phytron MCD+ User Manual

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Manual 2102-A005 GB

MCD

Compact Stepper Motor Power Stage for Wall Mounting

phytron

03/2008 Manual MA 2102-A005 GB

MCD+ 93–70

Compact Stepper Motor Power Stage

for Wall Mounting

Manual MCD

MA 2102-A005 GB 2

© 2008 All rights with: Phytron-Elektronik GmbH Industriestraße 12 82194 Gröbenzell, Germany Tel.: +49(0)8142/503-0 Fax: +49(0)8142/503-190 Every possible care has been taken to ensure the accuracy of this technical manual. All

information contained in this manual is correct to the best of our knowledge and belief but cannot be guaranteed. Furthermore we reserve the right to make improvements and enhancements to the manual and / or the devices described herein without prior notification.

We appreciate suggestions and criticisms for further improvement. Please send your comments to the following e-mail-address: doku@phytron.de You´ll find the updated version of this manual on the website of www.phytron.de

phytron

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Contents

1 MCD+ .......................................................... 4

1.1 Short Overview ..................................... 4

1.2 Extent of Supply ................................... 6

1.3 Signal Connector X3 ............................ 7 

1.4 ServiceBus Connectors X4 and X5 ...... 8

1.5 Operating Modes .................................. 8

1.5.1Rotary Switch Mode ....................... 9

1.5.2ServiceBus Mode .......................... 10

1.5.3Bus Mode Exclusive ...................... 11

1.6 LED ..................................................... 11

2 Technical Data Table ............................... 12

3 To Consider Before Installation ................. 15

3.1 Qualified Personnel ............................. 15

3.2 Safety Instructions ............................... 15

3.3 Protective Measure Options for the

Operation of Power Stages ................. 16

3.4 Putting into Service ............................. 17

3.4.1For Rotary Switch Mode ................ 17

3.4.2For ServiceBus Mode .................... 18

4 Dimensions and Mounting ......................... 19

5 Mains Supply Unit ..................................... 20

5.1 Insulation Overview ............................. 21

6 Motor Connection ...................................... 22

6.1 Motor Connector .................................. 23

6.2 Shielding .............................................. 23

6.3 Wiring Schemes .................................. 24

6.4 Motor Cables ....................................... 25

7 Inputs and Error Output ............................. 26

7.1 Inputs ................................................... 26

7.1.1Push-Pull- or OC-Controlling ......... 27

7.1.2Logic Level 24 V or 5 V ................. 27

7.1.3Control Pulse Input ........................ 28

7.1.4Direction Input ............................... 29

7.1.5Boost Input .................................... 29

7.1.6Activation Input .............................. 29

7.1.7Reset Input .................................... 30

7.2 Error Output......................................... 30

8 Rotary Switches ........................................ 32

8.1 Rotary Switch Mode ............................ 32

8.2 ServiceBus Mode ................................ 34

8.2.1USB-RS485-Converter .................. 35

8.2.2USB-Driver Installation .................. 36

9 Bus Connection Configuration................... 37

9.1 Definition ............................................. 37

9.2 Operating Parameters ......................... 38

9.2.1Extra Parameters .......................... 42

9.2.2Examples ...................................... 43 

Appendix A: Technical Details ....................... 45

A1 Full Step / Half Step / Ministep ............. 45

A2 Boost .................................................... 47

A3 Overdrive Function ............................... 48

A4 Current Delay Time .............................. 50 

A5 Current Shaping CS ............................. 51

Appendix B ................................................. 52

B1 Warranty ............................................... 52

B2 Trade Marks ......................................... 52 

B3 ESD Protective Measures..................... 52

Appendix C: Declarations of Conformity ........ 53

Index ....................................................... 55

Manual MCD

1 MCD+

In this chapter you’ll find a brief description of the power stage MCD+ 93-70.

1.1 Short Overview

Fig. 1: Operator’s controls

Ministep Compact Power Stage for 2-Phase Stepper Motors

The power stages type MCD are used for bipolar control of two-phase stepper motors with phytron’s welltried technology, now with enhanced 4 quadrant chopper type current control.

The operating parameters – run and stop current, step resolution, current delay time and preferential motor direction – can be set either by rotary switches or by ServiceBus.

The ServiceBus allows configuration and programming via PC by software ServiceBusComm

for Windows®.

In rotary switch mode the step resolution can be set to the following values: Full step, half step, 1/4, 1/5, 1/8, 1/10 and 1/20 step. You can select further step resolution up to 1/512 step in ServiceBus mode.

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With overdrive function, a dynamic boost function, the MCD offers a motor independent compensation of the torque decrease for higher frequencies. In ServiceBus mode the current shaping function (CS) can be activated for phase current adaptation.

Motor currents from 0.3 to 9 A

Peak

Rotary switch mode: Run and stop current can be individually set. You can change between 2 ranges (I or II) by the rotary switch ‘Current range setting’: Range I: from 0.3 to 3 A

Peak

(0.2 to 1.6 A

r.m.s.

, 100 mA steps)

Range II: from 1.1 to 9 A

Peak

(0.6 to 5.0 A

r.m.s.

, 300 mA steps)

ServiceBus mode: Phase currents can be programmed in 100 mA steps.

Supply voltage DC

A DC voltage from 24 to 70 VDC can be connected to the supply voltage connector.

Inputs

Two possibilities of input level: The MCD power stage can be controlled with 5 V or 24 V depending on the wiring.

The inputs Control pulse, Motor direction, Boost, Activation and Reset are designed for Push-Pull- or OC-Controlling. The inputs are optically insulated from the MCD power supply voltage.

ServiceBus The ServiceBus offers the following possibilities:

• Power stage parameter programming: e. g. Run, stop and boost current, step resolution, preferential motor direction and current delay time, etc.

• Configuration by software via 4-wire RS485 bus, optically insulated from the motor voltage

• Parameter memory to hold data safely in the power stage EPROM

• Activate or deactivate the functions Overdrive and Current Shaping

The power stage can easily and quickly be programmed by ServiceBus-Comm® for Windows® software (see manual ServiceBus-Comm®).

Manual MCD

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Easy to mount and EMC compliant

• Vario flat pack for wall or rail mounting

• EMC compliant metal housing, cable clamps and PE screws at the top and bottom of

the housing

• Built-in EMC filter and motor filter for power supply

• Easy mounting by means of screw-type connectors

• Mounting brackets for different mounting positions

1.2 Extent of Supply

The MCD is available in the following options ( #: Ident number):

• MCD Power stage for rail mounting with mating connectors X1 to X3 #10008200

• MCD Power stage for wall mounting with mating connectors X1 to X3 #10006576

• MCD Power stage with the phytron USB Converter (a cable 20 cm included) for wall

mounting with mating connectors #10006861

• MCD Power stage with the phytron USB Converter (a cable 20 cm included) for rail

mounting with mating connectors #10008201

Accessories:

• MCD Manual

• Phytron CD with ServiceBus-Comm® software

• ServiceBus-Comm

Manual

Supplementary parts are available:

• Rail mounting kit #10007882

• ServiceBus cable (connection A-A) 20 cm #10006857

• ServiceBus cable (connection A-A) 100 cm #10006880

• USB cable (connection A-B) 200 cm #10006881

• Cable connection RS422/485-A 200 cm #10007255

• Power supply PS 5-48 (5 A, 48 V) for wall mounting #10006780

• Power supply PS 5-48 (5 A, 48 V) for rail mounting #10006148

• Power supply PS 10-24 (10 A, 24 V) for wall mounting #10006781

• Power supply PS 10-24 (10 A, 24 V) for rail mounting #10006578

phytron

• Mating connector set X1 to X3 #10007287:

Connector Number of poles Mating connector Phoenix Identity number X1

2 MSTB2,5/2-STF-5,08 #02005267

4 IC 2,5/4-ST-5,08 #10005390

17 MC 1,5/17-ST-3,5 #10006319

1.3 Signal Connector X3

The power stage is adapted for 5 V or 24 V input voltage. There are different pin assignments for both input voltages.

