Motion DMD870 User Manual

Motion Control Products Ltd.

Innovative products for Automation Industry

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User’s Manual

For DMD870 Digital Stepper Drive

V2.0-20180926

(March 2018)

DMD870 Digital Stepper Drive User’s Manual

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

Motion Control Products Limited reserves the right to make changes without further
notice to any products herein to improve reliability, function or design. Motion Control
Products Limited 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.

Motion Control Product’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 Motion Control Product’s terms and
conditions of sales, the user of Motion Control Product’s products in life support or

aircraft applications assumes all risks of such use and indemnifies Motion Control
Products Limited against all damages.

Copyright © 2015 Motion Control Products Ltd. All rights reserved.

Motion Control Products Ltd

11-15 Francis Avenue

Bournemouth, Dorset, UK BH11 8NX

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DMD870 Digital Stepper Drive User’s Manual

!

Notice

!

Caution

!

Warning

HEALTH AND SAFETY

Read this manual carefully before trying to install the stepper drive into
your system. The person setup the stepper drive should have a better
understanding on electronics and mechanics. Contact us if there is any
question about the products or this manual.

 Make sure the power supply voltage does not exceed the drive’s

input range. Double check the connections and make sure the
power lead polarity is correct.

 Disconnect the motor from the load if you are not sure the move

direction. Adjust the axis in the middle before trying to run the
motor.

 Do NOT set high current on small stepper motor as this may damage

the motor.

 Never disconnect the motor wires when the power is on.

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DMD870 Digital Stepper Drive User’s Manual

Contents

1. INTRODUCTION, FEATURES AND APPLICATIONS ....................................................... 1

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

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

Applications ........................................................................................................ 2

2. SPECIFICATIONS ......................................................................................................... 2

Electronic Specification Tj = 25℃/77℉ .............................................................. 2

Operating Environment ...................................................................................... 2

Outline Dimensions (unit: mm [inch]) ................................................................ 3

Elimination of Heat ............................................................................................. 3

3. CONNECTORS AND PIN ASSIGNMENT ........................................................................ 4

Connector P1 Configurations .............................................................................. 4

Selecting Active Pulse Edge and Control Signal Mode ....................................... 5

Connector P2 Configurations .............................................................................. 5

4. CONTROL SIGNAL CONNECTOR (P1) INTERFACE ........................................................ 6

5. CONNECTING THE MOTOR......................................................................................... 7

4-lead Motors Connections ................................................................................ 7

6-lead Motors Connections ................................................................................ 7

Half Coil Configurations .................................................................................. 7

Full Coil Configurations ................................................................................... 8

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

6. POWER SUPPLY CONNECTION ................................................................................... 9

Regulated or Unregulated Power Supply ........................................................... 9

Multiple Drives .................................................................................................. 10

Selecting Supply Voltage ................................................................................... 10

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7. MICROSTEP RESOLUTION & DRIVE OUTPUT CURRENT............................................. 10

Microstep Resolution Selection ........................................................................11

Current Settings ................................................................................................12

Dynamic current setting ................................................................................12

Standstill current setting ...............................................................................13

8. WIRING NOTES ........................................................................................................ 13

9. TYPICAL CONNECTION ............................................................................................. 14

10. SEQUENCE CHART OF CONTROL SIGNALS .............................................................. 15

11. PROTECTION FUCTIONS ......................................................................................... 16

Over-current Protection ....................................................................................16

Over-voltage Protection ....................................................................................16

Phase Error Protection ......................................................................................16

Protection Indications .......................................................................................17

12. FREQUENTLY ASKED QUESTIONS ........................................................................... 17

Problem Symptoms and Possible Causes ..........................................................18

13. TUNING SOFTWARE - PROTUNER ........................................................................... 19

Introduction ......................................................................................................19

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

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

Testing the Stepper System ..........................................................................21

How to use the software ...................................................................................21

Option ...........................................................................................................21

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

Tuning ............................................................................................................22

SystemConfig.................................................................................................24

Anti-Resonance Introduction ........................................................................25

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DMD870 Digital Stepper Drive User’s Manual

