PLD545-G3 New generation stepper motor driver

PLD545-G3 New generation stepper motor driver I N S T R U CT I O N M A N U A L 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. General information Delivery set Technical features Driver installation and ventilation Driver functional capabilities Control Signal Connections to the driver Current and power option Stepper motor connection to the driver Protection functions, setup Step division option Terms of Warranty 2 2 3 4 5 6 10 10 11 13 14

01. General information! Check for more information. 01 General information PLD545-G3 is a modern and available microstepping stepper motor driver of a new generation. The driver has inbuilt coil short-circuit protection, back EMF effect protection, inbuilt automatic compensator of normal speed stepper motor resonance, morphing, polarity reversal power protection and soft starter scheme; dumper; STEP frequency generator. The device works with standard control protocol STEP/DIR/ENABLE or CW/CCW/ ENABLE. All driver s control inputs are optoisolated and logic levels 2.5V, 3.3V, 5V compatible. The driver is AUTO-SLEEP mode supplied which is turned on when there is no STEP signal. The device is optimal for control of bipolar and unipolar Purelogic R&D stepper motors (PL42/PL57 series). Work with other stepper motors is also possible. 02 Delivery set New generation stepper motor driver PLD545-G3 1 pcs. Instruction manual 1 pcs. Power off device before making any connections. Power switch should be installed before power supply, at ~220V side. Do not connect the drivers in series, only star connection is allowed. Do not connect power supply s «-» to ground, mass, housing, etc. Strictly observe the polarity of power supply and control signals connections. Technical features Module power supply Operating current of stepper motor driver Stepdivision (microstep) Inbuilt STEP generator frequency STEP Max signal frequency Max shaft rotation frequency Isolation resistance Operating temperature Unit weight without packaging 18...45V (bogey value 40V) 1:4, 1:8, 1:16, 1:32 ~2 khz 350kHz 500 MOhm 0...50 С 0,3 kg 03 2.5 5А regulation range 1 1.25 2.5А regulation range 2 (Fig.2) 138 cycles per second or 8200 cycles per minute (PL57H76, 45V, step division 1:8, 220kHz) All connections and mode changing of driver s work must be performed only when supply voltage is OFF. Do not mount the power switch after the power source (on the driver power line). The mounting of the power switch is allowed only as far as the power board, ~220V. Do not connect the drivers in series, only star connection is allowed. Do not connect - power source with grounding, mass, case, etc. Observe the correct polarity connection of the power source and operating signals. 3

04. Driver installation and ventilation 04 Driver installation and ventilation In order to ensure optimal thermal conditions of installation of the equipment inside the rack CNC control must be carried out, adhering to the scheme below: Installing environmental conditions 1) Working environment temperature: 0~45 C. 2) Work environment humidity: lower than 40~80% (non condensing). 3) Storage environment temperature: -40~55 C. 4) Storage environment humidity: lower than 80% (non condensing). 5) Vibrate: lower than 0.5G. 6) Avoid direct sunlight. 7) Prevent oil mist, erosion of salt. 8) Prevent corrosive liquid, gas. Driver functional capabilities 05 Optoisolation of module control signals STEP/DIR/ENABLE. Working mode STEP/DIR or CW/CCW Inbuilt testing STEP generator frequency (~ 2 khz) Expanded adjustment of working current of stepper motor phases with divider Stepper motor softstarter. After turning on the power or ENABLE signal, current is increasing gradually in stepper motor coils. This allows to exclude typical bump when turning stepper motor on. AUTO-SLEEP mode, driver after 1 sec standstill (lack of STEP signal) automatically enters rotor hold mode (full/half operating current) for heating reduction Coil short-circuit module protection, wrong stepper motor connection protection Protection against back EMF effect Polarity reversal power protection (driver will not be turned on) Protection against overheating (temperature sensor) Inbuilt automatic compensator of normal speed stepper motor resonance Phase current adjustment for vibrations exclusion at low revs Modifications scheme of phase current form Inbuilt dumper Optoisolated output of driver alarm indicator (ERROR) Convenient dismountable clip connectors to step motor, power source and control signals Alarm indication supplied by STEP frequency, inbuilt dumper operation Possibility of cooling fan (50х50mm) mounting on driver s radiator. Cooling fan power performs via external power source. Cooling fan is not included in the delivery set. 5