Fig. 2: 17-pole Phoenix Combicon connector MC 1,5/ 20-G-3,5

Please note that there are different pins for 5 V or 24 V inputs on X3! Do not connect a 5 V input to 24 V voltage! Danger of damages! See also chap. 7.1.

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Manual MCD

1.4 ServiceBus Connectors X4 and X5

The power stages MCD are connected to the 4-pole ServiceBus connectors in ServiceBus mode by A-A connection cables. See also chap. 8.2 in the ServiceBus-mode.

Fig. 3: 4-pole ServiceBus connector IN: X4

(DIN IEC 61076-3-107)

Fig. 4: 4-pole ServiceBus connector OUT: X5

(DIN IEC 61076-3-107)

1.5 Operating Modes

The MCD operating mode can be set by the 4 setting switches at the front panel:

Fig. 5: 16-step setting switch: setting 0...F

Operating mode: Setting switch mode Phase currents, Step resolution, preferential motor direction and device address are set by

the rotary switches I

Run, IStop,

STEP and Address.

Setting switch mode is selected, if the rotary switches S1, S2, S3 and S4 aren’t set to ‚0’.

Operating mode: ServiceBus mode

All settings are made on PC by ServiceBus–Comm

phytron software.

If the rotary switches S2, S3 and S4 are set to ‚0’, the MCD is in ServiceBus Mode. The rotary switch S1 addresses the device

Important: Each address must only be used once!

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Remark:

If only one setting switch (S2, S3 or S4) is set to ‘0’ in the ServiceBus mode, the MCD will be deactivated.

Operating mode: Bus mode exclusive

This operating mode is a special ServiceBus mode with safety locking. In Bus mode exclusive all settings at the rotary switches are ignored.

Important:

• In setting switch mode the rotary switch adjustments are only accepted after a Reset

signal.

• Settings in the power stage also can be changed in setting switch mode by

ServiceBus-Comm®. After Reset (and then only) the settings of the rotary switches are read.

1.5.1 Rotary Switch Mode

Run and stop current (I

Run

, I

Stop

), step resolution and preferential motor direction (STEP) to 15 positions (1…F), the device address (Address) to 16 positions (0…F) can be set by the four setting switches at the front side.

9 MA 2102-A005 GB

Fig. 6: Rotary switch mode – parameter setting by rotary switches

Manual MCD

In the Rotary switch mode, you can be change between 2 ranges (I or II) by the rotary switch ‘Current range setting’:

Fig. 7: Range I:

max. 1.6 A

r.m.s.

in 0.1 A steps

Fig. 8: Range II:

max. 5 A

r.m.s.

in 0.3 A steps

Remark:

The switch positions may be changed

• while the MCD is powered off or

• the power stage is deactivated. However, after changing the switch position the

power stage should be reset by the input Reset.

1.5.2 ServiceBus Mode

The ServiceBus mode is only activated, if all three rotary switches S2, S3 and S4 are set to ‚0’. The rotary switch S1 addresses the device (0…F).

Important: Each address must only be used once!

Fig. 9: ServiceBus Mode

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The ServiceBus mode allows configuration and programming via PC by software ServiceBus-Comm® for Windows®.

The step resolution can be programmed up to 1/512 step, the current delay time and the phase current in 100 mA steps.

The operating parameters are unconditionally set, i.e. the preset values are accepted

without Reset. Exception: The step resolution must be confirmed by Reset!

1.5.3 Bus Mode Exclusive

The Bus mode exclusive ensures safe operation in ServiceBus mode. If the power stage is set to Bus mode exclusive in ServiceBus mode by ServiceBus-Comm

, all rotary switch

settings are ignored.

1.6 LED

Bi-colour LED

Meaning

green Ready LED is shining permanently:

The MCD power stage is ready to operate and energized.

LED is blinking by second cycle (0.5 Hz): Power stage is deactivated

red Fault Error in MCD:

Overcurrent/Short circuit: LED is shining permanently Undervoltage: LED is blinking by second cycle (0.5 Hz) Overtemperature: LED is blinking fast (2 Hz)

Manual MCD

2 Technical Data Table

Technical Data

Stepper motor

2-phase-stepper motors with 4, 6 or 8 lead wiring scheme Winding resistance between 0.1 and 10 Ohm Winding inductance 0.5 to 10 mH per phase

Step resolution Rotary switch mode

The step resolution can be set by the rotary switch: 1/1, 1/2, 1/4, 1/5, 1/8, 1/10, 1/20 of a full step.

ServiceBus mode The step resolution is programmable:

1/1, 1/2, 1/4, 1/5, 1/8, 1/10, 1/16, 1/20, 1/32, 1/64, 1/128, 1/256, 1/512 of a full step.

Phase currents Rotary switch mode

Run current and stop current can be individually set by the rotary switches.

Run current and stop current can be changed between 2 ranges by the rotary switch CURRENT RANGE SETTING (I and II). Factory settings: Rotary switch: I (= low range) All rotary switches: ‚0’

Rotary switch position

Range I

Range II

Run and stop current Run and stop current

0.2 to 1.6 A

r.m.s.

(without Boost) in 0.1 A steps

0.3 to 2.1 A

r.m.s.

(with Boost)

0.4 to 3 A

Peak

0.6 to 5 A

r.m.s.

(without Boost) in 0.3 A steps

0.8 to 6.3 A

r.m.s.

(with Boost)

1.1 to 9 A

Peak

ServiceBus mode Run and stop current can be set independently by program.

Programmable from 0.1 to 5 A

r.m.s.

in 100 mA steps

Lead cross section of the motor cable

Minimum 1 mm² is recommended at max. current.

Supply voltage

Unregulated filtered DC voltage from 24 to 70 V

Nominal voltage 70 VDC Reinforced or double insulation between mains and secondary circuit.

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Technical Data

Error message

Supply voltage < 20 VDC or > 85 V

Overtemperature (T > 85° C) Overcurrent, short circuit The power stage is powered off in case of an error message.

Mounting

The MCD housing is constructed with wall mounting brackets at two side panels. We recommend a vertical mounting (labeling readable) because of a better heat dissipation. The clip for rail mounting is mounted on the back side (35 mm acc. to EN550022).

Weight

650 g

Connector at the supply cable X1

Phoenix Combicon connector, type MSTB 2,5/2-STF-5,08

Connector at the motor cable X2

Phoenix Combicon connector, type IC 2,5/4-ST-5,08

Connector at the I/O cable X3

17-pole Phoenix Mini Combicon connector, type MC 1,5/17-ST-3,5

Connector at X4: IN

4-pole ServiceBus connector, type DIN IEC 61076-3-107

Connector at X5: OUT

4-pole ServiceBus connector, type DIN IEC 61076-3-107

Inputs

The inputs are optically insulated from the motor voltage and can be controlled via push-pull driver or open collector, input level 5 V or 24 V

Signal level 5 V 24 V High 2.5 – 5.5 V 20 – 30 V Low < 0.4 V < 3 V Necessary driver current 10 mA minimum

Control pulse Maximum step frequency: 500 kHz

Minimum pulse width: 1 µs The step is done with the rising flank of the control pulse.

