Leadshine Technology M542 User Manual

User’s Manual

For

M542

Economical Microstepping Driver

Version 1.0

©2000 All Rights Reserved

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

F/3, Block 2, Nanyou Tianan Industry Park, Nanshan Dist, Shenzhen, China

PH. (86)755-26434369 FAX [phone]

Web site: www.leadshine.com E-Mail: [e-mail]

The content in this manual has been carefully prepared and is believed to be accurate, but no
responsibility is assumed for inaccuracies.

Leadshine reserves the right to make changes without further notice to any products herein to
improve reliability, function or design. Leadshine 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.

Leadshine’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 Leadshine’s terms and conditions of sales, the user of Leadshine’s products in life
support or aircraft applications assumes all risks of such use and indemnifies Leadshine against all
damages.

©2000 by Leadshine Technology Company Limited.

All Rights Reserved

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Contents

I

Table of Contents

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

Introduction········································································································· 1

Features··············································································································· 1

Applications ········································································································1

2. Specifications and Operating Environment ····························································· 1

Electrical Specifications ······················································································ 1

Operating Environment and other Specifications················································· 2

Mechanical Specifications··················································································· 2

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

Connector P1 Configurations ·············································································· 3

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·············································································· 5

Half Coil Configurations ·············································································5

Full Coil Configurations·············································································· 5

Connections to 8-lead Motors·············································································· 6

Series Connections ······························································································ 6

Parallel Connections···························································································· 6

6. Power supply Selection ··························································································· 7

Regulated or Unregulated Power Supply····························································· 7

Multiple Drivers·································································································· 7

Selecting Supply Voltage····················································································· 7

7. Selecting Microstep Resolution and Driver Output Current ···································· 8

Microstep Resolution Selection··········································································· 8

Current Settings ·································································································· 8

Dynamic Current Setting ············································································· 9

Standstill Current Setting············································································· 9

8. Wiring Notes··········································································································· 9

Contents

II

9. Typical Connection ······························································································· 10

10. Sequence Chart of Control Signals ······························································ 10

11. Protection Functions···························································································· 11

Over-voltage Protection····················································································· 11

Coil-ground Short Circuit Protection································································· 11

12. Frequently Asked Questions················································································ 11

Problem Symptoms and Possible Causes··························································· 11

APPENDIX ·············································································································· 13

Twelve Month Limited Warranty······································································· 13

Exclusions········································································································· 13

Obtaining Warranty Service ·············································································· 13

Warranty Limitations························································································· 13

Shipping Failed Product ···················································································· 13

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1. Introduction, Features and Applications

Introduction

The M542 is an economical microstepping driver based on patented technology of Leadshine. It is
suitable for driving 2-phase and 4-phase hybrid stepping motors. By using the advanced bipolar
constant-current chopping technique, it can output more speed and torque from the same motor,
compared with traditional drivers, such as L/R drivers. Its 3-state current control technology allows
coil currents to be well controlled and with relatively small current ripple, therefore less motor
heating is achieved.

Features

l Low cost and good high-speed torque
l Supply voltage up to +50VDC
l Output current up to 4.2A
l Optically isolated input signals
l Pulse frequency up to 300 KHz
l Automatic idle-current reduction
l 3-state current control technology

l 15 selectable resolutions
l Suitable for 2-phase and 4-phase motors
l DIP switch current setting with 8 different

values

l CW/CCW mode available (optional)
l Over-voltage and short-circuit protection
l Small size (118x75.5x33mm)

Applications

Suitable 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 tables, labeling machines, laser cutters, engraving machines,
pick-place devices, and so on. Particularly adapt to the applications desired with low vibration, high
speed and high precision.