Procedure for Achieving Optimum Performance ......................................... 27

Err_check ...................................................................................................... 28

About ............................................................................................................ 29

APPENDIX .................................................................................................................... 30

Twelve Month Limited Warranty ...................................................................... 30

Exclusions .......................................................................................................... 30

Shipping Failed Product & Obtaining Warranty Service ................................... 30

Warranty Limitations ........................................................................................ 30

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DMD870 Digital Stepper Drive User’s Manual

1. INTRODUCTION, FEATURES AND APPLICATIONS

Introduction

Motion Control Products Ltd (MCP)’s digital stepper drive DMD870 is a versatility fully
digital stepper drive based on a DSP with advanced control algorithm. The DMD870 is the
next generation of digital stepper controls. It brings a unique level of system smoothness,
providing optimum torque and nulls mid-range instability. Motor auto-identification and
parameter auto-configuration 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 Drives in the markets. Its unique features make the
DMD870 an ideal solution for applications that require low-speed smoothness.

Compared to the DMD432 (DM432C), broader input voltage and output current ranges
make DMD870 being able to drive much more motors from size NEMA 17 to NEMA 34.

What’s more, thanks to its higher performance DSP, driven motors can achieve much

higher speed (above 3000RPM), offering servo-like performances. DMD870 stepper drive
is regarded as an improved model originally from DMD556, while supports broader input
voltage range.

Features

 Anti-Resonance, provides optimum torque and nulls mid-range instability
 Motor auto-identification and parameter auto-configuration 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

 Output current programmable, from 0.5A to 7.0A
 Pulse input frequency up to 200 KHz
 TTL compatible and optically isolated input
 Automatic idle-current reduction
 Suitable for 2-phase and 4-phase motors
 Support PUL/DIR and CW/CCW modes
 Over-voltage, over-current, phase-error protections

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DMD870 Digital Stepper Drive User’s Manual

Parameters

DMD870

Minimum

Typical

Maximum

Output current (A)

0.5

-

7.5 (5.0RMS)

Input voltage (VDC)

+ 24

+ 48

+72

Logic signal current (mA)

7

10

16

Pulse input frequency (kHz)

0 - 200

Isolation resistance (MΩ)

500 - -

Cooling

Natural Cooling or Forced cooling

Operating
Environment

Environment

Avoid dust, oil fog and corrosive gases

Ambient Temperature

0ºC－40ºC (32ºF－104ºF)

Humidity

40%RH－90%RH

Operating Temperature

70˚C (158˚F) Max

Vibration

5.9m/s2 Max

Storage
Temperature

-20ºC －65ºC (-4ºF －149ºF)

Weight

Approx. 280g (10 oz)

Applications

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 DMD870
an ideal solution for applications that require both low-speed smoothness and high speed
performances.

2. SPECIFICATIONS

Electronic Specification Tj = 25℃/77℉

Operating Environment

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Outline Dimensions (unit: mm [inch])

Elimination of Heat

 Drive’s reliable working temperature (heat sink) should be <70

motor working temperature (surface) should be

 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;

 The drive must be mounted vertically to maximise heat sink area as shown in the

following picture. Use forced cooling method to cool the system if necessary

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<80°C (176°F);

C (158°F), and

°

DMD870 Digital Stepper Drive User’s Manual

Signal

Description

PUL+ / PUL-

Pulse signal: In single pulse (pulse/direction) mode, this input represents pulse
signal, each rising or falling active edge (software configurable); 4-5V when PUL­HIGH, 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, the pulse width should be longer than 2.5μs.

Series connect resistors for current-limiting when +12V or +24V is used. The same
as DIR and ENA signals.

Important NOTE: The drive must be mounted vertically onto a plate or a heat

sinking to maximize heat sink area as shown in the above picture. Please use

additional heat sinking or cool fan if necessary.

3. CONNECTORS AND PIN ASSIGNMENT

DMD870 stepper drive 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

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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 (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 at least 5μs. 4-5V when DIR-HIGH, 0-0.5V when
DIR-LOW.
Please note that rotation direction is also related to motor-Drive wiring match.
Exchanging the connection of two wires for a coil to the Drive will reverse motion
direction.