Motor direction When the optocoupler is energized, the motor rotates in the

reverse direction (as compared to the preferential motor direction selected). The direction of rotation signal should not be changed at least 1 µs before the rising flank and 4 µs after the falling flank of the control pulse!

Manual MCD

MA 2102-A005 GB 14

Technical Data

Boost In Rotary switch mode: When the optocoupler is energized,

the MCD increases the run and stop current by 30%.

Boost current is programmable in the ServiceBus mode. Activation When the optocoupler is energized, the power stage is ready. Reset When the input optocoupler is energized, all error messages

are reset and the control circuit is initialized. Output

Optically insulated from the motor voltage, type open-

collector

max

= 20 mA, U

max

= 30 V, P

total

= 300 mW,

UCE

sat

at 20 mA < 1 V

Error The output opens in case of the following error signals: short

circuit, overcurrent, undervoltage, overvoltage, overheat.

To avoid damages, the drive is deactivated at the same time.

Ambient temperatures

Operation: 4 to +40 °C *)

Storage: –25 to +55 °C

Transport: –25 to +85 °C

*) We recommend an additional cooling in case of higher

operation temperatures. Ambient standards

EN 50178 Electronic equipment for use in power

installations degree of pollution 2 should be observed

EN 61000-6-2

(EN 55011)

Immunity for industrial environments class A

EN 61000-6-3

(EN 55022)

Emission standard for industrial environments class B A line filter with 20 dB damping is necessary in the range from 0.15 to 1 MHz (f.ex. Corcom 5VR1). Remark: If PS 5, phytron’s power supply unit, is used, any line filter isn’t required.

EN 61000-6-4 Emission standard for industrial

environments class A

EN 61000-3-2 Electromagnetic compatibility (EMC)

Minimum free space

The MCD should be built-in vertically to ensure convection.

Minimum free space to other devices: 30 mm

Minimum free space below and above the device: 100 mm

Required free space for cables and connectors:

about 30 mm at the MCD front panel

phytron 3 To Consider Before Installation

Read this manual very carefully before installing and operating the MCD. Observe the safety instructions in the following chapter!

3.1 Qualified Personnel

Design, installation and operation of systems using the MCD may only be performed by qualified and trained personnel.

These persons should be able to recognize and handle risks emerging from electrical, mechanical or electronical system parts.

WARNING !

By persons without the proper training and qualification damages to devices and persons might result!

3.2 Safety Instructions

1. The MCD must only be operated in accordance with the protective measure in chap. 3.3.

2. The connector power supply X1 should be locked with the fixing screws.

3. The transformer must be constructed with reinforced or double insulation to avoid dangerous touch voltages (50 VAC and 120 VDC) in case of isolation error in the transformer.

4. If you need to open the MCD device:

Up to 3 minutes after turning off the supply voltage, dangerous voltages may still exist within the device.

5. Be careful handling the motor connectors X2 at the MCD and any motor cable coupling.

As long as the MCD is connected to supply voltage, a hazardous voltage level is present at motor connector and motor cable, even if the motor is not wired.

6. Always switch off the supply voltage if you connect or disconnect any wires or connectors at the MCD. Most important:

Do not unplug the motor connector while powered!

Danger of electric arcing.

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Manual MCD

7. The maximum voltage of the signal inputs and outputs must not exceed 5 V

and 24 V

(I/O connector X3). Please note that there are different pins for 5 V or 24 V inputs! Do not connect a 5 V input to 24 V voltage! Danger of damages!

8. Clearing the inputs Activation or Reset is no safe separation in the emergency case. The voltage supply has to be interrupted for switching off the drive safely.

9. Devices connected to MCD for control or communication should have reinforced or double insulation.

10. The surface of the MCD may reach temperatures of more than 85 °C during operation. Danger of injury if touching the surface!

3.3 Protective Measure Options for the Operation of Power Stages

The power stage must be operated by the protective measure PELV acc. to VDE 0100. Board and motor housing have to be grounded and/or connected to 0 V.

Various options are possible to achieve the protective measure PELV:

Fig. 10: PELV – Grounding: total

Fig. 11: PELV – Grounding: Power Stage and Motor. The secondary winding of the transformer

(SELV supply) must not be grounded because the equipment is grounded.

Fig. 12: PELV – Grounding: 0 V and Motor

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If there is no PE clamp on the motor, the 0 V wire must be grounded to complete the protective measure PELV (Fig. 13 and Fig.14):

Fig. 13: PELV – Grounding: 0 V and Power Stage

Fig. 14: PELV – Grounding: 0 V

Protective measure PELV for application of the +UB should not exceed 70 VDC or 50 VAC at dry environment (environmental conditions 3 acc. to IEC 61201).

The supply transformer must be constructed with reinforced or double insulation between supply and secondary winding (acc. to EN 61558).

Only use motors which are checked acc. to EN 60034-1 (500 VAC/1 minute).

3.4 Putting into Service

3.4.1 For Rotary Switch Mode

Please follow the described order when you put into service the MCD power stage:

1. Connect the MCD acc. to protective measure in chap. 3.3.

2. Wire the 17-pole Phönix connector (MC1,5/(17-ST-3,5)) with the required leads and connect it to the MCD (See fig. 2: male connector of the MCD (MC1,5/17-G-3,5)).

3. Connect the motor to the MCD. Use the Phönix connector called: IC2,5/4-ST-5,08. The equivalent male connector (IC2,5/4-G-5,08) is on the front panel of the MCD. Please note chapter 6.1 to 6.4.

4. Setting switch positions for Rotary switch mode For rotary switch setting see table in chapter 8.

17 MA 2102-A005 GB

• Set the rotary switch I

Run

to the required run current. The phase current should

not exceed the maximum admissible motor current.

Manual MCD

MA 2102-A005 GB 18

• The stop current is set by the rotary switch I

Stop

. We recommend the following setting: Stop current = 50 % of the run current.

• Set the step resolution and preferred motor direction by the rotary switch STEP.

• Connect the input signals to the Control pulse and Activation inputs.

5. Connect the supply voltage to the MCD. Use the 2-pole Phönix connector (MSTB2,5/STF-5,08). The equivalent male connector (MSTB2,5/2-GF-5,08) is on the front panel of the MCD (see chap. 5).

6. Power on the MCD. The MCD is designed for voltages from 24 to 70 V. The nominal voltage is 70 V. As soon as the MCD is powered on and there is no error, the green LED shines.

3.4.2 For ServiceBus Mode

Please follow the described order when you put into service the MCD power stage:

1. to 3. see chap. 3.4.1

4. Rotary switch setting for ServiceBus mode

• Set the rotary switches S2, S3 and S4 to position 0.

• Set the rotary switches S1 to the required device address (0…F).

• Using the USB-RS485-Converter:

Connect an USB-port of the PC to the USB input (IN) of the USB-RS485-converter by an USB-cable, type A-B. Install the required USB drivers, see phytron CD. After a successful installation connect the USB-RS485-converter (OUT) to the MCD (connector X4) (A-A connection of the 4-pole connector).

• Using the RS422/RS485-Interface: Connect the PC to the first MCD (X4) with an adapted ServiceBus cable. Then, connect the bus output of the MCD (X5) to the next MCD (See fig. 29). Continue until all MCD are connected in bus mode.

• Connect the input signals to the Control pulse and Activation inputs.

5. and 6. see chap. 3.4.1

phytron 4 Dimensions and Mounting

Fig. 15: Dimensions in mm (inch)

Mounting instruction

The MCD should be built-in vertically to improve convection. Minimum free space to other devices: 30 mm

Minimum free space below and above the device: 100 mm Required free space for cables and connectors: about 30 mm at the MCD front panel

Wall mounting

The MCD has been designed to be mounted in different mounting positions. The power stage can be fixed at the lateral cooling surface with 4 screws M4 or UNC 6-32, at the rear side with two screws (see fig.15).

