated by motor cois during motor shaft deceeration. Higher suppy votage can increase motor torque at higher speeds, thus hepfu for avoiding osing steps. However, higher votage may cause bigger motor vibration at ower speed, and it may aso cause over-votage protection or even driver damage. Therefore, it is suggested to choose ony sufficienty high suppy votage for intended appications, and it is suggested to use power suppies with theoretica output votage of +20 ~ +45VDC, eaving room for power fuctuation and back-emf. 7. Seecting Microstep esoution and Driver Output Current This driver uses an 8-bit DIP switch to set microstep resoution, and motor operating current, as shown beow: Microstep esoution Seection Microstep Steps/rev.(for 1.8 motor) SW5 SW6 SW7 SW Current Settings For a given motor, higher driver current wi make the motor to output more torque, but at the same time causes more heating in the motor and driver. Therefore, output current is generay set to be such that the motor wi not overheat for ong time operation. Since parae and seria connections of motor cois wi significanty change resuting inductance and resistance, it is therefore important to set driver output current depending on motor phase current, motor eads and 7 Microstep resoution is set by SW5, 6, 7, 8 of the DIP switch as shown in the foowing tabe:

8 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S connection methods. Phase current rating suppied by motor manufacturer is important in seecting driver current, however the seection aso depends on eads and connections. The first three bits (SW1, 2, 3) of the DIP switch are used to set the dynamic current. Seect a setting cosest to your motor s required current. Dynamic Current Setting Peak Current MS Current SW1 SW2 SW3 1.00A 0.71A 1.46A 1.04A 1.91A 1.36A 2.37A 1.69A 2.84A 2.03A 3.31A 2.36A 3.76A 2.69A 4.20A 3.00A Notes: Due to motor inductance, the actua current in the coi may be smaer than the dynamic current setting, particuary under high speed condition. Standsti Current Setting SW4 is used for this purpose. meaning that the standsti current is set to be haf of the seected dynamic current, and meaning that standsti current is set to be the same as the seected dynamic current. The current automaticay reduced to 50% of the seected dynamic current one second after the ast puse. Theoreticay this wi reduce motor heating to 36% (due to P=I2 * ) of the origina vaue. If the appication needs a different standsti current, pease contact Leadshine. Auto Tuning by SW4 28B Auto Tuning equirement and Procedure : 1. Motor is connected to drive. 2. Power is connected to drive. 3. Turn on the power. 4. Make sure there is no puse appied to drive. 5. Switch SW4 two times in one second. That is -- or 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 instaation. The motor parameter is identified and the drive s current oop parameters are cacuated automaticay when SW4 is activated. The motor shaft wi have a itte vibration during auto-configuration. If the user changes the motor or the power suppy, don s forget to togge SW4 once again.

9 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S 8. Wiring Notes In order to improve anti-interference performance of the driver, it is recommended to use twisted pair shied cabe. To prevent noise incurred in PUL/DI signa, puse/direction signa wires and motor wires shoud not be tied up together. It is better to separate them by at east 10 cm, otherwise the disturbing signas generated by motor wi easiy disturb puse direction signas, causing motor position error, system instabiity and other faiures. If a power suppy serves severa drivers, separatey connecting the drivers is recommended instead of daisy-chaining. It is prohibited to pu and pug connector P2 whie the driver is powered, because there is high current fowing through motor cois (even when motor is at standsti). Puing or pugging connector P2 with power on wi cause extremey high back-emf votage surge, which may damage the driver. 9. Typica Connection A compete stepping system shoud incude stepping motor, stepping driver, power suppy and controer (puse generator). A typica connection is shown as figure 10. Controer DM542 VCC = 5-24V PUL+ VCC 270O PULPuse DI+ 270O DIENA+ 270O ENAEnabe A+ Stepper Motor AB+ B- ecommended Power Suppy 20 ~ 45VDC +V GND Figure 10: Typica connection 9 Direction

10 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S 10. Sequence Chart of Contro Signas In order to avoid some faut operations and deviations, PUL, DI and ENA shoud abide by some rues, shown as foowing diagram: Figure 11: Sequence chart of contro signas emark: a) t1: ENA must be ahead of DI by at east 5ms. Usuay, ENA+ and ENA- are NC (not connected). See Connector P1 Configurations for more information. b) c) d) t2: DI must be ahead of PUL effective edge by 5ms to ensure correct direction; t3: Puse width not ess than 2.5ms; t4: Low eve width not ess than 2.5ms. 11. Protection Functions Priority Time(s) of Bink 1st 1 Over-current protection activated when peak current exceeds the imit. 2nd 2 Over-votage protection activated when drive working votage is greater than 52VDC Sequence wave of red LED Description When above protections are active, the motor shaft wi be free or the red LED binks. eset the driver by repowering it to make it function propery after removing above probems. 10 To improve reiabiity, the driver incorporates some buit-in protections features.

11 54, Annapurna Industria Estate, Tiak oad, E L E C T O N I C S 12. Frequenty Asked Questions In the event that your driver doesn t operate propery, the first step is to identify whether the probem is eectrica or mechanica in nature. The next step is to isoate the system component that is causing the probem. As part of th process you may have to disconnect the individua components that make up your system and verify that they opera independenty. It is important to document each step in the troubeshooting process. You may need this documentation to refer back to at a ater date, and these detais wi greaty assist our Technica Support staff in determining the probem shoud you need assistance. Many of the probems that affect motion contro systems can be traced to eectrica noise, controer software errors, o mistake in wiring. Probem Symptoms and Possibe Causes Symptoms Possibe Probems No power Microstep resoution setting is wrong Motor is not rotating DIP switch current setting is wrong Faut condition exists The driver is disabed Motor rotates in the wrong direction The driver in faut Motor phases may be connected in reverse DIP switch current setting is wrong Something wrong with motor coi Contro signa is too weak Contro signa is interfered Erratic motor motion Wrong motor connection Current setting is too sma, osing steps Current setting is too sma Motor stas during acceeration Motor is undersized for the appication Acceeration is set too high Power suppy votage too ow Inadequate heat sinking / cooing Excessive motor and driver heating Automatic current reduction function not being utiized Current is set too high 11 Something wrong with motor coi

Operating Manual For Stepper Driver

Contents Table of Contents Operating Manual For Stepper Driver 5042 High Performance Micro stepping Driver Attention: Please read this manual carefully before using the driver! E L E C T R O N I C S 54