2. Specifications and Operating Environment

Electrical Specifications (Tj = 25℃)

M542

Parameters

Min Typical Max Unit

Output current 1.0 - 4.2 (3.0A RMS) A
Supply voltage 20 36 50 VDC

Logic signal current 7 10 16 mA

Pulse input frequency 0 - 300 KHz

Isolation resistance 500 MΩ

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Operating Environment and other Specifications

Cooling

Natural Cooling or Forced cooling

Environment Avoid dust, oil fog and corrosive gases

Ambient Temperature 0 ℃－ 50℃

Humidity 40%RH － 90%RH

Operating Temperature 70 Max℃

Operating Environment

Vibration 5.9m/s2 Max

Storage Temperature

-20 ℃－ 65℃

Weight

Approx. 280 gram (9.9 oz)

Mechanical Specifications (unit:mm, 1 inch = 25.4 mm)

Front View Side View

Figure 1: Mechanical specifications

*Recommended to use side mounting for better heat dissipation

Elimination of Heat

l Driver’s reliable working temperature should be <65, and motor working temperature should ℃

be <80;℃

l It is recommended to use automatic idle-current reduction mode, namely current automatically

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

l It is recommended to side mounting to maximize heat sink area.

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3. Pin Assignment and Description

The M542 has two connectors, connector P1 for control signals connections, and connector P2 for
power and motor connections. The following tables are brief descriptions of the two connectors of the
M542. More detailed descriptions of the pins and related issues are presented in section 4, 5, 9.

Connector P1 Configurations

Pin Function Details

PUL+(+5V)

PUL-(PUL)

Pulse signal: In single pulse (pulse/direction) mode, this input represents pulse
signal, effective for each rising or falling edge (set by inside jumper J1); 4-5V
when PUL-HIGH, 0-0.5V when PUL-LOW. In double pulse mode
(pulse/pulse) , this input represents clockwise (CW) pulse，effective for high
level or low level (set by inside jumper J1). For reliable response, pulse width
should be longer than 2.5μs. Series connect resistors for current-limiting when
+12V or +24V used.

DIR+(+5V)

DIR-(DIR)

DIR signal: In single-pulse mode, this signal has low/high voltage levels,
representing two directions of motor rotation; in double-pulse mode (set by
inside jumper J3), this signal is counter-clock (CCW) pulse，effective for high
level or low level (set by inside jumper J1). 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.

ENA+(+5V)

ENA-(ENA)

Enable signal: This signal is used for enabling/disabling the driver. High level
(NPN control signal, PNP and Differential control signals are on the contrary,
namely Low level for enabling.) for enabling the driver and low level for
disabling the driver. Usually left UNCONNECTED (ENABLED).

Selecting Effective Pulse Edge or Effective Level and Control Signal Mode

There are two jumpers J1 and J3 inside the M542 specifically for the purpose of selecting effective
pulse edge or effective level and control signal mode, as shown in figure 2. Default setting is
PUL/DIR mode and upward-rising edge effective.

(a) J1, J3 open circuit (b) J1 short circuit, J3 open circuit

PUL/DIR mode and effective at upward-rising edge PUL/DIR mode and effective at downward-falling edge

(c) J1 open circuit, J3 short circuit (d) J1, J3short circuit

CW/CCW mode and effective CW/CCW mode and effective

at high level (The fixed level) at low level (The fixed level)

Figure 2: J1 and J3 jumpers

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Connector P2 Configurations

Pin Function Details

GND DC power ground

+V

DC power supply, 20~50VDC, Including voltage fluctuation and EMF

voltage.
A+, A- Motor Phase A
B+,B- Motor Phase B

4. Control Signal Connector (P1) Interface

The M542 can accept differential and single-ended input signals (including open-collector and PNP
output). The M542 has 3 optically isolated logic inputs which are located on connector P1 to accept
line driver control signals. These inputs are isolated to minimize or eliminate electrical noises coupled
onto the drive control signals. Recommend use line driver control signals to increase noise immunity
of the driver in interference environments. In the following figures, connections to open-collector and
PNP signals are illustrated.

Figure 3: Connections to open-collector signal (common-anode)

Figure 4: Connection to PNP signal (common-cathode)

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5. Connecting the Motor

The M542 driver 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 5: 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 6: 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

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motors should be run at only 70% of their rated current to prevent over heating.