05. Driver functional capabilities STEP/DIR or CW/CCW driver mode is installed via SW5 switch. When choosing CW/CCW mode, CW is connected to STEP contact, CCW is connected to DIR contact. As STEP signal frequency is increased, STEP LED intensity also changes. The scheme of differential input device and connection method to the controller with outputs open collector type is shown in fig. 2. Controlling signals connection to the module is performed according to the scheme in fig. 5. STEP/CW/CCW signal characteristics are the following: working voltage 2.5V, 3.3V, 5V (you may need extra current-limiting resistor connection), current consumption up to 20mА, min signal duration is 2ms. The step is carried out on the signal leading edge. DIR signal characteristics are working voltage 2.5V, 3.3V, 5V (you may need extra current-limiting resistor connection), current consumption up to 20мА, action time is 200 nsec before/after front edge STEP. ENABLE signal characteristics are working voltage 2.5V, 3.3V, 5V (you may need extra current-limiting resistor connection), current consumption up to 20mА, action time is 100 ms. Logic unit (voltage is applied to the input) stepper motor driver is off and coils are cut off the current, zero stepper motor driver is on and stepper motor coils are supplied. Fig. 1. PLD545-G3 driver dimensions 06 Control Signal Connections to the driver The driver operates with standard signals STEP/DIR/ or CW/CCW and ENABLE. The signals are transmitted to differential optoisolated inputs. Fig. 2. Differential input device 7

06. Control Signal Connections to the driver 45V Stepper motor driver Fig. 3. General scheme of CNC control 9

07. Current and power option 07 08 Current and power option Max supply voltage driver option depends on the applied stepper motor and desired max rotation speed. Optimal supply voltage calculation for the stepper motor is carried out according to the formula U=32*v (stepper motor phase inductance mh), but not more than 45V. Supply current must be chosen 50...70% from the claimed stepper motor coil current. Working current setting is carried via trimming resistor WORK CURRENT and DIP-switch SW4. When there is no STEP signal more than 1 sec, the driver goes to AUTO-SLEEP mode. and reduces the coil current to the value identified by DIP-switch SW3. Power off device before making any connections. Stepper motor connection to the driver PLD545-G3 driver is optimal for control of bipolar and unipolar stepper motors Purelogic R&D series PL42/PL57. Stepper motor connection to the driver is performed as it is shown in fig.5 (clips PH1.1[+A], PH1.2[-A] и PH2.1[+B], PH2.2[-B]). The driver has protection against wrong stepper motor coil connection and coils linked together / + power supply. Purelogic R&D stepper motor s connection to the driver is performed according fig. 4. Please note in case of changing phases PH1.x<>PH2.x, the motor will start rotating in the opposite direction ( inversion analogue of DIR signal). The length of wires leading to the stepper motor from the driver must not exceed 10 meters. Longer wires can lead to driver s work failures. It is strongly recommended to interlace the stepper motor wires per phase, then put this braid to the screened metal sheath. Sheathes and stepper motor frame must be grounded. PH1.1 [+А] PH1.2 [-А] PH2.1 [+B] PH2.2 [-B] Red (RED) Orange (ORG) Blue (BLU) Green (GRN) Fig. 4. Purelogic R&D stepper motor connection to the driver Protection functions, setup 09 Softstarter - As power voltage or ENABLE signal is turned on, current in stepper motor coils increases gradually. This allows to exclude typical bump when turning stepper motor on. Phase current adaptation exclusion of vibrations at low revs. Overheating protection the driver has inbuilt temperature sensor which changes radiator temperature. When radiator temperature reaches ~60 С the driver turns off. It will be on as soon as the temperature drops to ~50 С. Change of SW1-SW6 DIP switch-overs must be performed with the power supply OFF. In case of switch-overs change under the given current the driver will not react. It will react only at the moment of switching on. When the power is switched on, red signal ERR flashes on. When there is no alarm red LED ERR goes out (in 1 sec), green PWR flashes on. With STEP frequency, STEP light intensity changes (from green to orange). DUMP LED indicates dumper operation (back EMF compensation). When the protection function operates, the driver switches off stepper motor coils, red signal ERR flashes on, ERROR output operates. 11

