SOPROLEC DMD4022 Manuale utente

User’s Manual

For

DMD4022

Fully Digital Stepping Driver

Version 1.0

Attention: Please read this manual carefully before using the driver!

18 bis, rue du vert buisson

95470 VEMARS

France

Phone : +33 (0)6 3104 3562 Fax : +33 (0)1 3431 3917

Internet : www.soprolec.com E-Mail:cont[email protected]

Contents

The content in this manual has been carefully prepared and is believed to be accurate, but no

responsibility is assumed for inaccuracies.

Soprolec reserves the right to make changes without further notice to any products herein to

improve reliability, function or design. Soprolec does not assume any liability arising out of the

application or use of any product or circuit described herein; neither does it convey any license

under its patent rights of others.

Soprolec’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 Soprolec’s terms and conditions of sales, the user of Soprolec’s products in life

support or aircraft applications assumes all risks of such use and indemnifies Soprolec against all

damages.

Contents

Table of Contents

1. Introduction, Features and Applications.................................................................... 1

Introduction ........................................................................................................... 1

Features ................................................................................................................. 1

Applications........................................................................................................... 1

2. Specifications ............................................................................................................ 2

Electrical Specifications (Tj =25/77) .............................................................. 2

Mechanical Specifications ( unit: mm [inch] ) ...................................................... 2

Elimination of Heat ............................................................................................... 2

Operating Environment and other Specifications.................................................. 3

3. Pin Assignment and Description ............................................................................... 3

Connector P1 Configurations ................................................................................ 3

Selecting Active Pulse Edge and Control Signal Mode......................................... 4

Connector P2 Configurations ................................................................................ 4

4. Control Signal Connector (P1) Interface ................................................................... 4

5. Connecting the Motor................................................................................................ 5

Connections to 4-lead Motors................................................................................ 5

Connections to 6-lead Motors................................................................................ 6

Half Coil Configurations ............................................................................... 6

Full Coil Configurations................................................................................ 6

Connections to 8-lead Motors................................................................................ 7

Series Connections ........................................................................................ 7

Parallel Connections...................................................................................... 7

6. Power Supply Selection............................................................................................. 7

Regulated or Unregulated Power Supply .............................................................. 8

Multiple Drivers .................................................................................................... 8

Selecting Supply Voltage....................................................................................... 8

7. Selecting Microstep Resolution and Driver Output Current .....................................9

Microstep Resolution Selection.............................................................................9

Current Settings ..................................................................................................... 9

Contents

Dynamic current setting ..............................................................................10

Standstill current setting .............................................................................. 10

8. Wiring Notes............................................................................................................ 10

9. Typical Connection.................................................................................................. 11

10. Sequence Chart of Control Signals........................................................................ 11

11. Protection Functions .............................................................................................. 12

Over-current Protection ............................................................................... 12

Over-voltage Protection............................................................................... 12

Phase Error Protection.................................................................................13

Protection Indications.................................................................................. 13

12. Frequently Asked Questions.................................................................................. 13

Problem Symptoms and Possible Causes ............................................................ 14

13. Professional Tuning Software ProTuner................................................................ 15

Introduction ......................................................................................................... 15

Software Installation............................................................................................ 15

Connections and Testing...................................................................................... 19

RS232 Interface Connection................................................................................ 20

Testing the Stepping System................................................................................ 20

Software Introduction.......................................................................................... 20

Com Config Window................................................................................... 21

Tuning.......................................................................................................... 21

Anti-Resonance Introduction....................................................................... 24

Procedure for Achieving Optimum Performance ........................................ 25

APPENDIX ................................................................................................................. 29

Twelve Month Limited Warranty ........................................................................ 29

Exclusions ........................................................................................................... 29

Obtaining Warranty Service ................................................................................ 29

Warranty Limitations........................................................................................... 29

1. Introduction, Features and Applications

Introduction

The DMD4022 is a versatility fully digital stepping driver based on a DSP with advanced control

algorithm. The DMD4022 is the next generation of digital stepping motor controls. It brings a

unique level of system smoothness, providing optimum torque and nulls mid-range instability.

Motor self-test and parameter auto-setup technology offers optimum responses with different

motors and easy-to-use. The driven motors can run with much smaller noise, lower heating,

smoother movement than most of the drivers in the markets. Its unique features make the

DMD4022 an ideal solution for applications that require low-speed smoothness. Compared to the

DM432C, the DMD4022 has smaller size and lower cost.

Features

zAnti-Resonance, provides optimum torque

and nulls mid-range instability

zMotor self-test and parameter auto-setup

technology, offers optimum responses with

different motors

zMulti-Stepping allows a low resolution step

input to produce a higher microstep output

for smooth system performance

zMicrostep resolutions programmable, from

full-step to 102,400 steps/rev

zSupply voltage up to +40 VDC

zOutput current programmable, from 0.3A to

2.2A

zPulse input frequency up to 75 KHz

zTTL compatible and optically isolated input

zAutomatic idle-current reduction

zSuitable for 2-phase and 4-phase motors

zSupport PUL/DIR and CW/CCW modes

zOver-voltage, over-current, phase-error

protections

Applications

Suitable for a wide range of stepping motors, from NEMA frame size 14 to 23. It can be used in

various kinds of machines, such as laser cutters, laser markers, high precision X-Y tables, labeling

machines, and so on. Its unique features make the DMD4022 an ideal solution for applications that

require low-speed smoothness.

