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1. 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 9 DM422 Digital Stepping Drive Manual V1 0 Controller DM422 Driver 20 36 VDC Stepping Motor B a 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 should abide by some rules shown as following diagram t 25ys A t t 4 High Level gt 3 5V j l l PUL PUL CW Low Level lt 0 5V a l High Level gt 3 5V ity gt DUS DIR JIR CCW t 7 ops sn Low Level lt 0 5V ENA ENA PUL DIR CW CCW Figure 10 Sequence chart of control signals Remark a tl ENA must be ahead of DIR by at least 5us Usually ENA and ENA are2. A e 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 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 MC B B 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 P2 A B B Figure 7 8 lead motor series connections DM422 Digital Stepping Drive Manual V1 0 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 ou
3. NC not connected See Connector P1 Configurations for more information b t2 DIR must be ahead of PUL effective edge by 5us to ensure correct direction c t3 Pulse width not less than 7 5uUs d t4 Low level width not less than 7 5us DM422 Digital Stepping Drive Manual V1 0 11 Protection Functions To improve reliability the driver incorporates some built in protection functions The DM422 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 the limit 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 48 2 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 amp 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
4. Proluner All Setup F Installation Successful The ProTuner All 1 0 installation is complete Thank you for choosing ProTuner All Please click Finish to exit this installer Finish Figure 18 Finish installation Connections and Testing Connect the stepping system according to the contents in previous sections and connect the PC to the driver as the following figure RS232 Interface Connection 1 PC with ProTuner Digital Stepping Driver Special Cable Figure 19 RS232 interface connection Testing the Stepping System Turn on the power supply the green Power LED will light The DM422 has default parameters stored in the driver If the system has no hardware and wirings problem the motor should be locked and the driver should be ready If the red LED immediately turns on flickers then check power supply the motor motor wirings DM422 Digital Stepping Drive Manual V1 0 and try again Open the tuning software ProTuner and check driver status by clicking Err_check If it s Phase Error check the motor motor wirings and try again If it still doesn t work after you followed all of the previous steps please contact us If the RED LED is OFF and the motor is normal then you can start to tune the servo with ProTuner However we recommend you see the following contents before starting tuning Software Introduction ProTuner Main Window Menu Bar Leading Technology Shining Value LEADS
5. 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 DM422 Digital Stepping Drive Manual V1 0 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 DM422 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 re
6. a De PECICA ONS iur Electicalspecihcanon necese ron raa erere teen eee een teers Mechanical Specifications eienn oc 0h isha ON ees A TEER Pumin on or cr eeree neem E E n tT tere trn er name mrrrrer reer Operating Environment and other Specifications ccccccccceeeeeeeeeeeeeeeeeeeeeeeees 3 Pin Assignment and Description eriaren nnan a a a a S Connector PI Configurations soosse E Selecting Active Pulse Edge and Control Signal Mode ccccesssesseeeeseseeeeees Connector P2 COnme uranOns sreski nora n nee eee eee 4 Control signal Connector PT Interface scnisrcaini encase 5 Connecting the Motor sieni reni es COnne CONS 10 4 lead MOOLS iesicencnsiisieasveanassts GonemneeanecaiapsaRieiaaeubi aaa Ddeaesiat Connections to 6 lead Motors cceceecessseesessnsnceeeeeeeeeeeeeesesseeeeeennneaeeeeeeeeeeeeeeees Palt Om On C1 UB AN ONS a ce ocean ce et eee Full Coil Configurations ssi 22h wise Rie Wis ne Riese Wis ne Races Res Connections 10 Sica MOLOTS sccrasacs caren cedndeatashdakumine A denn DEES C ONMECHIONS herran EE EE Pata lel Onne ONS erase oie Seen aovee cnt Senen en A 6 Power Supply Selection sss ee GE A Reoulated or Unregulated Power SUDDIY actccticetcinectieer inet inet M l ple DIVES raene A O Selec ne Supp Volla caa a aly lar a A E inmaneanen 7 Selecting Microstep Resolution and Driver Output Current ccccceeeeeeeeees Microstep Resolution Selecion aer arren ar A AEN CUTE