Figure 7: 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 8: 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 9: 8-lead motor parallel connections

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6. Power supply Selection

The M542 can match medium and small size stepping motors (from Nema size 17 to 34) made by
Leadshine 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.)

Attention: NEVER connect power and ground in the wrong direction, as it will damage the M542.

Selecting Supply Voltage

The power MOSFETS inside the M542 can actually operate within +20V－+50VDC, 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～+ 45V, leaving room for power fluctuation and
back-EMF.

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7. Selecting Microstep Resolution and Driver Output Current

This driver uses an 8-bit DIP switch to set microstep resolution, and motor operating current, as
shown below:

Microstep Resolution Selection

Microstep resolution is set by SW5, 6, 7, 8 of the DIP switch as shown in the following table:

Microstep Steps/rev.(for 1.8°motor) SW5 SW6 SW7 SW8

2 400 OFF ON ON ON

4 800 ON OFF ON ON

8 1600 OFF OFF ON ON
16 3200 ON ON OFF ON

32 6400 OFF ON OFF ON
64 12800 ON OFF OFF ON

128 25600 OFF OFF OFF ON

5 1000 ON ON ON OFF
10 2000 OFF ON ON OFF
20 4000 ON OFF ON OFF

25 5000 OFF OFF ON OFF
40 8000 ON ON OFF OFF
50 10000 OFF ON OFF OFF

100 20000 ON OFF OFF OFF
125 25000 OFF OFF 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.

The first three bits (SW1, 2, 3) of the DIP switch are used to set the dynamic current. Select a setting

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closest to your motor’s required current.

Dynamic Current Setting

Peak current (A) RMS (A) SW1 SW2 SW3

1.00 0.71 ON ON ON

1.46 1.04 OFF ON ON

1.91 1.36 ON OFF ON

2.37 1.69 OFF OFF ON

2.84 2.03 ON ON OFF

3.31 2.36 OFF ON OFF

3.76 2.69 ON OFF OFF

4.20 3.00 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 1 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 Leadshine.

8. Wiring Notes

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

twisted pair shield cable.

l 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, system instability and other failures.

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

instead of daisy-chaining.

l 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.

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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 10.

Figure 10: Typical connection

10. Sequence Chart of Control Signals

In order to avoid some fault operations and deviations, PUL, DIR and ENA signals must abide by
some rules, as shown in the following diagram (assuming J1 default setting is upward-rising edge
effective):

Figure 11: Sequence chart of control signals

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Remark:

(1) 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.

(2) t2: DIR must be ahead of PUL effective edge by at least 5μs to ensure correct direction;
(3) t3: Pulse width not less than 1.5μs;
(4) t4: low level width not less than 1.5μs.

11. Protection Functions

To improve reliability, the driver incorporates some built-in protections features.

Over-voltage Protection

When power supply voltage exceeds +52VDC, protection will be activated and power indicator LED
will turn red.

Coil-ground Short Circuit Protection

Protection will be activated in case of short circuit between motor coil and ground.

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

sure that power supply leads correctly connected to the driver. Otherwise, the driver will be damaged
instantly. When power supply voltage is lower than +20VDC, the driver will not works properly.

12. Frequently Asked Questions

In the event that your M542 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

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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

Wrong motor connection

Something wrong with motor coil

Erratic motor motion

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

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APPENDIX

Twelve Month Limited Warranty

Leadshine Technology Co., Ltd. warrants its products against defects in materials and
workmanship for a period of 12 months from shipment out of factory. During the warranty period,
Leadshine 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 at e-mail: [e-mail] before returning product for service.
Customer shall prepay shipping charges for products returned to Leadshine for warranty service,
and Leadshine shall pay for return of products to customer.

Warranty Limitations

Leadshine makes no other warranty, either expressed or implied, with respect to the product.
Leadshine 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 at [e-mail] to

obtain a returned material authorization 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 distributor in your area or: Leadshine Technology Co., Ltd. Floor 3, Block 2,

Nanyou Tianan Industry Park, Nanshan Dist, Shenzhen, China. Also enclose information regarding

the circumstances prior to product failure.

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