Rail mounting

The clip for rail mounting is mounted on the rear side. Attention: screws admissible for mounting: M3 x 8

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Manual MCD

5 Mains Supply Unit

The MCD power stage can be supplied by means of an unregulated filtered DC voltage from 24 to 70 VDC.

Admissible voltage range: 24 to 70 VDC Nominal voltage: 70 VDC The voltage must not drop under 20 V and rise over 85 V, not even for a short time

(> 1 msec). If the external voltage breaks down under 20 V or rises over 85 V, the MCD detects undervoltage.

Fig. 16: Mains supply unit

For calculation and connection of the supply unit, the following instructions must be followed:

•

The transformer must be constructed with reinforced or double insulation.

•

The calculation of the F2 fuse depends on the preset phase current und the motor load:

Recommended values:

Phase current Fuse

<= 1 A T2A

2 A T4A 3 A T6A 4 A T8A 5 A T10A

>= 6 A T12A

• For the load capacitor, a value of 1,000 μF per Amp of motor current should be

calculated.

MA 2102-A005 GB 20

• Use shielded cables for DC supply.

phytron

+ U GND

Fig. 17: 2-pole Phoenix connector MSTB 2,5/2-GF-5,08 X1

Attention: Do not interchange the connections! The MCD is not protected against reverse polarity.

5.1 Insulation Overview

Fig. 18: Insulation MCD

The power stage must be operated with protective measure PELV. The transformer should be constructed with reinforced or double insulation.

The insulation of the MCD fulfills the requirements of a basic insulation for non-mainscircuits for voltages up to 141 V acc. to EN 50178.

The device has been designed for degree of pollution 2 acc. to EN 50178. The IO signals on connector X3 are optically insulated and safely insulated to withstand

voltages up to 800 V

The signals RS485 on X4 and X5 ServiceBus connectors are electronically insulated from the motor voltage by a separate DC/DC-converter (withstand voltage 1000 VDC).

Devices connected to MCD for control or communication should have reinforced or double insulation acc. to EN 50178.

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Manual MCD

6 Motor Connection

The following chapter describes how to wire different types of 2-phase stepper motors. MCD stepper motor power stages may be connected to stepper motors with 0.3 to 9 A

Peak

phase current. The stepper motor winding resistance should be more than 0.1 Ω and less than

10 Ω for full power. The winding inductivity of one phase should be in the range of 0.5 to 10 mH.

Stepper motors with 8 leads can be connected with the windings wired in parallel (1) or serial (2).

For 6-lead stepper motors, wiring scheme (3) with serial windings is recommended. If wiring scheme (3) or (4) cannot be used because of the motor construction, the motor

may be operated with only two of the four windings energized according to wiring scheme (5).

Warning:

5-lead stepper motors must not be connected to the MCD. Both 5-lead stepper motor and MCD might be damaged.

Motor time constant τ:

applies to the electric motor time constant τ.

The total inductivity L

total

is equal to the winding inductivity in a parallel circuit, because

of interlinked inductivities.

ges

= 4 x L applies to a serial circuit.

The result is an equal motor time constant

τ for a serial and a parallel circuit:

Circuit Serial parallel

Resistance R

total

2 x R

Inductivity L

total

4 x L L

Motor time constant τ

L x 2

R x 2

L x 4

serial ==τ

L x 2

R/2

parallel =τ

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6.1 Motor Connector

The figure shows the connection of a phytron 2-phase 4-lead stepper motor connected parallel.

Fig. 19: Motor connector X2

Attention: Do not unplug the motor connector while powered. Danger of electric arcing.

6.2 Shielding

To avoid disturbances affecting the wires and instruments installed close to the drive system, we recommend to use shielded cables.

The motor should be connected to the ground by a central earthing tab.

Fig. 20: Motor lead shielding

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Manual MCD

6.3 Wiring Schemes

Fig. 21: Connection diagrams for 4-, 6- and 8-wire stepper motors

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25 MA 2102-A005 GB

6.4 Motor Cables

We recommend to wire the stepper motor with a 5-lead cable with shielding mesh. For optimum electromagnetic compatibility (EMC), the cable should not be interrupted by additional connectors or screw terminals. We recommend to use a short motor cable because of EMC. See chap. 6.1 and 6.2.

The protective earth wire (green/yellow) of the motor cable should be connected to the earthing screw near the MCD motor connector. At the other motor cable end, the green/yellow wire should be connected to the motor's earthing screw (if available).

For best electromagnetic compatibility (EMC), you should connect the shielding mesh to the MCD housing. Use the cable clamps at the bottom and the top side of the MCD.

The shielding mesh should also be connected on a large surface to the motor housing. Use EMC-type conduit fittings. All parts of the motor should be conductively connected with each other. We recommend to use EMC conduit fittings at the motor side.

In case of motors without adapted conduit fittings the cable shielding must be connected as near to the motor as possible and has to be applied to PE.

Important: Motor leads not used should be insulated separately (important if using wiring scheme 3,4 or 5)!

Motor cable:

Motor cable length Min. lead cross section for phase currents up to 3 A

r.m.s.

from 3 to 6.3 A

r.m.s.

up to 10 m 1.0 mm2 1.0 mm2 from 10 m to 25 m 1.0 mm2 1.5 mm2 from 25 m to 50 m 1.5 mm2 2.5 mm2

Cable between MCD and mains supply unit:

We recommend to use a shielded cable, as short as possible (< 1 m):

Min. lead cross section for phase currents up to 3 A

r.m.s.

from 3 to 6.3 A

r.m.s.

1.0 mm2 1.5 mm2

Manual MCD

7 Inputs and Error Output

The I/O connector X3 is used to connect the signal inputs and outputs. Attention:

Please check the input level applied to the MCD: 5 V or 24 V! Do not connect a 5 V input to 24 V voltage! Danger of damages!

Important: In ServiceBus mode the logic input signals Control pulses, Motor direction, Boost and Activation can be reversed (HIGH active or LOW active). The input logic of Reset remains unchanged (always HIGH active).

7.1 Inputs

There are 3 pins for every input signal (Control pulses, Boost, Motor direction, Reset, Activation). Therefore, separate inputs for 5 V or 24 V signals are available. The signals are active, when current flows through the optocoupler. The controlling via push-pull driver confers optimum suppression of disturbances, because current always flows. Specially in case of long leads this kind of controlling should be preferred.

Fig. 22: Input wiring diagram

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7.1.1 Push-Pull- or OC-Controlling

We recommend to control the MCD inputs by push-pull drivers. This confers optimum suppression of disturbances.

Fig. 23: Push-pull controlling

Alternatively a controlling via open-collector is possible.

Fig. 24: Open Collector Controlling

7.1.2 Logic Level 24 V or 5 V

MCD power stages can be driven by input level 5 V or 24 V. The different values depend on the input level:

Signal level 5 V 24 V

High 2.5 – 5.5 V 20 – 30 V Low < 0.4 V < 3 V Necessary driver current 10 mA minimum

Attention:

Please check the input level applied to the MCD: 5 V or 24 V and connect the signals to the equivalent pins (see fig. 25)! Do not connect a 5 V input to 24 V voltage! Danger of damages!

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Fig. 25: Input level 5 V or 24 V connection

7.1.3 Control Pulse Input

Maximum step frequency: 500 kHz Minimum pulse width: 1 µs The step is done with the rising flank of the control pulse. The control pulse sequency must not suddenly start or stop, if the control pulse frequency

is higher than the start/stop frequency*) of the motor. Mispositioning of the drive would be the result.