7. drive faults 0 being the most recent 9 is the oldest See Figure 27 Figure 27 Error check window DM422 Digital Stepping Drive Manual V1 0 OverCurrent Over current Protection Protection will be activated when continuous current exceeds 16A OverVoltage Over voltage Protection When power supply voltage exceeds 42 1 VDC protection will be activated PhaseErr Phase Error Protection Motor power lines wrong amp not connected will activate this protection ErrCounter Displays current error s and current error history Erase Current Err Erase Current Err button The user can clear current error s by clicking this button Erase All Erase All button The user can clear all error s including error history by clicking this button About The user can choose two drop down menus by clicking About including Product Information and Contact Us Product Information window Shows some product information about ProTuner Contact Us window Shows some contact information about Leadshine Product Information Figure 28 Product information Tel 0 755 26433338 Fax 0 755 26402718 Web www leadshine com Addr Floor3 Block2 NanyouTianan Industrial Park Nanshan ZIP 518052 Figure 29 Contact information DM422 Digital Stepping Drive Manual V1 0 APPENDIX Twelve Month Limited Warranty Rayne Motors warrants its products against defects in materials and workmanship for a period of 12 months from shipme
8. in one second Current Tuning Figure 24 Kp 356 Ki 15 poor performances DM422 Digital Stepping Drive Manual V1 0 Notes However if the user does not want to tune the current loop after changing a different stepping motor then Motor self test and parameter auto setup technology of the DM422 can replace manual tuning the driver with ProTuner Just changes SW4 two times in 1 second without ProTuner or click Auto button and then the driver will auto identify the new motor and auto configure related control parameters for optimum responses Recommend use this function after changing the driven motor SystemConfig In SystemConfig window the user can configure Peak Current Microstep Elec Damp Idle Current Idle Time Command Type Active Edge and eliminate motor resonance A built in pulse generator can be used for test during tuning See Picture 25 SysteaConfiz StepperConfig PeakCulA 2 00 MircoStep lg Elec Damp 7000 Idle Current 50 Idle time ms 2000 5 CommandType ActiveEdge DirectionDef f PUL DIR Cw CCW Rising Falling Low High 1st ResonanceArea Ampl lo re Phase1 0 o no NO 2st ResonanceArea Amp2 lo shsh Phase2 0 _ _ _ _ n n 3st ResonanceArea Amp3 128 Phase3 1129 InternalPulser SS eS a xOO0l tps V Bidirectional Positive Intervat ms 50 Repeats 5 Distancefr f 0 Sa Figure 25 System Configure Wi
9. 21 TONE E eee eer ee nee eee ee ee ee oe eee ee 22 Anti Resonance Introduction s cessctecescencsesseatececeahadee sea ei a caaeeeeSeiceaeee 25 latera PRSE e etter eerene eesti re ete tent renee re eee eee 26 Procedure for Achieving Optimum Performance ccccccccccceeeeeeeeeeeeees 27 E ARE E E E AA E T E AT E AAT 28 ADU EDR RRS TR RAD RAEI TES RSS SAT ER RCT APR UES TA OR Pe TA 29 APPREND B Gaeme erent ene Teme NTT neeene NUTT Meaneer etree marr eT Me Ror neerene tte n nator rat tse tater 29 Contents DM422 Digital Stepping Drive Manual V1 0 Twelve Month Limited Warranty arsina apasarap eos 29 oe 1 Introduction Features and Applications EXCIUSIONS inano eae Role RUNS GGoe ER wee ORG 29 Obtamine Wattanty SCrviCe pit cto d tonite taint tai es 29 Introduction Waran i Minllatl ONS seni naan RAHNER 29 l i l l The DM422 is a versatility fully digital stepping driver based on a DSP with advanced control EKE A U EAE A A EEIE ATA EEE A EES ATYA IEEE AE EI AT A A 30 algorithm The DM422 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 DM422 an ideal solution for
10. 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 Connections to differential control signal 5 Connecting the Motor The DM422 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 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 1s 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 DM422 Digital Stepping Drive Manual V1 0 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