09. Protection functions, setup The driver restores its work after alarm cause removal and switching off/on power supply. Phase current adaptation (stepper motor smooth running) is carried out by PHASE TRIM potentiometer when vibrations and uneven stepping at low revs is found. Adaption strategy is as follows: 1) A potentiometer is set to the extreme left position (minimum value). 2) Stepper motor is connected, voltage is supplied, vibration frequency is set up by STEP frequency generator. 3) When smoothly rotating PHASE TRIM potentiometer clockwise, the vibration reduces. You may fail to reduce vibrations totally because of stepper motor specifics. When removed from one frequency, vibrations can appear in another frequency. Therefore it is necessary to choose the most suitable way of setting. The driver has inbuilt STEP frequency generator. Generator frequency is fixed and equals ~2 khz. Generator switching on is performed via DIP-switch SW6 (fig.1). In some cases by interturn short-circuit of stepper motor coil, short-circuit protection may not work because there is no exceeding of permissible alarm current. This happens because under such coil short circuit resistance does not equal 0 and the driver maintains the specified current. Step division option 10 Fig. 5. Stepper motor driver connection scheme The driver allows to divide electronically physical stepper motor step - 4, 8, 16 and 32. Thus positioning accuracy is higher. Step division mode is called microstep division. This mode allows to reduce stepper motor resonances at low revs. It is recommended to use PLD545-G3 driver in step division 1:8, 1:16 or 1:32. In these modes stepper motor rotates as smooth as possible, lowfrequency vibrations are minimal, automatic compensator of stepper motor mid frequency resonance works best. 13

10. Step division option Switching of step division mode is performed by dip-switches SW1 and SW2. (fig. 5). Step division choice must be performed only when driver supply is OFF. 11 Terms of Warranty The warranty period is 12 months after purchasing and is valid only if all operational conditions and scheduled maintenance are strictly followed. 1. General terms 1.1. In case of product acquisition as separate components, Seller guarantees working ability of every component, but does not assume responsibility for the quality of their joint work (mismatch of components). If you have questions please consult our technical support team. 1.2. Seller does not guarantee compatibility of the purchased product with the one that Buyer already has or bought from third parties. 1.3. Product s component parts and configuration can be changed by manufacturer without notice due to the product consistent technical improvement. 2. Conditions for warranty acceptance 2.1. The product is accepted only in the same completeness of set as it was purchased. 3. Warranty service procedure 3.1. Warranty service is performed by testing the claimed product defect. 3.2. If the defect is proved, warranty repair is carried out. 4. We do not assume any responsibility for glass, electric lamps, starters and expendable materials as well as: 4.1. Damaged product caused by inappropriate transport and store conditions, wrong connection, operation in abnormal (off-design) mode, or in conditions which are not manufacturer-supplied (including temperature and humidity out of limits of recommended range), having damages due to third-party circumstances (voltage jumps, natural disasters, etc.), also having mechanical or thermal damages. 4.2. The product with traces of foreign objects or substances impact, including dust, liquids, insects, also objects having extraneous inscription. 4.3. The product with traces of unauthorized tampering and (or) repair process (traces of opening, home-made soldering, elements changing etc). 4.4. The product with self-diagnostic function that shows improper exploitation. 4.5. Technically complex product in respect of which assembly and integration and start-up works were not performed by Seller specialists or by recommended organizations, except in cases directly regulated under goods documentation. 4.6. In cases when the product exploitation was performed in conditions when power supply did not correspond with manufacturer s requirements, also when there is no electrical protection device. 4.7. The product which was resold by the initial buyer to the third party. 4.8. The product with defects which were caused by low-quality spare parts or fulfilled their service life spare parts,consumable materials, also using spare parts, consumable materials not corresponding with manufacturer s requirements. Produced and accepted in accordance with obligatory requirements of valid technical documentation and is qualified for exploitation. Lot number: Technical Control Department 15

We draw your attention to the fact that there can be some changes in this instruction due to the product consistent technical improvement. You can always download our latest versions at www. purelog i c. r u Contacts Moscow +7 (495) 505-63-74 Voronezh +7 (473) 204-51-56 149 Office 160, Leninsky avenue, Voronezh, Russia, 394033 Monday - Thursday: 8.00 17:00 Friday: 8.00 16.00 Break: 12.30 13.30 sales@purelogic.ru