2. Specifications

Electrical Specifications (Tj =25℃/77℉)

DMD4022

Parameters

Min Typical Max Unit

Output current 0.3 - 2.2 (1.6 RMS) A

Supply voltage +20 - +40 VDC

Logic signal current 7 10 16 mA

Pulse input frequency 0 - 75 kHz

Isolation resistance 500 MΩ

Mechanical Specifications ( unit: mm [inch] )

Figure 1: Mechanical specifications

Elimination of Heat

zDriver’s reliable working temperature should be <70(158 ℉), and motor working

temperature should be <80(176℉);

zIt is recommended to use automatic idle-current mode, namely current automatically reduce

to 60% when motor stops, so as to reduce driver heating and motor heating;

zIt is recommended to mount the driver vertically to maximize heat sink area. Use forced

cooling method to cool the system if necessary.

Operating Environment and other Specifications

Cooling Natural Cooling or Forced cooling

Environment Avoid dust, oil fog and corrosive gases

Ambient Temperature 0－50 (32℉－122℉)

Humidity 40%RH－90%RH

Operating Temperature 70 (158℉) Max

Operating

Environment

Vibration 5.9m/s2 Max

Storage Temperature -20－65 (-4℉－149℉)

Weight Approx. 100g (3.5274oz)

3. Pin Assignment and Description

The DMD4022 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,

Connector P1 Configurations

Pin Function Details

PUL

Pulse signal: In single pulse (pulse/direction) mode, this input represents pulse

signal, each rising or falling edge active (software configurable); 4-5V when

PUL-HIGH, 0-0.5V when PUL-LOW. In double pulse mode (pulse/pulse) ,

this input represents clockwise (CW) pulse，active both at high level and low

level (software configurable). For reliable response, pulse width should be

longer than 7.5µs. Series connect resistors for current-limiting when +12V or

+24V used. The same as DIR and ENA signals.

DIR

DIR signal: In single-pulse mode, this signal has low/high voltage levels,

representing two directions of motor rotation; in double-pulse mode (software

configurable), this signal is counter-clock (CCW) pulse，active both at high

level and low level (software configurable). For reliable motion response, DIR

signal should be ahead of PUL signal by 5µs at least. 4-5V 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 of two wires for a coil

to the driver will reverse motion direction.

OPTO Opto-coupler power supply, and the typical voltage is +5V. Series connect

resistors (at the PUL, DIR, ENA terminals) for current-limiting when +12V or

+24V used.

ENA Enable signal: This signal is used for enabling/disabling driver. High level for

enabling the driver and low level for disabling the driver. Usually left

UNCONNECTED (ENABLED).

Selecting Active Pulse Edge and Control Signal Mode

The DMD4022 supports PUL/DIR and CW/CCW modes and pulse active at rising or falling edge.

See more information about these settings in Section 13. Default setting is PUL/DIR mode and

rising edge active.

Connector P2 Configurations

Pin Function Details

+Vdc Power supply, 20~40 VDC, Including voltage fluctuation and EMF voltage.

GND Power Ground.

A+, A- Motor Phase A

B+, B- Motor Phase B

4. Control Signal Connector (P1) Interface

The DMD4022 uses opto-couplers to increase noise immunity and interface flexibility. If the

opto-couplers’ supply voltage is higher than +5V, a current-limiting resistor needs to be

connected at each command signal terminal to prevent overheating the opto-couplers. In the

following figures, connections to open-collector and differential controller are illustrated.

Figure 2: Connections to open-collector signal (common-anode)

Figure 3: Connections to differential control signal

5. Connecting the Motor

The DMD4022 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.

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 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.

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

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.

Figure 6: 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 series mode, the motors should also be run at only 70% of their rated

current to prevent over heating.

Figure 7: 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.

Figure 8: 8-lead motor parallel connections

NEVER disconnect or connect the motor while the power source is energized.

6. Power Supply Selection

The DMD4022 can match medium and small size stepping motors (from NEMA frame size 14 to

23) made by Soprolec 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. However,

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.

Selecting Supply Voltage

The power MOSFETs inside the DMD4022 can actually operate within +20 ~ +40VDC, 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 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 ~ +36VDC, leaving room for power

fluctuation and back-EMF.

7. Selecting Microstep Resolution and Driver Output Current

Microstep resolutions and output current are programmable, the former can be set from full-step to

102,400 steps/rev and the latter can be set from 0.3A to 2.2A. See more information about

Microstep and Output Current Setting in Section 13.