11. HINE Status Bar HR www leadshine com Status Leadshine Technology Co Ltd Date 2010 11 8 TimejDigital Stepper ProTuner Figure 20 ProTuner ProTuner Toolbar Current Loop Tuning Product Information Com Configuration Error Check Contact Information Parameters Configuration System Configure Exit DM422 Digital Stepping Drive Manual V1 0 Option The user can choose three drop down menus by clicking Option including Com Configuration Parameters Configuration and Exit Com Configuration Configure Com communication interface Parameteres Configuration Read write parameters between the driver and the ProTuner or save configuration as a file and load configuration from a file l Exit Exit the ProTuner Com Config Window Com Config Com Config Serial Port com zl Baud Rate Figure 21 RS232 communication configuration window Serial Port Select the serial communication port to which the driver is connected The factory default setting is COM1 Baud Rate Select the communication baud rate The factory default setting is 38400 Click Open button to establish a connection with the specified settings When connecting you can read stored parameter setting from the driver to the ProTuner or write new parameter setting from the ProTuner to the driver settings in the parameters configuration window Parameters Configuration Window Recommend to always keep this window ac
12. TIE 56 CUI OS eget an Contents Dynamic caren setin iorra a cine Secure eeu ee eee 9 Standstill current SetINE eerie et a ea eae 10 Be WINE NOE a desist asd seated saath ath T E etd eet 10 De Py OIC ale ONGC LOM saafece rszateleratesa ersten eared emtanel ene emeanelenietiemeeneeetenenets 10 LO Sequetice Chart or Control Signals accu 11 ll Pr tection F UNCHIONS 4tue ana ee ee ea 12 OVC CUE ML Proce oo rrna 12 Over v ltage Protectiol aie oad ected ceed oad eet ed eed aA 12 Phase Error Protectio neren nianna reed ee ratte cert whet emcees 12 Protection Indications esc wise Nie Wise Mi Ae RS A Rs 12 12 Prequently Asked OUucStIONS erian E EE OET OTE 13 Problem Symptoms and Possible Causes cccccccccccccesseeeeeeeeeeeeeeeeeeeeeeeeseeeeees 14 13 Professional Tuning Software Pro Puneet cusses ake 15 TMtFOCUCHON 3 tae te ee eee deen ee A GS 15 DOM Walco 1S ala On costa tee Tossa Teesiceatee hiumatee si ates Seumatee siete heumatte samen tiimats 15 Comme cons and Vestn nerse eee ee 19 R9232 fatertace C Onn COM sanne anna aa tomes eaees 19 Testing the Steppin Systemlnccsewecieac os aair E a es how eset A eee 19 S ftware TIM OGUCHOM oeheccheceheint Sc senchevedeiet Reseneheueheiet tesene teeta ieee 20 Pro Tuner Main Window rrorseniotironoi ni ouA 20 Ponner a Daea TT 20 OPIO 0 Vane e E EE E EAE eee TO 21 Conon WW 1 OW rran a 21 Parameters Configuration Window eeeeeeeeseensnenennsesesseesenenenneesenneeeeeeeeene
13. User s Manual For DM422 Fully Digital Stepping Driver Version 1 0 2010 All Rights Reserved Attention Please read this manual carefully before using the driver ow s A os i em a wot 9 The content in this manual has been carefully prepared and is believed to be accurate but no responsibility is assumed for inaccuracies Rayne Motors reserves the right to make changes without further notice to any products herein to improve reliability function or design Rayne Motors 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 Rayne Motors 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 Rayne Motors terms and conditions of sales the user of Rayne Motors products in life support or aircraft applications assumes all risks of such use and indemnifies Rayne Motors against all damages Contents Table of Contents 1 Introduction Features and Applications ccccccccccccccccccccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess dha Te eye 0 e A 01a Nemmereen ene tee E een cere tne rie rene Tenner coher errr nr rere eee Pe CAUUICS erie A saab set A E E Rhee amie a erect PRC A ONS 54 Sete eget ans E T Salem anche ania Salem OT Salam cnet atid Kalam
14. an tune the Kp Proportional Gain and Ki Integral Gain of driver s current loop to optimize responses with different motors Start Restart a Step Response test to get an optimum response Kp Proportional Gain Proportional Gain determines the response of the driver to current setting command Low Proportional Gain provides a stable system doesn t oscillate has low stiffness and large current error causing poor performances in tracking current setting command in each step like Figure 23 Too large Proportional Gain values will cause oscillations and unstable systems DM422 Digital Stepping Drive Manual V1 0 Current Tuning Kp 998 Ki 337 I test 1 ZE Figure 23 Current Tuning window Ki Integral Gain Integral Gain