ENA+ / ENA-

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

Pin Function

Details

+Vdc

Power supply, 24~72 VDC, Including voltage fluctuation and EMF voltage.

GND

Power Ground.

A+, A-

Motor Phase A

B+, B-

Motor Phase B

Selecting Active Pulse Edge and Control Signal Mode

DMD870 stepper drive supports PUL/DIR and CW/CCW modes and pulse actives at rising or
falling edge. See more information about these settings in Section 13. Default setting is
PUL/DIR mode and rising edge active (NPN, and PNP control signal is on the contrary).

Connector P2 Configurations

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DMD870 Digital Stepper Drive User’s Manual

4. CONTROL SIGNAL CONNECTOR (P1) INTERFACE

DMD870 stepper drive accepts differential and single-ended inputs (including open­collector and PNP output). It has 3 optically isolated logic inputs, which are located on
connector P1 to accept line Drive control signals. These inputs are isolated to minimize or
eliminate electrical noises coupled onto the drive control signals. Recommend use line
Drive control signals to increase noise immunity of the Drive in interference environments.
In the following figures, connections to open-collector and PNP signals are illustrated.

Figure 1: Connections to open-collector signal (common-anode)

Figure 2: Connection to PNP signal (common-cathode)

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5. CONNECTING THE MOTOR

The DMD870 can drive any 2-pahse and 4-pahse hybrid stepping motors.

4-lead Motors Connections

4 lead motors are the least flexible but easiest to wire. Speed and torque will depend on
winding inductance. In setting the Drive output current, multiply the specified phase
current by 1.4 to determine the peak output current.

Figure 3: 4-lead Motor Connections

6-lead Motors Connections

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 Drive output current multiply the specified per
phase (or unipolar) current rating by 1.4 to determine the peak output current.

Figure 4: 6-lead motor half coil (higher speed) connections

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DMD870 Digital Stepper Drive User’s Manual

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
overheating.

Figure 5: 6-lead motor full coil (higher torque) connections

8-lead Motors Connections

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 6: 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.

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Figure 7: 8-lead motor parallel connections

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

6. POWER SUPPLY CONNECTION

The DMD870 can match medium and small size stepping motors (from frame size NEMA 17
to size NEMA 34) made by MCP 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.

Note: MEANWELL DRP-240-24 (24VDC, 240Watt power supply) must be selected in order to make

the whole system comply with UL standards for safety.

Regulated or Unregulated Power Supply

Both regulated and unregulated power supplies can be used to supply the Drive. 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-Drive 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 Drive 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

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DMD870 Digital Stepper Drive User’s Manual

considerably less than motor current. For example, two 3A motors can be well supplied by
one power supply of 4A rating.

Multiple Drives

It is recommended to have multiple Drives 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 Drives. Instead, please connect them to power supply separately.

Selecting Supply Voltage

The power MOSFETS inside the DMD870 can actually operate within +24 ~ +80VDC,
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 the
drive 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 +24 ~ +72VDC, leaving room for power fluctuation and back-EMF.

7. MICROSTEP RESOLUTION & DRIVE 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 0.5A to 7.0A. See more
information about Microstep and Output Current Setting in Section 13.

However, when it’s not in software configured mode, this Drive uses an 8-bit DIP switch to
set microstep resolution, and motor operating current, as shown below:

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Microstep

Steps/rev.

(for 1.8°motor)

SW5 SW6

SW7

SW8

1 to 512

Default/Software

configured

ON

ON

ON ON

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

Microstep Resolution Selection

When it’s not in software configured mode, microstep resolution is set by SW5, 6, 7, 8 of
the DIP switch as shown in the following table:

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DMD870 Digital Stepper Drive User’s Manual

Peak Current

RMS

Current

SW1

SW2

SW3

Default/Software configured

(0.5 to 7.0A)

OFF OFF OFF

2.6A

1.8A ON

OFF

OFF

3.4A

2.4A

OFF ON

OFF

4.0A

2.8A ON ON

OFF

4.8A

3.4A

OFF

OFF ON

5.4A

3.8A ON

OFF ON

6.1A

4.3A

OFF ON ON

7.0A

5.0A ON ON ON

Current Settings

For a given motor, higher Drive current will make the motor to output more torque, but at
the same time causes more heating in the motor and Drive. 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 Drive output current depending on motor
phase current, motor leads and connection methods. Phase current rating supplied by
motor manufacturer is important in selecting Drive 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

Notes: Due to motor inductance, the actual current in the coil may be smaller than the dynamic

current setting, particularly under high speed condition.