*) The start/stop frequency is defined as that frequency, from which a stepper motor can start from

standstill without losing a step. Typical values for the start/stop frequency are 200 to 2000 Hz. The exact value depends on the load torque and the load inertia of the motor shaft.

If the motor is to be operated above the start/stop frequency range, the indexer has to generate frequency ramps to accelerate and decelerate the motor.

Current delay time: After the last control pulse the stop current is activated after a waiting time. The waiting

time after the last control pulse until the change to the stop current is called current delay time. In Rotary switch mode the current delay time is set to 40 ms default value. In ServiceBus mode the current delay time is programmed as parameter and saved in the MCD (see appendix A4).

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7.1.4 Direction Input

This signal sets the direction of rotation of the motor. If the input optocoupler is not energized, the motor drives in the preferential direction. If the

input optocoupler is powered, the selected motor direction of rotation is reversed. The signal must only be modified when the motor is at a standstill or turns with the

frequency within the start/stop frequency. Don’t change the signal 1 µs before the control pulse and 4 µs after the control pulse!

Changing the motor direction when the motor is running will cause step losses and/or stop the motor.

In Rotary switch mode the preferential motor direction can be changed by the rotary switch STEP (see table in chap. 8). In ServiceBus mode the preferential motor direction can be programmed (see chap. 9.2.).

7.1.5 Boost Input

If the input optocoupler is energized the MCD changes to Boost current. The power stage increases the run and stop current by 30 % in Rotary switch mode. As long as the Boost input is energized, the run and stop current will always be 30 % higher.

The boost current can be programmed by the user in ServiceBus mode from 0 to 6.3 A

r.m.s.

. Thus, a higher torque can be reached during the acceleration and deceleration time of the motor by changing to boost current.

Also see appendix A2.

7.1.6 Activation Input

If the input optocoupler is energized, the power stage is ready. This input is useful, for instance, during maintenance operations to switch the power stage

off, without having to disconnect it physically from the mains. It is possible now to slowly rotate the motor by hand.

WARNING!

The Activation input is not in conformance with the professional emergency stop circuit requirements.

The input Activation may also be used to avoid the inevitable electrical noise emissions of the power stage, e.g. if you have to perform sensitive electrical measurements in the environment of the device.

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7.1.7 Reset Input

If the input optocoupler is energized, all error signals and the ring counter are reset. Then, the ring counter is in basic position. Both motor phases are energized by the same current value in basic position independent of the step resolution.

Fig. 26: Motor phases in basic position (half step)

After cut-off the reset signal, the power stage will enable the ready signal after approximately 500 ms.

7.2 Error Output

Open-Collector-Darlington output insulated by means of optocoupler. I

max

= 20 mA, U

max

= 30 V, P

total

= 300 mW, UCE

sat

at 20 mA < 1 V

Fig. 27: Output wiring diagram

Remark: If inductive loads (e. g. a relay) are connected, a protective diode must be mounted.

This output opens at the error messages: undervoltage, overcurrent/short circuit, overtemperature. At the same time the driver is deactivated to avoid damages.

An error message can be reset after error elimination or cooling. The MCD can be reset by the input Reset on X3 or in ServiceBus mode.

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phytron Error Messages:

Undervoltage/Overvoltage

The red LED blinks by second cycle in case of undervoltage/overvoltage. Reasons:

• The supply voltage at the internal load capacitor has dropped under 20 V.

• An electronic current limitation or a not adequate smoothing of the DC voltage

can be the reason for a short time break of the supply voltage.

• The rotator energy is supplied back as electric energy to the power stage like a generator. Raising in the internal load capacitor will be the result. The error message ‘overvoltage’ is caused off by operation with maximum power supply (70 V), by motor mass ineratia (> 1.3 x 10-4 kgm2 ) and high revolutions per minute ( > 20 rev/s).

Overcurrent/Short circuit

The red LED shines permanently in case of overcurrent/short circuit. Reason:

• A short circuit has occurred phase to phase or phase to ground. Short circuit phase to phase and phase to ground is detected from a

current setting of 0.7 A

r.m.s.

• The ohmic resistance of the motor winding is too less. See chap. 6.0

Overtemperature Power Stage

The red LED blinks fast. Reason:

• The temperature at the heat sink of the transistors is too high (> 85° C).

The power stage is powered off.

Resetting is possible under 70°C.

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8 Rotary Switches

8.1 Rotary Switch Mode

Run and stop current can be individually set by rotary switches. Step resolution and preferred motor direction can be set by rotary switch, too.

For fine run and stop current settings you can change between 2 ranges (I or II). Run and stop current are increased with Boost by 30% .

Rotary Switches

Position Run/stop current

r.m.s.

] without Boost

Run

/ I

Stop

Step resolution/ pref. motor direction (s. appendix A1)

Current range setting

0 ServiceBus mode activated 1 0.2 0.6 Full Step + 2 0.3 0.9 Half Step + 3 0.4 1.3 1/4 + 4 0.5 1.6 1/5 + 5 0.6 1.9 1/8 + 6 0.7 2.2 1/10 + 7 0.8 2.5 1/20 + 8 0.9 2.8 not used 9 1.0 3.1 Full Step – A 1.1 3.4 Half Step –

B 1.2 3.8 1/4 – C 1.3 4.1 1/5 – D 1.4 4.4 1/8 – E 1.5 4.7 1/10 – F 1.6 5.0 1/20 –

Factory settings

Important:

The current values of this table have been verified with the phytron stepper motor ZSH 87.2/200.6.5. Deviation is possible for other motors.

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Set up phase currents correctly fitting to the motor winding's design current!

• The stop current is normally set to 40-50% of the run current, to keep the motor temperature as low as possible.

• The table values refer to current values, if both motor phases are activated. The current in one phase is calculated as: table value x 2

• Max. run /stop current in Rotary switch mode: range I : 1.6 A x 2 x 1.3 = 3 A

range II : 5 A x 2 x 1.3 = 9 A

• Important: The run and stop current values, which are set by the rotary switches,

depend on the selected current rage, that means

Run current (without Boost)

Stop current (without Boost)

Range I 0.2 to 1.6 A

r.m.s.

0.2 to 1.6 A

r.m.s.

Range II 0.6 to 5 A

r.m.s.

0.6 to 5 A

r.m.s.

The switch positions may be changed

• while the MCD is powered off or

• the power stage is deactivated. However, after changing the switch

position the power stage should be reset by the input Reset.

Short circuit phase to phase and phase to ground is detected from a current

setting of 0.7 A

r.m.s.

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8.2 ServiceBus Mode

If more than one MCD is operated (max.16), the RS485 field bus is best choice (4 wire operation).

The ServiceBus Mode setting:

The ServiceBus Mode is activated by the rotary switches S1 to S4 on the MCD. The rotary switches S2, S3 and S4 must be set all to ‘0’. The rotary switch S1 is used for device address setting (0...F). Therefore, up to 16 MCD power stages can be connected by the connectors X4 and X5 and addressed.

Two possibilities for MCD connection acc. to RS485 (4-wire operation):

1. MCD connection to PC by an USB-RS485 converter:

Fig. 28: Connection PC Æ MCD by USB-RS485-converter

2. The power stage is connected to the RS422/RS485 interface of the PC:

Fig. 29: Connection PC Æ MCD by RS422/RS485-interface

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8.2.1 USB-RS485-Converter

The phytron USB-RS485-converter is screwed on the side of the MCD. The first of several MCD axes is addressed by 0, to which the USB-RS485-converter is screwed. All other power stages are addressed continuously (fig. 30).