helps the driver to overcome static current errors A low or zero value for the Integral Gain may have current errors at rest Increasing the Integral Gain can reduce the error If the Integral Gain is too large the systems may hunt oscillate about the desired position Start button The user can start a Step Response test by clicking this button Start Restart a Step Response test to get an optimum response like Figure 23 and remember to save the settings to the driver by clicking Write EEprom in parameters configuration window when finish tuning Auto button Click this button to auto configure Kp and Ki for the connected motor It has the same effect as changing SW4 two times
15. applications that require low speed smoothness Compared to the DM422C the DM422 makes the motor run into higher speed and the user can configure the standstill current in the software What s more a pulse filter smoother has been built into the DM422 Features Anti Resonance provides optimum torque and nulls mid range instability Motor self test and parameter auto setup technology offers optimum responses with different motors Multi Stepping allows a low resolution step input to produce a higher microstep output for smooth system performance Microstep resolutions programmable from full step to 102 400 steps rev Supply voltage up to 40 VDC Output current programmable from 0 3A to 2 2A Pulse input frequency up to 75 KHz TTL compatible and optically isolated input Automatic idle current reduction Reduction rate can be software configured Support PUL DIR and CW CCW modes Over 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 DM422 an ideal solution for applications that require low speed smoothness MI DM422 Digital Stepping Drive Manual V1 0 2 Specifications Electrical Specifications T 25 C 77F 20 40 VDC Mechanical Specifications uni
16. couplings or viscous loading generally does not need this feature If a system has compliant springy coupling and is absent appreciably viscosity it may not respond well to the active th anti resonant loop in the drive The anti resonant feature is not designed to damp such a 4 order system If the application of anti resonance results in degradation or instability it should be disabled 1 ResonanceArea Parameters for 1 resonance area It is usually between 0 6rps and 1 2rps Amp1 is Amplitude adjustment for 1 resonance area Phasel is Phase adjustment for 1 resonance area The user can enter a value directly in the text box or move the slider bar back and forth to get an optimum value 2 ResonanceArea Parameters for 2 resonance area It is usually between 1 2rps and 2 4rps Default Amp2 and Phase2 values are zero 3 ResonanceArea Parameters for 3 resonance area It is usually between 2 4rps and 4 8rps Default Amp3 and Phase3 values are 128 Internal Pluser Pulse Generator The internal pulse generator offers a simple motion control for self test and anti resonance tuning The user can adjust moving velocity configure the direction and repeats of the motion Bidirectional Click the check box to make the motion be bidirectional Otherwise the motor only run in one direction Positive It is used to change the initial direction for the motion DM422 Digital Stepping Drive Manual V1 0 Interval S
17. er All Setup Welcome WWelcome to the installer for ProTuner All 1 0 lt s strongly recommended that you exit all Windows programs before continuing with this installation Ifyou have any other programs running please click Cancel close the programs and run this setup again herwise click Next to continue Figure 11 Begin to install the ProTuner DM422 Digital Stepping Drive Manual V1 0 amp Proluner All Setup License Agreement Please read the following license agreement carefully Thank you for choosing Leadshine product do not agree to the terms of this license agreement 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 PA Pro uner All Setup User Information Enter your user information and click Next to continue Company Figure 13 User s information settings DM422 Digital Stepping Drive Manual V1 0 PA Proluner All Setup Installation Folder Where would you like ProTuner All to be installed The software will be installed in the folder listed below To select a different location either type in a new path or click Change to browse for an existing folder Insta