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Standstill current setting

SW4 is used for this purpose. OFF means that the standstill current is set to be half of the
selected dynamic current, and ON means 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 us.

8. WIRING NOTES

 In order to improve anti-interference performance of the Drive, 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, system instability and other failures.

 If a power supply serves several drives, separately connecting the drives is

recommended instead of daisy-chaining.

 It is prohibited to pull and plug connector P2 while the Drive 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 Drive.

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DMD870 Digital Stepper Drive User’s Manual

DRIVE

9. TYPICAL CONNECTION

A complete stepping system should include stepping motor, stepping Drive, power supply
and controller (pulse generator). A typical connection is shown as figure 8.

Figure 8: Typical connection

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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 9: 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 active edge by 5μs to ensure correct direction;
c) t3: Pulse width not less than 2.5μs;
d) t4: Low level width not less than 2.5μs.

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DMD870 Digital Stepper Drive User’s Manual

11. PROTECTION FUCTIONS

To improve reliability, the DMD870 stepper drive incorporates some built-in protection
functions. It 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 Drive 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 (3s).

Over-voltage Protection

When power supply voltage exceeds 91±1 VDC, protection will be activated and RED LED

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

Phase Error Protection

Motor power lines wrong & not connected will activate this protection. RED LED will turn
on four times within each periodic time (3s).

Attention: When above protections are active, the motor shaft will be free or the LED will turn red.

Reset the Drive 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 Drive. Otherwise, the Drive will be damaged instantly.

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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

Protection Indications

12. FREQUENTLY ASKED QUESTIONS

In the event that your drive 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 mistakes in wiring.

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DMD870 Digital Stepper Drive User’s Manual

Symptoms

Possible Problems

Motor is not rotating

No power

Microstep resolution setting is wrong

DIP switch current setting is wrong

Fault condition exists

The drive is disabled

Motor rotates in the
wrong direction

Motor phases may be connected in reverse

The drive in fault

DIP switch current setting is wrong

Motor coil problems/motor problem

Erratic motor motion

Control signal is too weak

Control signal is interfered

Wrong motor connection

Motor coil problems

Current setting is too small, losing steps

Motor stalls during
acceleration

Current setting is too small

Motor is undersized for the application

Acceleration is set too high

Power supply voltage too low

Excessive motor and
drive heating

Inadequate heat sinking / cooling

Automatic current reduction function not being utilised

Current is set too high

Problem Symptoms and Possible Causes

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DMD870 Digital Stepper Drive User’s Manual

How to Install ProTuner:

Double click “ProTuner_All_Setup_V1.0.exe” to begin the ProTuner. Click Next to
enter the “License Agreement” window. Choose “I agree to the terms of this license
agreement” and click Next to continue the installation. The user can enter user’s
information in the relevant fields. After entering the user’s information, click Next to
select installation folder, where you would like to install the ProTuner. Set the
“Shortcut Folder” as the next step and then click Next, an Installation Successful
window will appear if the ProTuner is installed successfully.

13. TUNING SOFTWARE - PROTUNER

This section will provide an overview of connection and basic setup instructions for our digital
stepping Drive DMD870 using the ProTuner software. These instructions will take you
through the following steps on how to set up your DMD870 stepper drive and the motor with
the software called ProTuner.

Introduction

The ProTuner is a Windows-based setup software for tuning all our DMD series digital
drives includes stepper drive DMD870. It can run in Windows systems, including
Win95/Win98/WindowsNT/ Windows 2000/Windows XP. And the selected PC should have
at least 1 serial port to communicate with the drive.

Connections and Testing

Connect the stepping system according to the contents in previous sections and connect
the PC to the Drive as the following figure.