Fig. 30: Power stage MCD with phytron USB-RS485-converter

Important: When the MCD is connected to the PC by USB-interface, USB drivers,

available at the phytron CD, have to be installed on the PC.

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8.2.2 USB-Driver Installation

Important: Administrator authorizations are required for the driver installation.

• Power on your PC. When the desktop is ready, insert the phytron CD and open the folder USB Treiber by the Windows Explorer. Select the .exe program which goes with your system software and start it by double click. The following window is shown on desktop after a successful installation:

• Connect the power stage directly or via USB converter to the USB port of your PC by USB cable.

Important: Use a USB cable with a maximum length of 2 m!

• For checking the correct USB driver installation, continue as follows:

Start the device manager by clicking StartÆSettingsÆSystem control and double-

click on System. Then select the Device manager tab. The USB components can be found in ComputerÆ Ports and in Universal Serial Bus Controller. Here the new USB-component is shown: USB Serial Port (Com X)

• Important: If you want to test several USB devices, which are identical in construction, you should use the same USB port on the PC. Thus, you avoid to change the COM port number.

• You’ll als o find information about the driv er installation for the chip FT232R on

http://www.ftdichip.com

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37 MA 2102-A005 GB

9 Bus Connection Configuration

If operating more than one MCD device (max. 16) at one serial interface, the RS485 field bus is the best choice. Many parameters in the MCD can be set by the serial bus connection. Thus, a safe stepper motor operation with correct preset parameters is assured.

9.1 Definition

The bus connection is defined as follows:

• RS485: 4 wire connection, also point to point connection possible

• Signal input: R+ R-

• Signal output: T+ T-

• insulated from the motor voltage by means of optocoupler

A well-defined protocol should be followed to assure a safe data exchange: Asynchronous transmission, 8 bits/byte, 1 stop bit, 1 parity bit Transmission rate: 57600 Baud Permanent telegram format: <STX> <address_H><address_L> <instruction> <value> : <csh> <csl> < ETX>

<STX> Start-of-text character, 02H <address_H> High-order byte of the power stage address 00H...0FH,

…15D; Admissible characters: 0…F

<address_L> Low-order byte of the power stage address 00

...0FH,

0D…15D; Admissible characters: 0…F

<instruction> Instruction byte: A....Z

<value> Data byte : Colon as separator, to distinguish between usable data

and checksum <csh> Upper byte of the 8 bit checksum value <csl> lower byte of the 8 bit checksum value < ETX> End-of-text character, 03H

Manual MCD

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The checksum is defined by summing up all bytes, beginning with the address byte and including the separator (:) in an exclusive-OR-operation (⊕):

CS = address_H address_L ⊕ data byte 1 ⊕ data byte 2 . . . ⊕ data byte n ⊕ separator

The checksum is calculated as one 8-bit binary value (00h to FFh). This byte is taken apart in its upper and lower byte (nibbles). After the HEX values of the two nibbles have been transferred to the corresponding two ASCII characters (0 to 9 instead of 0H to 9H and A to F instead of AH to F

that means to each nibble 30H or rather 37H is mathematically

added), the checksum is written into the telegram. The power stage also calculates (Exclusive OR) the checksum of the received data. The

telegram will be rejected if a difference to the received checksum is detected. If there is no need to validate the contents of the telegram, the checksum monitoring can

be set off. Instead of the checksum bytes, two X characters will be accepted by the power stage. As well, telegrams without checksum and also without : (separator) will be accepted, e.g.:

Example: <STX>| 1 | R | 4 | 0 | : | X | X |<ETX> or Example: <STX>| 1 | R | 4 | 0 |<ETX>

9.2 Operating Parameters

The operating parameters are stored in a permanent memory of the power stage. In the following table the operating parameters are defined with

W for write, R for read and X for execute.

For current values reading or writing is applied: Integer value x 1/10 = valid current or voltage value

Example: 48 x 1/10 = 4.8 (A

r.m.s

)

The MCD instruction set mostly consists of one-byte-instructions, this means, that from the second byte the data for the instruction will follow. The instructions for additional parameters with instruction code P are two byte instructions. The data will begin on the 3rd byte in these instructions. By L or U input after the instruction code the maximum permissible instruction limits, by I input after the instruction code the function of the instruction are displayed. By S and E scale and unit (Einheit) of current and time values can be read.

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39 MA 2102-A005 GB

The following table gives an overview:

Additional input to the instruction code

Function Example Description Answer

Information about the

instruction

FI Information about

the instruction F

f‚R/– MCD status’

Upper limit of the

number range

SU Stop current:

highest value

S63

Lower limit of the

number range

RL Run current:

lowest value

Scale of current or temperature values: 1=1:1 10=1:10

SS Read scale value

of the stop current

s10

Unit of current- and time values:

A, mA, ms, s

SE Read unit of the

stop current

Read the preset value R? Display run

current: 2.5 A

r25

<value>

Set the value S5 Stop current

0.5 A

Important:

• If the instruction input values are faulty, the actual preset value will be the answer.

• If an instruction code is entered which is not implemented, the instruction code is

answered by a minuscule with –character. Example: Enter K Æ Answer: k–

Manual MCD

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Instruction code

Parameter name

Type Value Description De-

fault values

A Boost R/W 0 to 63 Boost current

from 0.1 to 6.3 A

r.m.s.

B Software

version

R <String> Read power stage software version –

C Reset X – Power stage reset – E Delete

EPROM

X – Delete user’s parameters in the

EPROM

–

F MCD status R Read the MCD status (0001 to FFFF) –

Hex.

Dec.

Va-

lency

Description

0001 1

∗)

Error under-/overvoltage

0002 2 1

Error overtemperature /short circuit

0020 32 5

Power stage is in basic

position 0040 64 6 Error checksum 0080 128 7 Reset in MCD

G Pref. direction R/W 0 or 1 1=preferential direction

0=contrary to pref. direction

J Zero position X Enforce the basic position

–

LA LB LD LT

Input logic level for: Activation Boost Direction Control pulse

R/W 0 or 1 Define input logic level:

0 = HIGH active 1 = LOW active

Status can be read as dec. or hex. number. See chap. 9.2.2

∗)

If both error bits are set, the status means “short circuit in power stage”.

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41 MA 2102-A005 GB

Instruction code

Parameter name

Type Value Description De-

fault values

M Step width R/W 0 to 12 0= 1/1

1= 1/2 2= 1/4 3= 1/5 4= 1/8 5=1/10 6=1/16

7=1/20 8=1/32 9=1/64 10=1/128 11=1/256 12=1/512 step

O Output logic

level Error (open collector)

R/W 0 or 1 Define output error logic level:

0 = Transistor opened 1 = Transistor locks

P Extra

parameters

R/WX 1st byte of the instructions ‚Extra

parameters’, to define security functions See chap. 9.2.1

–

Q Error inquiry R 0 to 3 0=no error

1=undervoltage/overvoltage 2=overtemperature 3=overcurrent

–

R Run current R/W 0 to 63 Run current values from

0 to 6.3 A

r.m.s.

S Stop current R/W 0 to 63 Stop current values from

0 to 6.3 A

r.m.s.

T Delay time R/W 0 to 15 0= 1

1= 2 2= 4 3= 6 4= 8 5=10 6=12 7=14

8= 16 9= 20 10= 40 11= 60 12= 100 13= 200 14= 500 15=1000 ms

Power stage deactivation

R/W 0 or 1 0 = activated

1 = deactivated

) Remark for ServiceBus mode: Please deactivate the power stage only by U=0, if it isn’t still deactivated by

the input Activation (connector X3).