18. esponse DIR signal should be ahead of PUL signal by Sus 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 DM422 Digital Stepping Drive Manual V1 0 Selecting Active Pulse Edge and Control Signal Mode The DM422 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 O Vde Power supply 20 40 VDC Including voltage fluctuation and EMF voltage Power Ground Motor Phase A Motor Phase B 4 Control Signal Connector P1 Interface The DM422 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 Controller DM422 Driver 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 2 Connections to open collector signal Ccommon anode DM422 Digital Stepping Drive Manual V1 0 VCCo DM422 Driver R 0 if VCC
19. ion number RMA before returning product for service Please include a written description of the problem along with contact name and address Send failed product to Rayne Motors Also enclose information regarding the circumstances prior to product failure DM422 Digital Stepping Drive Manual V1 0
20. ll ProTuner All to D Program Files ProTuner All Space required 27 5 MB Space available on selected drive 5 46 GB Figure 14 Installation folder settings PA Proluner All Setup Shortcut Folder Where would you like the shortcuts to be installed The shortcut icons will be created in the folder indicated below If you dont want to use the default folder you can either type a new name or select an existing folder from the list Shortcut Folder ProTuner All Install shortcuts for current user only Make shortcuts available to all users Cancel Figure 15 Shortcut folder setting Set the Shortcut Folder in Figure 15 and continue to install the ProTuner by following Figure 16 and Figure 17 An Installation Successful window will appear if the ProTuner is installed successfully See Figure 18 DM422 Digital Stepping Drive Manual V1 0 o Pro uner All Setup Ready to Install You are now ready to install ProTuner All 1 0 The installer now has enough information to install ProTuner All on your computer The following settings will be used Install folder D iProgram FilesiProTuner All Shortcut folder ProTuner All Please click Next to proceed with the installation PA Pro uner All Setup Installing ProTuner All Please wait Installing Files Seeking TT Cancel Figure 17 Installing the ProTuner DM422 Digital Stepping Drive Manual V1 0 amp
21. ndow DM422 Digital Stepping Drive Manual V1 0 PeakCur Peak Current The value is the peak current to the selected motor and can be set from 0 1 to 2 2 A The user can set the peak current with ProTuner or DIP switches see more information about setting output current of the driver in section 5 Connecting the Motor and section 7 Selecting Microstep Resolution and Driver Output Current MicroStep Microstep Resolution The value is driver s microstep resolution setting and can be set from 1 to 512 The user can set the microstep with ProTuner or DIP switches See more information about setting output current of the driver in section 7 Selecting Microstep Resolution and Driver Output Current ElecDamp Electronic Damping Coefficient The electronic damping restrain resonance of the system and prevent amplitude of the oscillation from increasing to the extend that it makes the motor out of control The optimal value depends on the system and the default value is 3000 Idle Current Standstill Current when motor stop When the motor stop time exceeds the Idle Time the motor coil current reduces to Idle Current In percentage The percentage is rated to the Peak Current Idle Time See Idle Current Pulse Filter Enable Click the check box will turn on the internal pulse smoother or filter of DM422 DirectionDef Direction Definition Relate the default running direction to a HIGH level input in DIR or Low level inp
22. nt 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 Notes Due to motor inductance the actual current in the coil may be smaller than the dynamic current setting particularly under high speed condition DM422 Digital Stepping Drive Manual V1 0 Standstill current setting SW4 is used for this purpose OFF meaning that the standstill current is software configured and ON meaning that standstill current is set to be the same as the selected dynamic current By default the current automatically reduced to 60 of the selected dynamic current two second after the last pulse Theoretically this will reduce motor heating to 36 due to P I R of the original value Reduction rate and idle time can be configured in the PC software ProTuner See more information in section 13 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 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