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RS232 Communication Connector

RJ11 Connector

Pin

Signal

Description

I/O

1

NC

Not connected

-

2

+5V

leave it unconnected
when connect to a PC
serial port

+5V power only for STU

O

3

TxD

RS232 transmit

O

4

GND

Ground

GND 5 RxD

RS232 receive

I 6 NC

Not connected

-

RS232 Interface Connection

Figure 10: RS232 interface connection

DMD870 Digital Stepper Drive User’s Manual

DM870

DMD870

Below diagram is the cable connection to a PC serial port (Male DB9)

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Testing the Stepper System

Turn on the power supply, the green (Power) LED will light. The DMD870 has default
parameters stored in the Drive. If the system has no hardware and wirings problem, the
motor should be locked and the Drive should be ready.

If the red LED immediately turns on (flickers), then check power supply, the motor, motor
wirings and try again. Open the tuning software ProTuner and check Drive 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 our technical team

[e-mail] for the support.

If the RED LED is off and the motor is normal, you can start to tune the drive and motor
system with ProTuner. However, we recommend the users to read the following contents
before starting tuning.

How to use the software

Option

The user can choose three drop-down menus by clicking “Option”, including Com Config,
SaveToDrive and Exit.

Com Config: Configure Com communication interface.

Save To Drive: Download the current parameter settings to the Drive.

Exit: Exit the ProTuner.

Com Config Window

Figure 11: RS232 communication configuration window

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DMD870 Digital Stepper Drive User’s Manual

Serial Port: Select the serial communication port to which the Drive 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 choose SaveToDrive to download the current parameter settings to the Drive, or to
upload the stored Drive settings into the ProTuner by clicking Tuning > Position Loop on the
menu bar.

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 can tune the Kp (Proportional Gain) and
Ki (Integral Gain) of Drive’s current loop to optimise 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 Drive 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 13. Too large Proportional Gain values will cause
oscillations and unstable systems.

Figure 12: Current Tuning window

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DMD870 Digital Stepper Drive User’s Manual

Ki: Integral Gain. Integral Gain helps the Drive 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 12, and remember to save the
settings to the Drive when finish tuning. See Figure 14.

Figure 13: Kp=543, Ki=0 (poor performances)

Figure 14: Finish tuning and save setting to the drive

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DMD870 Digital Stepper Drive User’s Manual

Notes:

However, if the user does not want to tune the current loop after changing a different
stepping motor, then Motor auto-identification and parameter auto-configuration
technology of the DMD870 can replace manually tuning the drive with ProTuner. Just
change SW4 two times in 1 second, and then the drive will auto-identify the new motor
and auto-configure related control parameters for optimum responses. Recommend to use
this function after changing the driven motor.

SystemConfig

In SystemConfig window, the user can configure Peak Current, Microstep, Command Type,
Active Edge, and eliminate motor resonance. A built-in pulse generator can be used for test
during tuning. See Figure 15.

Figure 15: SystemConfig window

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DMD870 Digital Stepper Drive User’s Manual

PeakCur: Peak Current. The value is the peak current to the selected motor and can be set

from 0.5 to 5.6 A. The user can set the peak current with ProTuner or DIP switches, see
more information about setting output current of the drive in Section 5 “CONNECTING THE

MOTOR” and Section 7 “MICROSTEP RESOLUTION AND DRIVE OUTPUT CURRENT”.

MicroStep: Microstep Resolution. The value is Drive’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 Drive in Section 7 “MICROSTEP

RESOLUTION AND DRIVE 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.

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 Drive works in CW/CCW mode, no matter what level is at fixed level
terminal, the Drive can works properly.

DirectionDef: Direction Definition. Relate the default running direction to a HIGH level input
in DIR or Low level input 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.

Anti-Resonance Introduction

Stepper motors are highly resonant, which results in vibration and ringing. The ringing
utilizes a large fraction of the motor's available torque - thereby wasting performance.
Furthermore, at mid-range velocities, the resonance can become so severe that the motor
loses synchronisation and stalls. The DMD870 drive provides robust anti-resonance control
to stop the vibrations and maintain equilibrium. This feature requires that the drive be
configured with respect to the total inertia in the system. If set improperly, the
effectiveness of the feature may be diminished.