Manual MCD

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Instruction code

Parameter name

Type Value Description De-

fault values

W Write

EPROM

X – Write parameter into EPROM –

Z Motor test X + or – Self test: one motor rotation with

preset run current

–

9.2.1 Extra Parameters

Instruction code

Parameter name

Type Value Description De-

fault values

PB Operation

mode

R/W 0 or 1 Set operation mode

0 = Bus 1 = Stand alone

PC Current

Shaping

R/W 0 or 1 Define Current Shaping CS

0 = On 1 = Off

PH Overdrive

upper switching frequency

R/W 225 to

225,000

Define Overdrive upper switching frequency unit: Hz

PN Axis name R/W <String Assign or read an axis name

(max. 40 characters) into the EPROM

–

PO Overdrive R/W 0 or 1 Define function Overdrive

0 = Off 1 = On

PX Bus mode

eXclusive

R/W 0 or 1 Rotary switch

0= Don’t ignore rotary switches 1= Ignore rotary switches

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9.2.2 Examples

Instruction code Action Answer

A? A40

Read Boost current Set Boost current to 4.0 A

r.m.s.

e. g. a50 (= 5.0 A

r.m.s.

)

a40

B? Read power stage software version b<String>

(e. g. bMCDV1.0) C Reset power stage c1 E Delete EPROM e1 F?

FH?

Read MCD status in decimal mode Read MCD status in hexadecimal mode

e. g. f1

e. g. f01

(= Error undervoltage/

overvoltage) G?

G1 or G0

Read preferential direction Set preferential direction

g0 or g1

g1 or g0 J Enforce the basic position j1 LB?

LT0 or LT1

Read input logic level Boost Set input logic level Control Pulse

lb0 or lb1

lt0 or lt1

M0....M12

Set step width Read step width

M0...m12

m0...m12 O?

O0 or O1

Read output logic level Set output logic level

O0 or O1

O0 or O1 PB?

PB0 or PB1

Read operation mode Set operation mode

pb0 or pb1

pb0 or pb1 PC?

PC0 or PC1

Read current shaping CS Set current shaping CS

pc0 or pc1

pc0 or pc1 PH?

PH725

Read overdrive switching frequency Set overdrive switching frequency to 725 Hz

e. g. ph500

ph725

PN?*) PNAxis7 PN/

Read the axis name Store the axis name Delete the axis name

pn<String> (e.g. Axis4)

pnAxis7

pn0

Remark: pn0 is also the answer of PN?, if no name is saved.

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Instruction code Action Answer

PO? PO0 or PO1

Read function Overdrive Set function Overdrive

po0 or po1

po0 or po1 PX?

PX0 or PX1

Read bus mode eXclusive Set bus mode eXclusive

px0 or px1

px0 or px1 Q? Error inquiry q0...q3 R?

R150

Read run current Set run current to 1.5 A

r.m.s.

e. g. r18 (= 1.8 A

r.m.s.

)

r15 S?

S240

Read stop current Set stop current to 2.4 A

r.m.s.

e. g. s18 (= 1.8 A

r.m.s.

)

s24 T?

T10

Read delay time Set delay time to 40 ms

e. g. t9 (= 20 ms)

t10 U?

U0 or U1

Read deactivation of the power stage Set deactivation of the power stage

e. g. u0 or u1

u0 or u1 W Write EPROM w1 Z+, Z- Do the motor self test z1

phytron Appendix A: Technical Details

A stepper motor can be used with different step resolutions, which are described in the first part of this chapter. The functions Boost, Overdrive, Current delay time and the Current Shaping you’ll find in the second part.

A1 Full Step / Half Step / Ministep Full step (FS)

The FULL STEP mode is the operating mode in which a 200-step motor, for example, drives 200 steps per revolution. In the full step mode, both stepper motor phases are permanently energized.

Fig. 31: Phase current curves

Half step (HS)

The motor step resolution can be electronically multiplied by 2 by alternately energizing the stepper motor’s phases 1, 1+2, 2 etc. This is the HALF STEP mode. The torque, however, is reduced in the half step mode, compared to the full step mode.

To compensate this lack of torque, the operating mode HALF STEP MODE WITH TORQUE COMPENSATION was developed: the current is increased by 2 in the active

phase. Compared to the full step mode, the torque delivered is almost the same. Most of the resonance is suppressed.

The following diagram shows extent and direction of the holding torques of a 4-step motor during one revolution without and with torque compensation. In the full step position two phases, in the half step position only one phase is energized. The total moment is the result of superpositioning both phase moments.

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The moment in the full step mode, M

FS,

as compared to the moment in the half-step mode,

MHS is: ⏐MFS⏐ = ⏐MHS⏐ × 2 This means, when a single phase is energized, the current must be increased by a 2

factor to obtain an identical torque.

Fig. 32: Holding torques without/with torque compensation

Ministep/ Microstep

In Rotary switch mode the power stage MCD increases the step resolution by a factor 2, 4, 5, 8, 10 or 20 of a full step – MINISTEP MODE.

In ServiceBus mode the step resolution can be increased by a factor 2, 4, 5, 8, 10, 16, 20, 32, 64, 128, 256 or 512 of a full step – MICROSTEP MODE.

Various advantages are obtained by the MINISTEP MODE:

• The torque undulation drops when the number of ministeps is increased.

• Resonance and overshoot phenomena are greatly reduced; the motor operation is almost resonance-free.

• The motor noise also drops when the number of ministeps is increased.

Fig. 33: Ministep 1/10 of a full step

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phytron A2 Boost

The motor torque required during acceleration and deceleration is higher than that required during continuous motor operation (f

max

). For fast acceleration and deceleration settings, (steep ramps), the motor current is too high during continuous operation and results in motor overheating. However, a lower phase current results in too flat acceleration and deceleration ramps.

Therefore, different phase currents should be used:

• Continuous operation: run current

• During acc eleration and deceleration: Boost current

The Boost signal is activated by the superior controller. While input Boost is energized, a 30 % higher current is flowing.

In the ServiceBus mode the boost value is programmable from 0 to 6.3 A

r.m.s.

Fig. 34: Boost

After the last control pulse the stop current is activated after a waiting time. The waiting time after the last control pulse until the change to the stop current is called current delay time (see appendix A4).

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A3 Overdrive Function

The MCD power stages can compensate the phase current decrease in the upper speed range by the Overdrive function. Overdrive is independent of the motor type.

Overdrive is a dynamic boost function, which will be automatically switched on if this makes sense in regard of the current shape:

Fig. 35: Phase currents with Overdrive

The stepper motor phase current decreases with increasing step frequency caused by the counter-electromotive force of the motor.

The Overdrive function compensates the decrease of current and torque. The phase current is increased by about 20 % in Overdrive function. The switching frequency based on FS can be selected from 225 Hz to 225 kHz. This switching frequency is set to 1,000 Hz input control pulse by default. The switching-off frequency is 10 % lower than the switching-on frequency for producing a hysteresis.

The stepper motor torque decreases by increasing of the rotation speed. The Overdrive function works against the reducing of the torque at middle and high rotation speeds. The function Overdrive is activated on delivery and can be switched off in the ServiceBus mode by ServiceBus-Comm®.

The parameterization is done by the ‚PH‘ instruction code.