23. nt out of factory During the warranty period Rayne Motors will either at its 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 before returning product for service Customer shall prepay shipping charges for products returned to Rayne Motors for warranty service and Rayne Motors shall pay for return of products to customer Warranty Limitations Rayne Motors makes no other warranty either expressed or implied with respect to the product Rayne Motors 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 to obtain a returned material authorizat
24. solutions 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 Dynamic Current Microstep Resolution AIL ON is software configured AIL ON is software configured tp 2 34 isto Standstill Current ON haft OFF full Motor auto identification and parameter auto configuration 2 change in 1 second Microstep Resolution Selection When it s not in software configured mode microstep resolution is set by SWS 6 of the DIP switch as shown in the following table DM422 Digital Stepping Drive Manual V1 0 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 curre
25. t mm inch 86 3 388 20 5 0 808 55 2 167 79 3 113 Figure 1 Mechanical specifications Elimination of Heat Driver s reliable working temperature should be lt 70 C 158 F and motor working temperature should be lt 80 C 176 F It 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 It is recommended to mount the driver vertically to maximize heat sink area Use forced cooling method to cool the system if necessary DM422 Digital Stepping Drive Manual V1 0 Operating Environment and other Specifications Environment Avoid dust oil fog and corrosive gases BEEE 40 RH 90 RH 2 Vibration 5 9m s Max Weight Approx 100g 3 527402 3 Pin Assignment and Description The DM422 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 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 r
26. tive In this window the user can read the parameter setting from the driver or write parameters setting to the driver after finishing to configure all the settings In addition the user can also save the configuration to a file for later use or load a configuration from a stored file See figure 22 DM422 Digital Stepping Drive Manual V1 0 Read RAM Read parameter settings from the driver s RAM to the ProTuner Write RAM Write parameter settings from the ProTuenr to the driver s RAM Write EEprom Write parameter settings from the ProTuenr to the driver s EEprom Reset Driver Reset all parameter to default value Load configurations from a file Save configuration to a file Close this window Parameters Configuration Setting Range Current Loop Proport 998 0 3000 Current Loop Integra 365 0 1000 200 PeakCurrent 3 0 1 5 6 UnitO 1A 1 MircoStep 16 i Sl2 1 Amplitude 1 2533 0 3500 0 Phase 1 0 O0 1608 0 Amplitude 2 0 0 3500 0 Fhase 2 0 0 1608 0 Amplitude 3 126 0 256 126 Phase 3 126 0 256 126 Idle Current 50 O 100 Unit 50 Idle time 2000 10 3000 Unit ms 2000 Filtering Enable 0 OOR1 0 Electronic Damp 1000 0 6000 1000 Write RAM Write EEprom z Reset Driver tikl Figure 22 Parameters configuration window Tuning The user can choose one or two drop down menu s by clicking Tuning including CurrentLoop and SystemConfig CurrentLoop In Current Tuning window the user c
27. top time before the next motion repeat Unit ms Repeats Motion repeat times If it is bidirectional one repeat is moving forward then back Distance Moving distance in one direction in revolution Start Stop Start Stop the motion Note When you adjust the velocity by moving the slider forth and back the motor velocity would not change immediately as you expected That is because the driver only read the new speed when it changes direction Also be careful about the initial direction and moving distance if the motor is installed on a machine It is recommended that set low speed and small distance if you are not sure whether the direction and distance is correct or not Procedure for Achieving Optimum Performance Step 1 Start the motion test by clicking Start Stop button Find a resonance speed by slightly moving the slider bar of internal pulse generator back and forth You can also use the arrow keys to adjust the speed precisely Step 2 Run the motor at the resonance speed and verify the motor smoothness You may find a better smoothing value by slightly moving the slider bars of AMP s and Phase s back and forth It is very important to make the AMP s and Phase s adjustments at the proper test speeds with an unloaded motor Running at an incorrect test speed will not excite the motor at its peak resonance making it more difficult to find proper adjustment values Optimum AMP s and Phase s values may be a little different bet