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DMD870 Digital Stepper Drive User’s Manual

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 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, anti-resonant loop in the drive. The anti-resonant
feature is not designed to damp such a 4th order system. If the application of anti-resonance
results in degradation or instability, it should be disabled.

1st Resonance Area: Parameters for 1st resonance area. Usually between 0.6rps and 1.2rps.

Amp1 is Amplitude adjustment for 1st resonance area.

Phase1 is Phase adjustment for 1st 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.

2nd Resonance Area: Parameters for 2nd resonance area. Usually between 1.2rps and

2.4rps. Default Amp2 and Phase2 values are zero.

3rd Resonance Area: Parameters for 3rd resonance area. Usually between 2.4rps and

4.8rps. Default

Amp3 and Phase3 values are 128.

Interner Pulser: There is an internal pulse generator designed for Drive self-testing and

anti-resonance tuning. You can issue a motion by this simple controller.

Cycle check box: The motion will repeat if this box is checked.

Reverse check box: The motor shaft will reverse direction if this box is checked. Interval

edit box: The stop time between each cycle, unit is millisecond. Repeat edit box: Total
motion cycles.

Length edit box: Move distance of each cycle, unit is revolution.

Start/Stop button: The user can Start/Stop a motion test by clicking this button.

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DMD870 Digital Stepper Drive User’s Manual

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. See Figure 16.

Figure 16: Anti-resonance tuning

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)

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DMD870 Digital Stepper Drive User’s Manual

and Phase(s) values may be a little different between running the tests with an unloaded
motor and a load motor.

Please remember to click SavetoDrive to download the final parameter settings to the Drive

when finish tuning. See Figure 17.

Figure 17: Finishing tuning and download parameter settings to the Drive

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 drive faults. #0 being the
most recent, #9 is the oldest. See Figure 18.

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DMD870 Digital Stepper Drive User’s Manual

Figure 18: Error check window

OverCurrent: Over-current Protection. Protection will be activated when continuous
current exceeds 16A.

OverVoltage: Over-voltage Protection. When power supply voltage exceeds 91±1 VDC,
protection will be activated.

PhaseErr: Phase Error Protection. Motor power lines wrong & 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 the contact information.

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DMD870 Digital Stepper Drive User’s Manual

APPENDIX

Twelve Month Limited Warranty

Motion Control Products Ltd. warrants its products against defects in materials and
workmanship for a period of 12 months from the shipping date. During the warranty
period, Motion Control Products will either, at its option, repair or replace products which
are proved to be defective.

Exclusions

The above warranty shall not apply to defects resulting from: improper or inadequate
handling by the customer; improper or inadequate customer wiring; unauthorised
modification or misuse; or operation beyond the electrical specifications of the product
and/or operation beyond environmental specifications for the product.

Shipping Failed Product & Obtaining Warranty Service

If your product should fail during the warranty and want to obtain warranty service, a RMA

(returned material authorisation number) request form must be filled in on our website

http://www.motioncontrolproducts.com/pages/returns.php before returning the

product for service. Please include a written description of the problem along with contact
name and address. Customer shall prepay shipping charges returned to Motion Control
Products for warranty service, and Motion Control Products shall pay for return of products
to the customer, providing the fault is not customer caused. Send the failed product to

your distributor for your area or to Motion Control Products Limited, 11-15 Francis

Avenue, Bournemouth, Dorset BH11 8NX, UK. Also enclose information regarding the
circumstances prior to the product failure. For full terms and conditions of Warranty and

Returns Policy, please refer to our website

http://www.motioncontrolproducts.com/pages/returns.php

Warranty Limitations

Motion Control Products makes no other warranty, either expressed or implied, with
respect to the product. Motion Control Products specifically disclaims the implied
warranties for a particular purpose. Some jurisdictions do not allow limitations on how long
the implied warranty lasts, so the above limitation or exclusion may not apply to you.
However, any implied warranty is limited to the 12-month duration of this written
warranty.

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