However, when it’s not in software configured mode, this driver uses a 6-bit DIP switch to set

microstep resolution, and motor operating current, as shown below:

Microstep Resolution Selection

When it’s not in software configured mode, microstep resolution is set by SW5, 6 of the DIP

switch as shown in the following table:

Microstep Steps/rev.(for 1.8°motor) SW5 SW6

1 to 512 Default/Software configured ON ON

8 1600 OFF ON

16 3200 ON OFF

32 6400 OFF OFF

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

connection methods. Phase current rating supplied by motor manufacturer is important in selecting

driver current, however the selection also depends on leads and connections.

When it’s not in software configured mode, 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

Peak Current RMS Current SW1 SW2 SW3

Default/Software configured (0.3 to 2.2A) ON ON ON

0.5A 0.35 A OFF ON ON

0.7A 0.50 A ON OFF ON

1.0A 0.71 A OFF OFF ON

1.3A 0.92 A ON ON OFF

1.6A 1.13 A OFF ON OFF

1.9A 1.34 A ON OFF OFF

2.2A 1.56 A OFF OFF OFF

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 60% of the selected dynamic current one second after the last

pulse. Theoretically, this will reduce motor heating to 36% (due to P=I2*R) of the original value. If

the application needs a different standstill current, please contact Soprolec.

8. Wiring Notes

zIn order to improve anti-interference performance of the driver, it is recommended to use

twisted pair shield cable.

zTo prevent noise incurred in PUL/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.

zIf a power supply serves several drivers, separately connecting the drivers is recommended

instead of daisy-chaining.

zIt 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.

Figure 9: Typical connection

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:

Figure 10: Sequence chart of control signals

Remark:

a) t1: ENA must be ahead of DIR by at least 5µs. 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 5µs to ensure correct direction;

c) t3: Pulse width not less than 7.5µs;

d) t4: Low level width not less than 7.5µs.

11. Protection Functions

To improve reliability, the driver incorporates some built-in protection functions. The DMD4022

uses one RED LED to indicate what protection has been activated. The periodic time of RED is 3

s (seconds), and how many times the RED turns on indicates what protection has been activated.

Because only one protection can be displayed by RED LED, so the driver will decide what error to

display according to their priorities. See the following Protection Indications table for displaying

priorities.

Over-current Protection

Over-current protection will be activated when continuous current exceeds 16A or in case of short

circuit between motor coils or between motor coil and ground, and RED LED will turn on once

within each periodic time (3 s).

Over-voltage Protection

When power supply voltage exceeds 42±1 VDC, protection will be activated and RED LED will

turn on twice within each periodic time (3 s).

Phase Error Protection

Motor power lines wrong & not connected will activate this protection. RED LED will turn on

four times within each periodic time (3 s).

Attention: 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.

Since there is no protection against power leads (﹢,﹣) reversal, it is critical to make sure that power

supply leads correctly connected to driver. Otherwise, the driver will be damaged instantly.

Protection Indications

Priority Time(s) of ON Sequence wave of RED LED Description

1st 1 Over-current protection

2nd 2

Over-voltage protection

3rd 4 Phase error protection

12. FrequentlyAsked Questions

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

Symptoms Possible Problems

No power

Microstep resolution setting is wrong

DIP switch current setting is wrong

Fault condition exists

Motor is not rotating

The driver is disabled

Motor rotates in the wrong direction Motor phases may be connected in reverse

DIP switch current setting is wrong

The driver in fault Something wrong with motor coil

Control signal is too weak

Control signal is interfered

Erratic motor motion

Wrong motor connection

Something wrong with motor coil

Current setting is too small, losing steps

Current setting is too small

Motor is undersized for the application

Acceleration is set too high

Motor stalls during acceleration

Power supply voltage too low

Inadequate heat sinking / cooling

Automatic current reduction function not being utilized

Excessive motor and driver heating

Current is set too high

13. Professional Tuning Software ProTuner

Introduction

This section will provide an overview of connection and basic setup instructions for Soprolec’s

digital stepping driver DMD4022 using the ProTuner software. These instructions will walk you

through the following steps necessary to start up your driver and motor. This section is intended for

setting up the driver with the ProTuner.

Software Installation

The ProTuner is windows based setup software for tuning Soprolec’s digital stepper driver

DMD4022. It can run in windows systems, including Win95/Win98/WindowsNT/ Windows

2000/Windows XP. And the selected PC should have 1 serial port at least for communicating with

the driver.

Double click “ProTuner_DMD4022.exe” to begin installing the ProTuner. See Figure 11. Click

Next to enter the “License Agreement” window. See Figure 12.

Figure 11: Begin to install the ProTuner

Figure 12: License agreement

Choose “I agree to the terms of this license agreement” and click Next to continue installation. The

user can enter user’s information in the following window. See Figure 13. After entering the user’s

information, click Next to select installation folder, where you would like to install the ProTuner.

See Figure 14.

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