28. tput current P2 Figure 8 8 lead motor parallel connections NEVER disconnect or connect the motor while the power source is energized 6 Power Supply Selection The DM422 can match medium and small size stepping motors from NEMA frame size 14 to 23 made by Rayne Motors 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
29. ut in DIR This panel is used for PUL DIR command type only Please note that the default direction is also related to motor coil connections CommandType Command Type of control signal including PUL DIR and CW CCW Set this parameter according to Command Type of motion controller ActiveEdge Active Edge The user can set the triggered edge of pulse command signal in this panel When the driver works in CW CCW mode no matter what level is at fixed level terminal the driver can works properly Anti Resonance Introduction Step motors are highly resonant which results in vibration and ringing The ringing utilizes a large DM422 Digital Stepping Drive Manual V1 0 fraction of the motor s available torque thereby wasting performance Furthermore at mid range velocities the resonance can become so severe that the motor looses synchronization and stalls The DM422 driver provides robust anti resonance control to stop the vibrations and maintain equilibrium This feature requires that the driver be configured with respect to the total inertia in the system If set improperly the effectiveness of the feature may be diminished The user can invoke or disable the feature by setting Amp and Phase values in SystemConfig window Amp and Phase values all zero is to disable the feature otherwise is to invoke the feature It should be enabled unless the system configuration either does not need it or cannot tolerate it A system with loose
30. ve Manual V1 0 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 DM422 Digital Stepping Drive Manual V1 0 13 Professional Tuning Software ProTuner Introduction This section will provide an overview of connection and basic setup instructions for Rayne Motors digital stepping driver DM422 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 Rayne Motors digital stepper driver DM422 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_DM422 Setup V2 0 exe to begin installing the ProTuner See Figure 11 Click Next to enter the License Agreement window See Figure 12 Note The user can get the software from either Leadshine CD or website Please get the latest version from http www leadshine com Protun
31. ween running the tests with an unloaded motor and a load motor For example we find a resonance speed at 0 98 rps We begin to move the Amp slider forth and the motor vibration and noise became lower and lower Finally we find the move is the smoothest when Amp 1 is 3300 The motor vibration and noise increase if Amp 1 exceeds 3300 Then we follow the same procedure to search the best point for Phase 1 See Figure 26 Anti resonance tuning is done Please remember to click Write EEprom to write the final parameter settings to the driver when finish tuning DM422 Digital Stepping Drive Manual V1 0 SystemConfizg r StepperConfig PeakCurlA 2 00 MircoStep E Elec Damp 1000 Idle Current 50 Idle time ms 2000 F Pulse Filter Enable CommandType ActiveEdge DirectionDef e PUL DIR C Cw CCW Rising Falling e Low High Ist ResonanceArea mpi 3300 Phaset 74 2st ResonanceArea Amp2 0 ka Phase2 0 3st ResonanceArea Amp3 128 Phase3 128 I InternalPulser x001 ps Bidirectional Positive Intervat ms 50 Repeats 5 Distance r fio Oo owo o Figure 26 1 Anti Resonance Tuning Speed 0 98rps Err check Error Check This window shows both the present status of each error event and their history Current error event s can be reset by clicking Erase Current Err button and all error events can be reset by clicking Erase All button List of the last ten
32. 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 ON iP 1 Be Over current protection 0 25 03s Over voltage protection 3 4 o Phase error protection ze 2 DM422 Digital Stepping Drive Manual V1 0 12 Frequently Asked 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 DM422 Digital Stepping Dri
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