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Step resolution Input control pulse frequency PH ServiceBus parameter

Default

Overdrive on at > Overdrive off at <

1/1 = VS 1 kHz 0.9 kHz 1 kHz 1/2 = HS 2 kHz 1.8 kHz 1 kHz

1/4 4 kHz 3.6 kHz 1 kHz 1/5 5 kHz 4.5 kHz 1 kHz

1/8 8 kHz 7.2 kHz 1 kHz 1/10 10 kHz 9.0 kHz 1 kHz 1/16 16 kHz 14.4 kHz 1 kHz 1/20 20 kHz 18.0 kHz 1 kHz 1/32 32 kHz 28.8 kHz 1 kHz 1/64 64 kHz 57.6 kHz 1 kHz

1/128 128 kHz 115 kHz 1 kHz 1/256 256 kHz 230 kHz 1 kHz 1/512 512 kHz 460 kHz 1 kHz

Example for 500 Hz switching frequency during VS operation:

Step resolution Input control pulse frequency PH ServiceBus parameter

Overdrive on at > Overdrive off at <

1/1 = VS 0.5 kHz 0.45 kHz 500 Hz 1/2 = HS 1 kHz 0.9 kHz 500 Hz

1/4 4 kHz 1.8 kHz 500 Hz

1/5 2.5 kHz 2.25 kHz 500 Hz

1/8 4 kHz 3.6 kHz 500 Hz 1/10 5 kHz 4.5 kHz 500 Hz 1/16 8 kHz 7.2 kHz 500 Hz 1/20 10 kHz 9.0 kHz 500 Hz 1/32 16 kHz 14.4 kHz 500 Hz 1/64 32 kHz 28.8 kHz 500 Hz

1/128 64 kHz 57,6 kHz 500 Hz 1/256 128 kHz 115.2 kHz 500 Hz 1/512 256 kHz 230.4 kHz 500 Hz

Manual MCD

A4 Current Delay Time

After the last control pulse the stop current is activated after a waiting time. The waiting time after the last control pulse until the changing to the stop current is called current delay time. We recommend to specify t

Delay

so that the motor’s oscillations are dying out after the last motor step and mispositioning is avoided. In Rotary switch mode the current delay time is set to 40 ms. In ServiceBus mode the delay time can be programmed from 1 to 1000 ms in 15 steps.

Automatic change from run to stop current:

The ratio between both phase currents remains equal in the respective current feed pattern. Changing from run to stop current is synchronously. In the following figure the next motor step follows after every rising control pulse edge:

Fig. 36: Decrease to stop current after the last control pulse (full step)

Decreasing to stop current takes the following advantages:

• Motor and power stage heating is reduced.

• EMC is improved because of smaller current values

MA 2102-A005 GB 50

phytron A5 Current Shaping CS

Current Shaping (CS) is a circuitry method for delivering a true phase current which corresponds for a wide range of frequencies to a selected current shape. If the stepper motor is driven without CS, the true current differs from the specified current, even in the lower speed frequencies.

The 1/20 sine wave mode results in a current deviation as shown in fig. 37, for average speed:

Fig. 37: Current Shaping CS

These typical deformations can be observed for all types of curves. They are caused by the stepper motor inductance and the generator feedback which increases with the motor speed.

The resulting ‚current queue’ makes precise current regulation possible by Current Shaping (CS= 4 quadrant current regulation), only. The amplitude of the ‚current queue’ varies strongly remarked during one revolution and may provoke a motor resonance effect which causes step losses or desynchronization of the motor.

If the CS function is activated, the ‚current queue’ disappears and the resulting current is close to the ideal shape.

We recommend to use CS in higher current and speed frequency ranges. In ServiceBus mode CS can be activated by a button in ServiceBus-Comm®.

51 MA 2102-A005 GB

Manual MCD

MA 2102-A005 GB 52

Appendix B

In this chapter warranty, trade marks and ESD protective measures are described.

B1 Warranty

The MCD power stages are subject to legal warranty. phytron will repair or exchange devices which show a failure due to defects in material or caused by the production process. This warranty does not include damages which are caused by the customer, as there are, for example, not intended use, unauthorized modifications, wrong treatment or wrong wiring.

B2 Trade Marks

In this manual several trade marks are used which are no longer explicitly marked as trade marks within the text. The lack of this signs may not be used to draw the conclusion that these products are free of rights of third parties. Some product names used herein are for instance

• ServiceBus-Comm is a trade mark of the Phytron-Elektronik GmbH.

• Microsoft is a registered trade mark and WINDOWS is a trade mark of

the Microsoft Corporation in the USA and other countries.

B3 ESD Protective Measures

All the products which we deliver have been carefully checked and submitted to a longterm test. To avoid the failure of components sensitive to electrostatic discharge (ESD), we apply a great number of protective measures during manufacturing, from the component input check until the delivery of the finished products.

Warning: Manipulation of ESD sensitive devices must be effected by respecting special protective

measures (EN 61340–5). Only return the modules or boards in adapted packaging.

phytron's warranty is cancelled in case of damages arising from improper manipulation or transportation of ESD modules and components.

phytron Appendix C: Declarations of Conformity

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Manual MCD

MA 2102-A005 GB 54

phytron

55 MA 2102-A005 GB

Index

A

Activation 14, 29 Address 37 Ambient standards 14 Ambient temperatures 14

B

Basic position 30 Boost 14, 29, 47 Bus mode exclusive 9, 11

C

Checksum 38 Connector 13 Control pulse 13 Copyright 2 Current delay time 28, 47, 50 Current range setting 5, 10, 12, 32 Current Shaping 5, 51

D

DC voltage 5 Declarations of Conformity 53 Delay time 41 Dimensions 19

E

Earthing screw 25 EMC 6, 14, 25 Error 14 ESD protective measures 52 Extra parameter 42

F

Frequency 28 Full step 45

H

Half step 45

I

Input level 26, 27 Input logic 26, 40 Input wiring diagramm 26 Inputs 13 Installation 15 Instruction code 39

Insulation 16, 21

L

Lead cross section 12, 25 LED 11, 31 Line filter 14

M

Mating connector 6 Minimum free space 19 Ministep 46 Motor cable 25 Motor connection 22 Motor connector 23 Motor direction 13, 29 Motor time constant 22 Mounting bracket 19

O

Open Collector Controlling 27 Operating parameter 38 Operator’s control 4 Output 14, 30 Output logic level 41 Overdrive 5, 48

P

PELV 16 Phase current 12 Power supply 6, 20 Preferential motor direction 29, 32 Programming 5, 38 Protective measure 16 Pulse width 28 Push-pull controlling 27 Push-pull driver 26 Putting into service 17

R

Rail mounting 6, 19 Reset 14, 30 Resonance 45, 46 Ring counter 30 Rotary switch 9, 12 Rotary switch mode 9, 17, 32 RS422 34 RS485 5, 34, 37

Manual MCD

MA 2102-A005 GB 56

S

Safety instructions 15 Scale 39 ServiceBus 37 ServiceBus connector 8, 13 ServiceBus mode 8, 10, 34 ServiceBus Mode 18 ServiceBus-Comm® 6 Setting switch mode 8 Shielding 23 Short circuit 31, 33 Signal level 13 Start/Stop frequency 28 Step resolution 12, 45 Stepper motor 12, 22 Supply voltage 12

T

Technical Data 12

Touch voltage 17 Trade marks 52

U

Untervoltage 13 USB cable 6 USB driver 35, 36 USB port 36 USB-RS485-converter 6, 35

W

Wall mounting 6 Warranty 52 Weight 13 Winding inductivity 22 Winding resistance 22 Wiring scheme 22

Phytron-Elektronik GmbH • Industriestraße 12 • 82194 Gröbenzell, Germany

Tel. +49(0)8142/503-0 • Fax +49(0)8142/503-190 • E-Mail info@phytron.de • www.phytron.de

Phytron, Inc. • 600 Blair Park Road Suite 220 • Williston, VT 05495 USA

Tel. +1-802-872-1600 • Fax +1-802-872-0311 • Email info@phytron.com • www.phytron.com

phytron MCD+ User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual