Excellence in Motion TM IM483H & IM805H

Transcription

1 TM intelligent motion systems, inc. Excellence in Motion TM IM483H & IM805H HYBRID MICROSTEPPING DRIVERS HFC-22 HEAT SINK/FAN/CLIP ASSEMBLY IM483H-DK1 DEVELOPER S KIT PR-22 PIN RECEPTACLE CARRIER OPERATING INSTRUCTIONS 370 N. MAIN ST., PO BOX 457, MARLBOROUGH, CT PH. (860) , FAX (860) Internet: info@imshome.com PATENT PENDING

2 Change Log Date Revision Changes 03/22/2006 R Updated IMS Contact info, warranty and disclaimer info on cover The information in this book has been carefully checked and is believed to be accurate; however, no responsibility is assumed for inaccuracies. Intelligent Motion Systems, Inc., reserves the right to make changes without further notice to any products herein to improve reliability, function or design. Intelligent Motion Systems, Inc., 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. Intelligent Motion Systems and are trademarks of Intelligent Motion Systems, Inc. Intelligent Motion Systems, Inc. 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. Per Intelligent Motion Systems, Inc. s terms and conditions of sales, the user of Intelligent Motion Systems, Inc., products in life support or aircraft applications assumes all risks of such use and indemnifies Intelligent Motion Systems, Inc., against all damages. IM483H/IM805H Operating Instructions Revision R Intelligent Motion Systems, Inc. All Rights Reserved

3 Table of Contents Section 1: Introduction... 4 The IM483H/IM805H Hybrid... 4 Features and Benefits... 5 IM483H/IM805H... 5 The Product Manual... 6 Hyperlinks... 6 Notes and Warnings... 6 Section 2: Hardware Specifications... 7 Section Overview... 7 Mechanical Specifications... 7 Dimensional Information - IM483H/IM805H... 7 Dimensional Information - PR Electrical Specifications... 9 IM483H DC Electrical Characteristics... 9 IM805H DC Electrical Characteristics IM483H/IM805H AC Electrical Characteristics Thermal Specifications Pin Assignment and Description IM483H/IM805H Connector P IM483H/IM805H Connector P Section 3: Mounting the IM483H/IM805H Section Overview Mounting the IM483H/IM805H Direct Mounting the IM483H/IM805H to a PC Board Mounting the IM483H/IM805H Using the PR-22 Receptacle Recommended Mounting Hardware Attaching the HFC-22 Heat Sink/Fan/Clip Assembly Removing the HFC-22 Heat Sink/Fan/Clip Assembly Section 4: Theory of Operation Section Overview Circuit Operation Microstep Select (MSEL) Inputs Stepping Dual PWM Circuit Fullstep Output Signal Timing Section 5: Power Supply Requirements Section Overview Selecting a Power Supply Selecting a Motor Supply (+V) Recommended IMS Power Supplies Selecting a +5VDC Supply Recommended Wiring Rules of Wiring and Shielding AC Line Filtering Section 6: Motor Requirements Section Overview Selecting a Motor Types and Construction of Stepping Motors Sizing a Motor for Your System Recommended IMS Motors

4 Motor Wiring Connecting the Motor IM483H/IM805H Lead Motors Lead Motors Lead Motors Section 7: Interfacing to the IM483H/IM805H Section Overview Layout and Interface Guidelines Motor Power VDC Input Interfacing the Current Adjust Input Determining the Output Current Setting the Output Current Current Adjust Resistor and Reference Values (IM483H) Current Adjust Resistor and Reference Values (IM805H) Reducing/Disabling the Output Current Interfacing the IM483H/IM805H Inputs The Microstep Resolution Select Inputs (MSEL) Interfacing the Fault Input Minimum Connections Section 8: Troubleshooting Section Overview Basic Troubleshooting Problem Symptoms and Possible Causes Contacting Application Support The IMS Web Site Returning Your Product to IMS Appendix A: The IM483H/IM805H Developer s Kit Section Overview Assembling the IM483H/IM805H-DK The INT-483H/IM805H Interface Board Pin Assignment and Descriptions Electrical Specifications Dimensional Information Setting the Output Current Isolated Inputs Microstep Resolution Settings LED Indicators Fault Protection Full Step Output Minimum Connections for the IM483H/IM805H-DK

5 List of Figures Figure 2.1: IM483H/IM805H Dimensions... 7 Figure 2.2: PR-22 Dimensions... 8 Figure 2.3: IM483H/IM805H Connectors Figure 3.1: PCB Hole Pattern Figure 3.3: PCB Hole Pattern for PR-22 Pin Receptacle Carrier Figure 3.4: PCB Mounting Figure 3.5: HFC-22 Exploded Figure 4.1: IM483H/IM805H Block Diagram Figure 4.2: Recirculating PWM Figure 4.3: Non-Recirculating PWM Figure 6.1 A & B: Per Phase Winding Inductance Figure 6.2: 8 Lead Series Motor Connections Figure 6.3: 8 Lead Parallel Motor Connections Figure 6.4: 6 Lead Half Coil (Higher Speed) Motor Connections Figure 6.5: 6 Lead Full Coil (Higher Torque) Motor Figure 6.6: 4 Lead Motor Connections Figure 7.1: Power Interface Figure 7.2: Current Adjust Resistor Connection Figure 7.3: Setting the Output Current using an External Source Figure 7.4: Reducing the Output Current Figure 7.5: Current Reduction Interface Figure 7.6: Input Pull-Up Resistors Figure 7.7: MSEL Inputs, Interface Example Figure 7.8: IM483H/IM805H Inputs Figure 7.9: Reset Timing Figure 7.10: Interfacing the Fault In/Reset Inputs Figure 7.11: Multiple Drives - One Reset Figure A.1: IM483H/IM805H Developer s Kit Figure A.2: HFC-22 Exploded Figure A.3: INT-483H/805H Interface Board Dimensions Figure A.4: INT-483H/805H Current Adjust and Reduction Resistor Placement Figure A.5: INT-483H/805H Jumper Settings Figure A.6: INT-483H/805H Opto-Isolated Inputs Figure A.7: INT-483H/805H MSEL Switch Figure A.8: INT-483H/805H Minimum Connections List of Tables Table 2.1: IM483H DC Electrical Characteristics... 9 Table 2.2: IM805H DC Electrical Characteristics Table 2.3: IM483H/IM805H AC Electrical Characteristics Table 2.4: IM483H/IM805H Thermal Specifications Table 2.5: IM483H/IM805H Connector P1 Configuration Table 2.6: IM483H/IM805H Connector P2 Configuration Table 5.1: IM483H/IM805H Motor Power Supply Specifications Table 5.2: IM483H/IM805H +5VDC Power Supply Specification Table 7.1: IM483H Current Adjust Resistor and Reference Values Table 7.2: IM805H Current Adjust Resistor and Reference Values Table 7.3: Motor Resolution Select Settings Table 7.4: IM483H/IM805H Minimum Connections Table A.1: INT-483H/805H Interface Board Pinout and Descriptions Table A.2: INT-483H/805H Interface Board Electrical Characteristics Table A.3: INT-483H/805H Resolution Select Switch Settings

6 S e c t i o n 1 T h e I M H / I M H H y b r i d I n t r o d u c t i o n The IM483H/IM805H is a high performance, yet low cost microstepping driver that utilizes advanced hybrid technology to greatly reduce size without sacrificing features. The IM483H/IM805H is exceptionally small, easy to interface and use, yet powerful enough to handle the most demanding applications. The IM483H/IM805H has 14 built-in microstep resolutions (both binary and decimal). The resolution can be changed at any time without the need to reset the driver. This feature allows the user to rapidly move long distances, yet precisely position the motor at the end of travel without the expense of high performance controllers. With the development of proprietary and patented circuits, ripple current has been minimized to reduce motor heating common with other designs, allowing the use of low inductance motors to improve high speed performance and system efficiency. The IM483H/IM805H, because of its ultra small size and low cost, can be used to increase accuracy and smoothness in systems using higher step angle motors. In many instances mechanical gearing can be replaced with microstepping, reducing cost and eliminating potential maintenance. Available as options for the IM483H/IM805H are the HFC-22 Heat Sink/Fan/Clip assembly and the PR-22 Pin Receptacle carrier. The HFC-22 provides a unique cooling solution and was designed specifically for the IM483H and IM805H Hybrid Microstepping Drivers. The HFC-22 will easily maintain a reliable rear plate temperature without using large heat sinks and cumbersome mounting hardware. The heat sink and fan are easily mounted to the driver by means of a removeable clip developed by IMS. The HFC-22 fully assembled with the IM483H or IM805H takes up only 6.8 in 3 of space! For applications where ease of removal is required, the PR-22 provides reliable, high quality receptacle set which comes attached to a high temperature plastic throwaway carrier that allows for ease of placement for wave or hand soldering. The IM483H/IM805H was developed to provide designers with affordable, state-ofthe-art technology for the competitive edge needed in today s market. 4

7 F e a t u r e s a n d B e n e f i t s I M H / I M H Very Low Cost. Ultra Miniature 2.10 x 2.60 x (53.34 x x 9.19 mm). Advanced Hybrid Design. High Input Voltage (+12 to +48VDC/+24 to +75 VDC). High Output Current (3A RMS, 4A Peak/5A RMS, 7A Peak). No Minimum Inductance. FAULT Input and Output. Phase to Phase Short Circuit Protection. Over-Temperature Protection. Microstep Resolution to 51,200 Steps/Rev. Microstep Resolutions can be Changed On-The-Fly Without Loss of Motor Position. 20 khz Chopping Rate. Automatically Switches Between Slow and Fast Decay for Unmatched Performance. 14 Selectable Resolutions both in Decimal and Binary. Adjustable Automatic Current Reduction. At Full Step Output. Optional Cooling Solution (HFC-22). Optional Receptacle Carrier (PR-22). 5

8 T h e P r o d u c t M a n u a l The IM483H/IM805H product manual in its electronic format may be downloaded from the IMS website at This version includes a Bookmarks feature that allows the reader to link from a Bookmarked Topic in the Table of Contents to a full description of that feature s attributes and functions. You can also select a Topic directly from the Table of Contents Pages. Topics with a hyperlink function are further identifiable because the cursor changes from a normal pointer to a finger pointer when placed over the word. N o t e s a n d W a r n i n g s WARNING! The IM483H/IM805H components are sensitive to ElectroStatic Discharge (ESD). All handling should be done at an ESD protected workstation. WARNING! Hazardous voltage levels may be present if using an open frame power supply to power the IM483H/IM805H. WARNING! Ensure that the power supply output voltage does not exceed the maximum input voltage of the IM483H/IM805H. WARNING! Do not apply power to the IM483H/IM805H without proper heat sinking or cooling! The included thermal pad (TN-22)MUST be used between the IM483H/IM805H and the heat sink! The maximum rear plate temperature of the IM483H/ IM805H is 70 C! 6

9 S e c t i o n 2 H a r d w a r e S p e c i f i c a t i o n s S e c t i o n O v e r v i e w This section will acquaint you with the dimensional information, pin description, power, environmental and thermal requirements of the IM483H/IM805H. It is broken down as follows: Mechanical Specifications. Electrical Specifications. Thermal Specifications. Pin Assignment and Description. M e c h a n i c a l S p e c i f i c a t i o n s D i m e n s i o n a l I n f o r m a t i o n - I M H / I M H Dimensions are in inches, parenthesis dimensions are in millimeters (53.34) (26.67).720 (18.29).780 (19.81) (66.04).375 (9.52) (59.69) P2 P1 8 X.200 (5.08) DIA. PIN (1.14 DIA. PIN) 2X.150 DIA. THRU (3.81 DIA. THRU) 23 X.156 (3.96).362 (9.19).525 (13.34) 13 X.100 (2.54).025 DIA. PIN (0.64 DIA PIN) 1.25 (31.75) HEATSINK/FAN/CLIP ASSY Figure 2.1: IM483H/IM805H Dimensions 7

10 0.115 (2.92) (71.12) (2.54) PR-22 IMS (33.02) (38.10) (43.18) (7.36) (5.08).050 (1.27).050 (1.27).118 DIA. (3.00 DIA.).100 DIA. (2.50 DIA.).117 (2.97).255 (6.48).290 (7.36).072 DIA. (1.83 DIA.).055 DIA. (1.40 DIA.).090 (2.28).230 (5.84).290 (7.36) Figure 2.2: PR-22 Dimensions 8

11 E l e c t r i c a l S p e c i f i c a t i o n s I M H D C E l e c t r i c a l C h a r a c t e r i s t i c s Specification Test Condition Min. Typ. Max. Unit Input Voltage * VDC Phase Output Current RMS 0.4** 3 A Phase Output Current Peak 4 A Supply Current (+5V) Inputs/Outputs Floating 100 ma Active Power Dissipation I OUT =3A RMS ma Low Level Input Voltage All Inputs 0.8 V High Level Input Voltage All Inputs Except Reset 2.0 V High Level Input Voltage Reset 2.3 V Low Level Input Current SCLK,DIR,H/F, Enable -1.2 ma Input Pull-Up Resistance Fault, MSEL 0-3, Enable kω Input Pull-Up Resistance Step Clock, Direction kω Input Pull-Up Resistance Reset Input Only 1.27 kω Low Level Output Current Fault, Fullstep -6 ma High Level Output Current Fault, Fullstep 3 ma Low Level Output Voltage Fault, Fullstep 0.4 V High Level Output Voltage Fault, Fullstep 4.5 V Fan Operating Voltage V Fan Operation Current 170 ma Table 2.1: IM483H DC Electrical Characteristics *Includes Motor Back EMF. **Lower Currents may be used for Current Reduction. 9

12 I M H D C E l e c t r i c a l C h a r a c t e r i s t i c s Specification Test Condition Min. Typ. Max. Unit Input Voltage * VDC Phase Output Current RMS 1** 5 A Phase Output Current Peak 5 A Supply Current (+5V) Inputs/Outputs Floating 100 ma Active Power Dissipation I OUT =3A RMS ma Low Level Input Voltage All Inputs 0.8 V High Level Input Voltage All Inputs Except Reset 2.0 V High Level Input Voltage Reset 2.3 V Low Level Input Current SCLK,DIR,H/F, Enable -1.2 ma Input Pull-Up Resistance Fault, MSEL 0-3, Enable kω Input Pull-Up Resistance Step Clock, Direction kω Input Pull-Up Resistance Reset Input Only 1.27 kω Low Level Output Current Fault, Fullstep -6 ma High Level Output Current Fault, Fullstep 3 ma Low Level Output Voltage Fault, Fullstep 0.4 V High Level Output Voltage Fault, Fullstep 4.5 V Fan Operating Voltage V Fan Operation Current 170 ma Table 2.2: IM805H DC Electrical Characteristics *Includes Motor Back EMF. **Lower Currents may be used for Current Reduction. 10

13 I M H / I M H A C E l e c t r i c a l C h a r a c t e r i s t i c s IM483H /IM805H AC Electrical C haracteristics Specification Test Condition Min Typ Max Unit Reset Pulse Width 1. 0 µs MSEL, Direction Setup Time 100 ns Step Clock Pulse Width 50 ns Step Clock Execution Time Step Clock Execution Time No Direction or MSEL Chang e 100 ns Direction or MSEL Change 200 ns Step Clock to Full-Step Output 75 ns Step Clock Input Frequency 10 MHz PWM Chopper Frequency 20 khz Table 2.3: IM483H/IM805H AC Electrical Characteristics T h e r m a l S p e c i f i c a t i o n s IM483H Thermal Specifications( C ) Specification Range A mbient Temperature 0 to +50 S torage Temperature -40 to +125 M aximum Plate Temperature +65 Table 2.4: IM483H/IM805H Thermal Specifications WARNING! Do not apply power to the IM483H/IM805H without proper heat sinking or cooling! The included thermal pad (TN-22) MUST be used between the IM483H/IM805H and the heat sink! The maximum rear plate temperature of the IM483H/ NOTE: Care should be taken when choosing a heat sink to ensure that there is good thermal flow, otherwise hot spots may occur in the IM483H/IM805H which will reduce the effectiveness of the thermal protection. NOTE: An optional cooling fan assembly (Part # HFC-22) is available for the IM483H/IM805H. 11

14 P i n A s s i g n m e n t a n d D e s c r i p t i o n IM483H/IM805H Connector P1 Configuration PIN # FUNCTION Current Reference Output Current Adjustment Input Current Reduction Adjust Input DETAILS Phase Current Reference Output. A resistor is connected between this 1mA current source output and the ground pin (P2:4) to generate the reference voltage used to set the peak phase current in the motor. Phase Current Adjustment Input. A voltage applied to this input sets the peak phase current in the motor. Phase Current Reduction Adjustment Input. A resistor connected between this pin and P1:2, if used to set the motor phase current, will proportionately reduce the current in both motor windings approximately.5 seconds after the last positive edge of the step clock input. 4 Fault Inpu t 5 Resolution Select 0 6 Resolution Select 1 7 Resolution Select 2 8 Resolution Select 3 9 Step Clock Inpu t 10 Direction Inpu t A logic LOW signal on this input will generate a latched FAULT condition. Microstep Resolution Select Inputs. Used to select the number of microsteps per step of the motor. These inputs are internally pulled-up and should be connected to a DIP switch, open collector sinking (NPN) or TTL output on an IMS or third party controller. A positive going edge on this input advances the motor one increment. The size of the increment is dependant upon the settings of the resolution select inputs. This input is used to change the direction of the motor. Physical direction also depends upon the connection of the motor windings. 11 Enable/Disable Input This input is used to enable/disable the output section of the driver. When in a Logic HIGH (not connected) state, the outputs are enabled. Sinking this input will disable the driver output. However, this input does not inhibit the step clock, therefore, the outputs will update by the number of clock pulses (if any) applied to the driver while it was disabled. 12 On-Full-Step Output 13 Fault Output 14 Reset Inpu t This output indicates when the driver is positioned at full step. This output can be used to count the number of full steps the motor has moved, regardless of the number of microsteps in between. This output is active HIGH. This output indicates that either a short circuit condition has occurred or a LOW signal was detected on the fault input. This output is active HIGH. When LOW, this input will reset the driver (phase outputs will disable). When released, the driver will be at its initial state (Phase A OFF, Phase B ON). Table 2.5: IM483H/IM805H Connector P1 Configuration 12

15 IM483H/IM805H Connector P2 Configuration PIN # 1 FUNCTION Motor Phase Output B DETAILS Phase B is connected between this pin and pin 3. 2 GND B Motor Phase B Ground. This ground should be connected to the ground lead of the external capacitor for Phase B. 3 Motor Phase Output B Phase B is connected between this pin and pin 1. 4 GND 5 + V Power Ground. The is connected here. ground, or return, of the power supply Motor Supply Voltage. +12 to +48VDC for the IM483H, +24 to +75VDC for the IM805H V Inpu t +5VDC logic supply voltage. 7 Motor Phase Output A Phase A is connected between this pin and pin 9. 8 GND A Motor Phase A Ground. This ground should be connected to the ground lead of the external capacitor for Phase A. 9 Motor Phase Output A Phase A is connected between this pin and pin 7. Table 2.6: IM483H/IM805H Connector P2 Configuration Pin 1 Bottom View P1 P2 Pin 1 Figure 2.3: IM483H/IM805H Connectors 13

16 S e c t i o n 3 M o u n t i n g t h e I M H / I M H S e c t i o n O v e r v i e w This section covers mounting the IM483H/IM805H in your system. The following mounting options are covered: Mounting the IM483H/IM805H to a PCB. Mounting the IM483H/IM805H using the PR-22 Pin Receptacle. Recommended Mounting Hardware. Attaching/Removing the HFC-22 Heat Sink/Fan/Clip Assembly. M o u n t i n g t h e I M H / I M H The IM483H & IM805H hybrids are designed to be soldered into the users PC board, however, they may also be mounted using the PR-22 pin receptacle carrier for ease of removal. D i r e c t M o u n t i n g t h e I M H / I M H t o a P C B o a r d The IM483H and IM805H hybrids are designed to be soldered directly into a PC board. The following diagram contains the hole pattern and recommended pad sizes for direct mounting of the IM483H/IM805H. Recommended Soldering Practices Max. Soldering Temp C Max. Soldering Time...10 sec (9.5) (5.08) 0.70 (1.80) DIA. HOLE (3.80) DIA. PAD 9 PLACES (18.3) (4.2) DIA. HOLE 2 PLACES (19.8) (1.00) DIA. HOLE (1.90) DIA. PAD 14 PLACES (13.30) (2.54) (59.70) Figure 3.1: PCB Hole Pattern (Direct Mounting of the IM483H/IM805H to a PC Board) 14

17 Recommended Solder Recommended Cleaning Solvent Kester 245 No Clean Tech Spray Envirotech 1679 Alpha Metals Telecore Plus Chemtronics Flux-off NR 2000 Multicore X39B No Clean Mounting the IM483H/IM805H Using the PR-22 Receptacle The PR-22 pin receptacle carrier allows for easy placement of multi-fingered receptacle pins facilitating easy removal and placement of the IM483H/IM805H driver. The PR-22 is a disposable plastic frame containing 23 receptacles in a layout that matches the pin layout of the IM483H/IM805H hybrid. This tool enables the user to insert the 23 receptacles into their PC board design in a single operation for wave or hand solder. The plastic frame can then be Figure 3.2: PR-22 Pin Receptacle Carrier lifted out and discarded. The following figure (Figure 3.3) shows the PCB hole pattern and recommended pad size that should be used on the end-user PC board. The recommended mounting hardware are the same as illustrated in Figure 3.4. To lift the disposable carrier after soldering, gently pry the carrier from the PCB with a flat head screwdriver or, to avoid chancing PC board damage, use the optional pry bar (PB-22) (9.5) 0.200" (5.08) (2.72) DIA. HOLE (3.96) WIDE PAD (4.47) LONG PAD 9 PLACES (18.3) (4.2) DIA. HOLE 2 PLACES (19.8) (1.57) DIA. HOLE (2.29) WIDE PAD (2.79) LONG PAD 14 PLACES (13.30) 0.100" (2.54) 2.350" (59.70) Figure 3.3: PCB Hole Pattern (for Mounting of the PR-22 Pin Receptacle Carrier) 15

18 R e c o m m e n d e d M o u n t i n g H a r d w a r e The following figure (Figure 3.4) illustrates the recommended mounting hardware. This hardware and associated torque specification will be the same whether the PR-22 pin receptacle carrier is used or the driver is directly mounted to a PC Board. U.S. Phillips Pan HD #6 Stainless Mach. Screw #6 Split Lock Washer Stainless (.04TH,.24OD) #6 Flat Washer Stainless (.04TH,.24OD) Keystone #4866 or equivalent #6 threaded insert (Mounted from bottom of PCB METRIC. Phillips Pan HD M3 X 0.5 Stainless Mach. Screw M3 Split Lock Washer Stainless (.08TH, 6.20 Dia. Max) M3 Flat Washer Stainless (.05TH, 6.20 Dia. Max) PEM #KFS2-M3 or equivalent M3 X 0.5 threaded insert (Mounted from bottom of PCB Figure 3.4: PCB Mounting Hardware (Direct Mounting or Socketed) NOTE! The torque specification for the mounting screws is 5.0 to 7.0 lb-in (0.60 to 0.80 N-m). Do not over tighten screws! WARNING! The IM483H/IM805H Drivers are not hermetically sealed. DO NOT wash the PCB with the Driver soldered in place. Always wash the PCB prior to mounting the Driver. NEVER use compressed air. Attaching the HFC-22 Heat Sink/Fan/Clip Assembly The figure at right illustrates the HFC-22 mounted to the IM483H/IM805H. To attach the HFC-22 complete the following: 1) Placing the heat sink on the driver, align so that the dot on the heat sink is on the same side as the dot on the driver, with the TN-22 thermal pad sandwiched between them. 2) Insert two of the arms from the fan/clip assembly into the corresponding slots in the driver, aligning the curved fingers on the clip between the posts of the heat sink. Insert the other two locking tabs into the opposite slots and snap into place. The locking tabs on all four arms should be completely through the slots on the driver. R e c o m m e n d e d C o n n e c t o r The HFC-22 fan connector plugs into the following pin header: Molex Part Number: Digikey Part Number: WM-4200-ND Samtec Part Number: TSW T-D 16

19 WARNING! The heat sink mounting surface must be a smooth, flat surface with no burrs, protrusions, cuttings or other foreign objects. NOTE! If the curved fingers do not align between the posts on the heat sink do not try and force them. Verify that the heat sink is sitting square on the driver and that the dot on the heat sink is on the same side as the dot on the driver! CLIP FAN HEAT-SINK FINGERS ARM LOCKING TAB THERMAL PAD DRIVER Figure 3.5: HFC-22 Heat Sink/Fan/Clip Assembly NOTE! Be certain to remove the clear protective sheet from the TN-22 Thermal Pad before installation. Removing the HFC-22 Heat Sink/Fan/Clip Assembly To remove the HFC-22 from the the driver: 1) Squeeze the two arms on one side of the assembly until the locking tabs are free in the slot on the drive. 2) Gently lift the freed side away from the drive. The HFC-22 will separate from the drive. (The fan will be locked inside the clip.) 17

20 S e c t i o n 4 T h e o r y o f O p e r a t i o n S e c t i o n O v e r v i e w This section will cover the circuit operation for the IM483H/IM805H microstepping driver hybrid. Circuit Operation Microstep Select Inputs Stepping Dual PWM Circuit Fullstep Output Timing C i r c u i t O p e r a t i o n Microstepping drives have a much higher degree of suitability for applications that require smooth operation and accurate positioning at low speeds than do half/fullstep drivers and reduction gearing. The IM483H/IM805H, with its ability to be set to microstep resolutions as high as 51,200 microsteps/rev (256 Microsteps/step) using a 1.8 stepping motor, is ideal for such applications. In order to subdivide motor steps into microsteps while maintaining positional accuracy, precise current control is required. The IM483H/IM805H accomplishes this by the use of a unique Dual PWM circuit built into the patented IM2000 Microstep Controller ASIC, which resides at the heart of the IM483H/ IM805H. This PWM circuit uses an alternating recirculating/non-recirculating mode to accurately regulate the current in the windings of a two phase stepping motor. Figure 4.1: IM483H/IM805H Block Diagram 18

21 M i c r o s t e p S e l e c t ( M S E L ) I n p u t s Another unique feature of the IM2000 is the ability to change resolutions at any time. A resolution change can occur whether the motor is being clocked or is at rest. The change will not take place until the rising edge of the next STEP CLOCK input. At this time, the new resolution is latched and implemented before the step clock pulse takes effect. If a resolution is chosen such that the sine/cosine output of the IM2000 would not land on an electrical fullstep of the motor, then the IM2000 will automatically align itself to the full step position on the step clock pulse that would have caused the motor to rotate past the full step. The step clock pulses, from that point forward, will be equal to the selected resolution. This feature allows the user to switch resolutions at any time without having to keep track of sine/cosine location. Now the On-Full-Step output of the IM483H/IM805H can easily be used to monitor position. Interface guidelines and settings for the Microstep Resolution inputs are located in Section 7 of this document, Interfacing to the IM483H/IM805H. S t e p p i n g The IM2000 contains a built-in sine/cosine generator used for the generation of Phase A and Phase B position reference. This digitally encoded 9 bit sine and 9 bit cosine signal is directly fed into a digital to analog converter. The step clock (SCLK) and direction (DIR) inputs are buffered using Schmidt triggered buffers for increased noise immunity and are used to increment or decrement the sine/cosine position generator. The position generator is updated on the rising edge of the step clock input. It will increment or decrement by the amount specified by the microstep resolution select (MSEL) inputs. The direction (DIR) input determines the direction of the position generator and hence the direction of the motor. The DIR input is synchronized to the SCLK input. On the rising edge of the SCLK input the state of the DIR input is latched in. The position generator will then look to see if there has been a change in direction and implement that change before executing the next step. By utilizing this method to implement the direction change, the noise immunity is greatly increased and no physical change in the motor occurs if the direction line is toggled prior to the step clock input. The enable/disable input does not effect the step clock input. The sine/cosine generator will continue to update if a signal is applied to the step clock input. The IM2000 outputs both sine and cosine data simultaneously when applying a step clock input. Dual internal look-up tables are used to output a unique position for every step clock input to enhance system performance. 19

22 D u a l P W M C i r c u i t The IM2000 contains a unique dual PWM circuit that efficiently and accurately regulates the current in the windings of a two phase stepping motor. The internal PWM accomplishes this by using an alternating recirculating/non-recirculating mode to control the current. R e c i r c u l a t i n g In a recirculating PWM, the current in the windings is contained within the output bridge while the PWM is in its OFF state. (After the set current is reached.) This method of controlling the current is efficient when using low inductance motors, but lacks response because of its inability to remove current from the windings on the downward cycle of the sine/ cosine wave. (See figure 4.1) N o n - R e c i r c u l a t i n g 20 In a non-recirculating PWM, the current flows up through the bridge and back to the supply in the OFF phase of the cycle. This method of controlling current allows for much better response but reduces efficiency and increases current ripple, especially in lower inductance motors. (See Figure 4.3) DRIVE CURRENT RECIRCULATION Figure 4.3: Non- Recirculating PWM DRIVE CURRENT RECIRCULATION Figure 4.2: Recirculating PWM The IM2000 s PWM utilizes the best features of both by combining recirculating and non-recirculating current control. On the rising edge of the sine/cosine waveform, the PWM will always be in a recirculating mode. This mode allows the driver to run at peak efficiency while maintaining minimum current ripple even with low inductance motors. On the downward cycle of the sine/cosine waveform, the PWM operates in a two part cycle. In the first part of its cycle, the PWM is in a nonrecirculating mode to pull current from the motor windings. In the second part of the cycle the PWM reverts back to recirculating mode to increase efficiency and reduce current ripple. The IM2000 will automatically change

23 the non-recirculating pulse widths to compensate for changes in supply voltage and accommodate a wide variety of motor inductances. This method also allows for the use of very low inductance motors with your IM483H/IM805H driver, while utilizing a 20kHz chopping rate which reduces motor heating but maintains high efficiency and low current ripple. F u l l s t e p O u t p u t S i g n a l The fullstep output signal from the IM483H/IM805H is an active high output at connector P1:12. This output will be TRUE for the duration of the full step. A full step occurs when either Phase A or Phase B crosses through zero (i.e. full current in one motor winding and zero current in the other winding). This fullstep position is a common position regardless of the microstep resolution selected. The fullstep output can be used to count the number of mechanical fullsteps that the motor has traveled without the need to count the number of microsteps in between. A controller that utilizes this output can greatly reduce its position tracking overhead, thus substantially increasing its throughput. Interface guidelines and a sample application for the fullstep output are located in Section 7 of this document, Interfacing to the IM483H/IM805H. T i m i n g The direction and microstep resolution select inputs are synchronized with the positive going edge of the step clock input. When the step clock input goes HIGH, the direction and microstep resolution select inputs are latched. Further changes to these inputs are ignored until the next rising edge of the step clock input. After these signals are latched, the IM483H/IM805H looks to see if any changes have occurred to the direction and microstep resolution select inputs. If a change has occurred, the IM483H/IM805H will execute the change before taking the next step. Only AFTER the change has been executed will the step be taken. If no change has occurred, the IM483H/IM805H will simply take the next step. This feature works as an automatic debounce for the direction and microstep resolution select inputs. The reset and enable inputs are asynchronous to any input and can be changed at any time. 21

24 S e c t i o n 5 P o w e r S u p p l y R e q u i r e m e n t s S e c t i o n O v e r v i e w This section covers the power supply requirements of the IM483H/IM805H. Precise wiring and connection details are to be found in Section 7: Interfacing to the IM483H/IM805H. The following is covered by this section: Selecting a Power Supply. Recommended Wiring. AC Line Filtering. S e l e c t i n g a P o w e r S u p p l y S e l e c t i n g a M o t o r S u p p l y ( + V ) Proper selection of a power supply to be used in a motion system is as important as selecting the drive itself. When choosing a power supply for a stepping motor driver, there are several performance issues that must be addressed. An undersized power supply can lead to poor performance and possibly even damage to your drive. T h e P o w e r S u p p l y - M o t o r R e l a t i o n s h i p Motor windings can basically be viewed as inductors. Winding resistance and inductance result in an L/R time constant that resists the change in current. To effectively manipulate the rate of charge, the voltage applied is increased. When traveling at high speeds, there is less time between steps to reach current. The point where the rate of commutation does not allow the driver to reach full current is referred to as voltage mode. Ideally you want to be in current mode, which is when the drive is achieving the desired current between steps. Simply stated, a higher voltage will decrease the time it takes to charge the coil and, therefore, will allow for higher torque at higher speeds. Another characteristic of all motors is back EMF. Back EMF is a source of current that can push the output of a power supply beyond the maximum operating voltage of the driver. As a result, damage to the stepper driver could occur over a period of time. T h e P o w e r S u p p l y - D r i v e r R e l a t i o n s h i p 22 The IM483H/IM805H is very current efficient as far as the power supply is concerned. Once the motor has charged one or both windings of the motor, all the power supply has to do is replace losses in the system. The charged winding acts as an energy storage in that the current will recirculate within the bridge and in and out of each phase reservoir. This results in a less than expected current draw on the supply.

25 Stepping motor drivers are designed with the intent that a user s power supply output will ramp up to greater than or equal to the minimum operating voltage. The initial current surge is substantial and could damage the driver if the supply is undersized. The output of the power supply could fall below the operating range of the driver upon a current surge, if it is undersized. This could cause the power supply to start oscillating in and out of the voltage range of the driver and result in damage to either the supply, the driver, or both. There are two types of supplies commonly used, regulated and unregulated, both of which can be switching or linear. Each have advantages and disadvantages. R e g u l a t e d v s. U n r e g u l a t e d An unregulated linear supply is less expensive and more resilient to current surges, however, the voltage decreases with increasing current draw. This can cause problems if the voltage drops below the working range of the drive. Also of concern are the fluctuations in line voltage. This can cause the unregulated linear supply to be above or below the anticipated or acceptable voltage. A regulated supply maintains a stable output voltage, which is good for high speed performance. These supplies are also not effected by line fluctuations, however, they are more expensive. Depending on the current regulation, a regulated supply may crowbar or current clamp and lead to an oscillation that, as previously stated, can cause damage to the driver and/or supply. Back EMF can cause problems for regulated supplies as well. The current regeneration may be too large for the regulated supply to absorb. This could lead to an over voltage condition which could damage the output circuitry of the IM483H/IM805H. Non IMS switching power supplies and regulated linear supplies with overcurrent protection are not recommended because of their inability to handle the surge currents inherit in stepping motor systems. Motor Power Supply Specifications Specification IM483H IM805H Recommended Supply Type Unregulated DC R ipple Voltage ±10% Output Voltage Output Current* + 12 to +45 VDC +24 to +75 VDC 3A Peak 4A Peak * The output current needed selection and the load. is dependant on the power supply voltage, the motor Table 5.1: Motor Power Supply Specifications 23

26 R e c o m m e n d e d I M S P o w e r S u p p l i e s IMS has designed a series of low cost miniature unregulated Switching and Linear Supplies that can handle extreme varying load conditions. This makes them ideal for stepper motor drives and DC servo motors. Each of these is available in either 120 or 240 VAC configuration. See the IMS Catalog or website ( for more information. Listed below are the power supplies recommended for use with the IM483H/IM805H. I P / I S P ( I M H ) Range Input 120 VAC Version VAC 240 VAC Version VAC IP404 Unregulated Linear Supply No Load Output Voltage* Amps Continuous Output Rating* Amps Peak Output Rating* Amps ISP200-4 Unregulated Switching Supply No Load Output Voltage* Amps Continuous Output Rating* Amps Peak Output Rating* Amps I P / I S P ( I M H ) Range Input 120 VAC Version VAC 240 VAC Version VAC IP804 Unregulated Linear Supply No Load Output Voltage* Amps Continuous Output Rating* Amps Peak Output Rating* Amps ISP200-7 Unregulated Switching Supply No Load Output Voltage* Amps Continuous Output Rating* Amps Peak Output Rating* Amps * All measurements were taken at 25 C, 120 VAC, 60 Hz. S e l e c t i n g a + 5 V D C S u p p l y +5VDC Power Supply Specifications Specification IM483H IM805H Recommended Supply Type Regulated Linear or Switch Mode DC R ipple Voltage ±10% Output Voltage + 5VDC +5VDC Output Current 100mA 300mA Table 5.2: +5VDC Power Supply Specifications 24

27 R e c o m m e n d e d W i r i n g R u l e s o f W i r i n g a n d S h i e l d i n g Noise is always present in a system that involves both high power and small signal circuitry. Regardless of the power configuration used for your system, there are some wiring and shielding rules that should be followed to keep the noise to signal ratio as small as possible. R u l e s o f W i r i n g Power supply and motor wiring should be shielded twisted pairs run separately from signal carrying wires. A minimum of 1 twist per inch is recommended. Motor wiring should be shielded twisted pairs using 20-gauge wire or, for distance greater than 5 feet, 18 gauge or better. Power ground return should be as short as possible to established ground. Power supply wiring should be shielded twisted pairs. Use 18 gauge wire if load is less than 4 amps, or 16 gauge for more than 4 amps. Do not Daisy-Chain power wiring to system components. R u l e s o f S h i e l d i n g The shield must be tied to zero-signal reference potential. In order for shielding to be effective, it is necessary for the signal to be earthed or grounded. Do not assume that earth ground is true earth ground. Depending on the distance to the main power cabinet, it may be necessary to sink a ground rod at a critical location. The shield must be connected so that shield currents drain to signal-earth connections. The number of separate shields required in a system is equal to the number of independent signals being processed plus one for each power entrance. The shield should be tied to a single point to prevent ground loops. A second shield can be used over the primary shield, however, the second shield is tied to ground at both ends. R e c o m m e n d e d P o w e r S u p p l y C a b l e s Power supply cables must not run parallel to logic level wiring as noise will be coupled onto the logic signals from the power supply cables. If more than one driver is to be connected to the same power supply, run separate power and ground leads to each driver from the power supply. The following Belden cables (or equivalent) are recommended for use with the IM483H/IM805H. 25

28 Twisted pair jacketed <4Amps DC...Belden Part# 9740 or equivalent 18 Gauge >4Amps DC...Belden Part# 8471 or equivalent 16 Gauge A C L i n e F i l t e r i n g Since the output voltage of an unregulated power supply will vary with the AC input applied, it is recommended that an AC line filter be used to prevent damage to the IM483H/IM805H due to a lightning strike or power surge. WARNING! Verify that the power supply wiring is correct prior to power application. If +V and GND are connected in reverse order, catastrophic damage to the IM483H/IM805H may occur! Ensure that the power supply output voltage does not exceed +48/75VDC, the maximum input voltage of the IM483H/IM805H! WARNING! Hazardous voltage levels may be present if using an open frame power supply to power the IM483H/IM805H! 26

29 S e c t i o n 6 M o t o r R e q u i r e m e n t s S e c t i o n O v e r v i e w This section covers the motor configurations for the IM483H/IM805H. Selecting a Motor. Motor Wiring. Connecting the Motor. S e l e c t i n g a M o t o r When selecting a stepper motor for your application, there are several factors that need to be taken into consideration. How will the motor be coupled to the load? How much torque is required to move the load? How fast does the load need to move or accelerate? What degree of accuracy is required when positioning the load? While determining the answers to these and other questions is beyond the scope of this document, they are details that you must know in order to select a motor that is appropriate for your application. These details will effect everything from the power supply voltage to the type and wiring configuration of your stepper motor. The current and microstepping settings of your IM483H/ IM805H drive will also be effected. T y p e s a n d C o n s t r u c t i o n o f S t e p p i n g M o t o r s The stepping motor, while classed as a DC motor, is actually an AC motor that is operated by trains of pulses. Although it is called a stepping motor, it is in reality a polyphase synchronous motor. This means it has multiple phases wound in the stator and the rotor is dragged along in synchronism with the rotating magnetic field. The IM483H/IM805H is designed to work with the following types of stepping motors: 1) Permanent Magnet (PM) 2) Hybrid Stepping Motors 27

30 Hybrid stepping motors combine the features of the PM stepping motors with the features of another type of stepping motor called a variable reluctance motor (VR), which is a low torque and load capacity motor that is typically used in instrumentation. The IM483H/IM805H cannot be used with VR motors as they have no permanent magnet. On hybrid motors, the phases are wound on toothed segments of the stator assembly. The rotor consists of a permanent magnet with a toothed outer surface which allows precision motion accurate to within ± 3 percent. Hybrid stepping motors are available with step angles varying from 0.45 to 15 with 1.8 being the most commonly used. Torque capacity in hybrid steppers ranges from ounce-inches. Because of their smaller step angles, hybrid motors have a higher degree of suitability in applications where precise load positioning and smooth motion is required. S i z i n g a M o t o r f o r Yo u r S y s t e m The IM483H/IM805H is a bipolar driver which works equally well with both bipolar and unipolar motors (i.e. 8 and 4 lead motors, and 6 lead center tapped motors). To maintain a given set motor current, the IM483H/IM805H chops the voltage using a constant 20kHz chopping frequency and a varying duty cycle. Duty cycles that exceed 50% can cause unstable chopping. This characteristic is directly related to the motor s winding inductance. In order to avoid this situation, it is necessary to choose a motor with a low winding inductance. The lower the winding inductance, the higher the step rate possible. W i n d i n g I n d u c t a n c e Since the IM483H/IM805H is a constant current source, it is not necessary to use a motor that is rated at the same voltage as the supply voltage. What is important is that the IM483H/IM805H is set to the motor s rated current. See Section 7: Interfacing to the IM483H/IM805H for more details. As was discussed in the previous section, Power Supply Requirements, the higher the voltage used the faster the current can flow through the motor windings. This in turn means a higher step rate, or motor speed. Care should be taken not to exceed the maximum voltage of the driver. Therefore, in choosing a motor for a system design, the best performance for a specified torque is a motor with the lowest possible winding inductance used in conjunction with highest possible driver voltage. The winding inductance will determine the motor type and wiring configuration best suited for your system. While the equation used to size a motor for your system is quite simple, several factors fall into play at this point. The winding inductance of a motor is rated in millihenrys (mh) per Phase. The amount of inductance will depend on the wiring configuration of the motor. 28

31 Actual Inductance Seen By the Driver Specified Per Phase Inductance PHASE A PHASE A Actual Inductance Seen By the Driver Specified Per Phase Inductance PHASE A PHASE A PHASE B PHASE B 8 Lead Stepping Motor Series Configuration (Note: This example also applies to the 6 lead motor full copper configuration and to 4 lead stepping motors) A PHASE B PHASE B 8 Lead Stepping Motor Parallel Configuration (Note: This example also applies to the 6 lead motor half copper configuration) B Figure 6.1 A & B: Per Phase Winding Inductance The per phase winding inductance specified may be different than the per phase inductance seen by your IM483H/IM805H driver depending on the wiring configuration used. Your calculations must allow for the actual inductance that the driver will see based upon the motor s wiring configuration used. Figure 6.1A shows a stepper motor in a series configuration. In this configuration, the per phase inductance will be 4 times that specified. For example: a stepping motor has a specified per phase inductance of 1.47mH. In this configuration the driver will see 5.88 mh per phase. Figure 6.1B shows an 8 lead motor wired in parallel. Using this configuration the per phase inductance seen by the driver will be as specified. Maximum Motor Inductance (mh per Phase) =.2 X Minimum Supply Voltage NOTE: In calculating the maximum phase inductance, the minimum supply output voltage should be used when using an unregulated supply. Using the following equation we will show an example of sizing a motor for a IM483H/IM805H used with an unregulated power supply with a minimum voltage (+V) of 18 VDC:.2 X 18 = 3.6 mh The maximum per phase winding inductance we can use is 3.6 mh. 29

32 R e c o m m e n d e d I M S M o t o r s IMS stocks the following 1.8 hybrid stepping motors that are recommended for the IM483H/IM805H. All IMS motors are CE marked. For more detailed information on these motors, please see the IMS Full Line catalog or the IMS website at 17 Frame (IM483H) Single Shaft Double Shaft M S... M D M S... M D M S... M D 23 Frame (IM483H/IM805H) Single Shaft Double Shaft M S... M D M S... M D M S... M D M S... M D 34 Frame (IM805H) Single Shaft Double Shaft M S... M D M S... M D M S... M D E n h a n c e d S t e p p e r M o t o r s IMS also carries a new series of 23 frame enhanced stepping motors that are recommended for use with the IM483H/IM805H. These motors use a unique relationship between the rotor and stator to generate more torque per frame size while ensuring more precise positioning and increased accuracy. The special design allows the motors to provide higher torque than standard stepping motors while maintaining a steadier torque and reducing torque drop-off. The motors are available in 3 stack sizes, single or double shaft, with or without encoders. They handle currents up to 3 Amps in series or 6 Amps parallel, and holding torque ranges from 95 oz.-in. to 230 oz.-in (67 N-cm to 162 N-cm). These CE rated motors are ideal for applications where higher torque is required. 23 Frame High Torque Motors (IM483H/IM805H) Single Shaft Double Shaft MH-2218-S...MH-2218-D MH-2222-S...MH-2222-D MH-2231-S...MH-2231-D 30

33 I M S I n s i d e O u t S t e p p e r M o t o r s The new inside out stepper (IOS) motor was designed by IMS to bring versatility to stepper motors using a unique multi-functional, hollow core design. This versatile new motor can be converted to a ball screw linear actuator by mounting a miniature ball screw to the front shaft face. Ball screw linear actuators offer long life, high efficiency, and can be field retrofitted. There is no need to throw the motor away due to wear of the nut or screw. The IOS motors offer the following features: The shaft face diameter offers a wide choice of threaded hole patterns for coupling. The IOS motor can be direct coupled in applications within the torque range of the motor, eliminating couplings and increasing system efficiency. The IOS motor can replace gearboxes in applications where gearboxes are used for inertia dampening between the motor and the load. The induced backlash from the gearbox is eliminated providing improved bi-directional position accuracy. Electrical or pnuematic lines can be directed through the center of the motor enabling the motors to be stacked endto-end or applied in robotic end effector applications. The through hole is stationary, preventing cables from being chaffed by a moving hollow shaft. Light beams can be directed through the motor for refraction by a mirror or filter wheel mounted on the shaft mounting face. The IOS motor is adaptable to valves enabling the valve stem to protrude above the motor frame. The stem can be retrofitted with a dial indicator showing valve position. The motor is compatible with IMS bipolar drivers, keeping the system cost low. The IOS motor can operate up to 3000 rpm s. The IOS motor is available in the following frames: Frame Size IMS PN 17 Frame...M IOS 23 Frame...M IOS 34 Frame...M IOS 31

34 M o t o r W i r i n g As with the power supply wiring, motor wiring should be run separately from logic wiring to minimize noise coupled onto the logic signals. Motor cabling exceeding 1 in length should be shielded twisted pairs to reduce the transmission of EMI (Electromagnetic Interference) which can lead to rough motor operation and poor system performance overall. For more information on wiring and shielding, please refer to Rules of Wiring and Shielding in Section 5 of this manual. Below are listed the recommended motor cables: NOTE: The physical direction of the motor with respect to the direction input will depend upon the connection of the motor windings. To switch the direction of the motor with respect to the direction input, switch the wires on either Phase A or Phase B outputs. WARNING! Do not connect or disconnect motor or power leads with power applied! Dual Twisted Pair Shielded (Separate Shields) < 5 feet...belden Part# 9402 or equivalent 20 Gauge > 5 feet...belden Part# 9368 or equivalent 18 Gauge When using a bipolar motor, the motor must be within 100 feet of the drive. C o n n e c t i n g t h e M o t o r The motor leads are connected to the following connector pins: I M H / I M H Phase Connector: Pin Phase B...P2: 3 Phase B...P2: 1 Phase A...P2: 9 Phase A...P2: 7 32

35 8 L e a d M o t o r s 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. S e r i e s C o n n e c t i o n A series motor configuration would typically be used in applications where a higher torque at low speeds is needed. Because this configuration has the most inductance, the performance will start to degrade at higher speeds. Use the per phase (or unipolar) current rating as the peak output current, or multiply the bipolar current rating by 1.4 to determine the peak output current. PHASE A PHASE A PHASE B PHASE B Figure 6.2: 8 Lead Series Motor Connections P a r a l l e l C o n n e c t i o n 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. PHASE A PHASE A PHASE B PHASE B Figure 6.3: 8 Lead Parallel Motor Connections 33

36 6 L e a d M o t o r s 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. H a l f C o i l C o n f i g u r a t i o n 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 copper. In setting the driver output current multiply the specified per phase (or unipolar) current rating by 1.4 to determine the peak output current. PHASE A PHASE A NO CONNECTION PHASE B PHASE B NO CONNECTION Figure 6.4: 6 Lead Half Coil (Higher Speed) Motor Connections F u l l C o i l C o n f i g u r a t i o n 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. Use the per phase (or unipolar) current rating as the peak output current. PHASE A NO CONNECTION PHASE A PHASE B NO CONNECTION PHASE B Figure 6.5: 6 Lead Full Coil (Higher Torque) Motor 34

37 4 L e a d M o t o r s 4 lead motors are the least flexible but easiest to wire. Speed and torque will depend on winding inductance. In setting the driver output current, multiply the specified phase current by 1.4 to determine the peak output current. PHASE A PHASE A PHASE B PHASE B Figure 6.6: 4 Lead Motor Connections 35

38 S e c t i o n 7 I n t e r f a c i n g t o t h e I M H / I M H S e c t i o n O v e r v i e w The IM483H/IM805H was designed to be incorporated directly in the user s printed circuit board. In order to operate, the IM483H/IM805H must have the following connections: Motor Power (+V). +5VDC Input. MSEL Inputs. Current Adjust (Reduction is optional). Logic Interface. Minimum Connections. L a y o u t a n d I n t e r f a c e G u i d e l i n e s Logic level signals should not run parallel to motor phase signals. The motor phase signals will couple noise onto the logic level signals. This will cause rough motor motion and unreliable system operation. Motor phase signals should be run as pairs and should be separated from other signals by ground traces where possible. When leaving the board, motor cables should not run parallel with other wires. Phases should be wired using twisted pairs. If motor cabling in excess of one foot is required, motor cabling should be shielded twisted pairs to reduce the transmission of EMI. The shield must be tied to AC ground at driver end only (or the supply ground if AC ground is not available). The motor end must be left floating. If more than one driver is connected to the power supply, separate power and ground connections from each driver to the power supply should be used. The power supply cables need to be a twisted pair if power is connected from a source external to the board. If multiple drivers are used with an external power source, and it is not possible to run separate power and ground connections to each driver, a low impedance electrolytic capacitor equivalent to two times the total capacitance of all driver capacitors and of equal voltage must be placed at the power input of the board. 36

39 M o t o r P o w e r Pins 5 (+V), and 2 & 8 (GND) on connector P2 are used to connect motor DC power to the IM483H/IM805H. Two local capacitors are needed. These must be located as close to the IM483H/IM805H s motor power input pins as possible to ensure stable operation. The first two capacitors, one for each motor phase, are low impedance aluminum electrolytics. The continuous operating voltage of the capacitor should exceed the maximum supply voltage as well as any additional voltage caused by the motor s back EMF. The value of the capacitors should be approximately CALCULATING THE VALUE OF THE INPUT CAPACITORS EXAMPLE: 3.2A (Peak Output 45VDC) X 150µF = 480µF 63V 150µF for every amp of peak per phase output current. For power supply specifications and recommendations, see Section 5: Power Supply Requirements. + + GNDA +5V +V GND GNDB P uF 10V,TANT.1uF 100V.1uF 100V + ADDITIONAL ELECTROLYTIC CAPACITOR ADDITIONAL ELECTROLYTIC CAPACITOR MOTOR SUPPLY +5VDC SUPPLY TOPSIDE PCB TRACES BOTTOMSIDE PCB TRACES Figure 7.1: Power Interface 37

40 + 5 V D C I n p u t The IM483H/IM805H requires an external regulated +5VDC, ±5% power supply. The supply is connected between P2:6 (+5VDC Supply) and P2:4 (Power Ground). A 68 microfarad 10V tantalum capacitor must be placed as close to the IM483H/IM805H as possible between the +5VDC input pin (P2:6) and ground. (See figure 7.1 on the previous page for PCB layout example.) The +5VDC supply ground and the motor supply ground should not be connected together at the power supplies. The common ground connection between the motor power supply and the +5VDC supply should be made at the ground pin of the additional electrolytic capacitor used for the motor supply. ( See figure 7.1 on the previous page for PCB layout example.) I n t e r f a c i n g t h e C u r r e n t A d j u s t I n p u t For any given motor, the output current used for microstepping is determined differently from that of a half/full step driver. In the IM483H/IM805H, a sine/cosine output function is used in rotating the motor. Therefore, when microstepping, the specified phase current of the motor is considered an RMS value. D e t e r m i n i n g t h e O u t p u t C u r r e n t Stepper motors can be configured as 4, 6 or 8 leads. Each configuration requires different currents. Shown below are the different lead configurations and the procedures to determine the peak per phase output current setting that would be used with different motor/lead configurations. 4 L e a d M o t o r s Multiply the specified phase current by 1.4 to determine the peak output current. 6 L e a d M o t o r s EXAMPLE: A 4 lead motor has a specified phase current of 2.0A 2.0A x 1.4 = 2.8 Amps Peak 1) When configuring a 6 lead motor in a half coil configuration (i.e. connected from one end of the coil to the center tap (high speed configuration)) multi- 38

41 ply the specified per phase (or unipolar) current rating by 1.4 to determine the peak output current. 2) When configuring the motor so the full coil is used (i.e. connected from end-to-end with the center tap floating (higher torque configuration)) use the per phase (or unipolar) current rating as the peak output current. EXAMPLE: A 6 lead motor in half coil configuration has a specified phase current of 3.0A 3.0A x 1.4 = 4.2 Amps Peak 8 L e a d M o t o r s SERIES CONNECTION: When configuring the motor windings in series, use the per phase (or unipolar) EXAMPLE: A 6 lead motor in full coil configuration with a specified phase current of 3.0A 3.0A per phase = 3.0 Amps Peak current rating as the peak output current, or multiply the bipolar current rating by 1.4 to determine the peak output current. PARALLEL CONNECTION: When configuring the motor windings in parallel, multiply the per phase (or unipolar) current rating by 2.0 or the bipolar current rating by 1.4 to determine the peak output current. EXAMPLE: An 8 lead motor in series configuration with a specified unipolar current of 3.0A 3.0A per phase = 3.0 Amps Peak An 8 lead motor in series configuration with a specified bipolar current of 2.8A 2.8 x 1.4 = 3.92 Amps Peak 39

42 EXAMPLE: An 8 lead motor in parallel configuration with a specified unipolar current of 2.0A 2.0A per phase X 2.0 = 4.0 Amps Peak An 8 lead motor in parallel configuration with a specified bipolar current of 2.8A 2.8 x 1.4 = 3.92 Amps Peak S e t t i n g t h e O u t p u t C u r r e n t The output current can be set on the IM483H/IM805H one of two ways: 1) By connecting the current reference output (P1:1) to the current adjust input (P1:2) and placing a resistor between this connection and ground (P2:4). This uses the internal 1mA current source provided at the current reference pin P1:1 (see figure 7.2). 2) By applying and external reference voltage to P1:2 (see figure 7.3). Tables 7.1 and 7.2 show both the current adjust resistor values and the reference voltage required for peak per phase output current settings for the IM483H and IM805H. The current adjustment resistor orternal reference voltage used to set the per phase output current of the IM483H/IM805H sets the peak per phase output of the sine/cosine waves not the RMS value. Therefore, the peak per phase output current must be used to determine the value to which the IM483H/IM805H will be set. See Section 7 Determining the Output Current for more information. CURRENT REFERENCE CURRENT ADJUST Pin 1 CURRENT ADJUST RESISTOR SEE TABLES 7.1 AND 7.2 FOR VOLTAGE VALUES P1 P2 POWER GROUND Bottom View Pin 1 Figure 7.2: Current Adjust Resistor Connection 40 WARNING! A current adjustment resistor is always necessary to keep the Driver and/or Motor in a safe operating range. DO NOT operate the IM483H/IM805H Drivers without a current adjustment resistor in place.

43 EXTERNAL REFERENCES SEE TABLES 7.1 AND 7.2 FOR VOLTAGES Pin1 P1:2 CURRENT ADJUST Bottom View Pin1 Figure 7.3: Setting the Output Current using an External Source Current Adjust Resistor and Reference Values (IM483H) Current Adjust Resistor and Reference Values for the IM483H Output Current (Amps Peak) Reference (Volts) Resistor Value (Ohms 1%) Table 7.1: Current Adjust Reference/Output Current (IM483H) 41

44 Current Adjust Resistor and Reference Values (IM805H) Current Adjust Resistor and Reference Values for the IM483H Output Current (Amps Peak) Reference (Volts) Resistor Value (Ohms 1%) Table 7.2: Current Adjust Reference/Output Current (IM805H) 42

45 R e d u c i n g / D i s a b l i n g t h e O u t p u t C u r r e n t The IM483H/IM805H will automatically reduce the current in the motor windings after a move provided the onboard 1mA current source, along with a current adjustment resistor, is used to set the output current and a resistor is placed between pins 2 and 3 of connector P1. Using this will greatly reduce the amount of motor and drive heating in your system. The amount of current reduced will depend upon the value of the Reduction Adjust Resistor (R Red ) and the value of the current adjust resistor (R Adj ). The Current will be reduced 0.5 seconds after the rising edge of the last Step Clock Pulse. The value of R Red is calculated as follows: IM483H I Run x I Hold R Red = 500 x ( IRun - I Hold ) I Run is the desired peak running current. Range 0.4A to 4A Peak I Hold is the desired peak holding current. Range 0.2A to 4A Peak IM805H I Run x I Hold R Red = 150 x ( IRun - I Hold ) I Run is the desired peak running current. Range 1.0A to 7A Peak I Hold is the desired holding current. Range 0.5A to 7A Peak CURRENT REFERENCE CURRENT ADJUST CURRENT REDUCTION Pin 1 CURRENT ADJUST RESISTOR P1 CURRENT REDUCTION ADJUST RESISTOR P2 POWER GROUND Bottom View Pin 1 Figure 7.4: Current Reduction Adjustment Resistor Connection 43

46 If zero current is required at stand still then the current reduction output (P1:3) may be tied directly to the enable input (P1:11). This will disable the outputs 0.5 seconds after the last step clock input. When the current reduction output is used in this manner an open collector output or blocking diode is RE- QUIRED or damage may occur to the internal circuitry. The diode or open collector transistor should be placed after the enable/reduction connection as shown in figure 7.5. If a voltage is used to set the output current the current reduction output (P1:3) will provide an open drain, active low output that occurs 0.5 seconds after the last step clock input and is OPEN COLLECTOR INTERFACE INTERFACE CIRCUIT INTERFACE CIRCUIT ENABLE/ REDUCTION INPUT referenced to ground (P2:4) the RDS ON of the internal MOSFET is approximatly 6.5Ω. I n t e r f a c i n g t h e I M H / I M H I n p u t s The inputs to the IM483H/IM805H are internally pulled up to the +5VDC supply. Figure 7.6 shows the inputs and their associated pull up resistor values. See Section 2: Hardware Specifications, for resistor tolerance. When interfacing to the IM483H/IM805H logic inputs an open collector output is recommended. OR BLOCKING DIODE ENABLE/ REDUCTION INPUT SCHOTTKY TYPE Figure 7.5: Interfacing the Current Reduction Input 1 Bottom View +5V P2 FAULT IN MSEL 0 MSEL 1 MSEL 2 MSEL 3 SCLK DIR ENABLE 4.99k Ω 4.99k Ω 4.99k Ω 4.99k Ω 4.99k Ω 2.21k Ω 2.21k Ω RESET P1 1.27k Ω 44 Figure 7.6: Input Pull-Up Resistors

47 The Microstep Resolution Select Inputs (MSEL) Microsteps per step are selected via Pins 5-8 on connector P1. The table below shows the standard resolution values and the associated input settings. The microstep resolution can be changed at any time. There is no need to reset the drive or cycle the power. On-the-fly gear shifting facilitates high speed slewing combined with high resolution positioning at either end of the move. When the microsteps are changed so that the IM483H/IM805H does not fall on a full step (i.e. zero crossing of the sine/cosine) the IM483H/IM805H will readjust itself at the next pulse that would overshoot the fullstep position. This feature allows the IM483H/IM805H to readjust the motor position no matter what resolution is chosen when it is changed. Resolution Microstep Select Line States Microsteps/Step Microsteps/Rev MSEL0 MSEL1 MSEL2 MSEL3 Binary Microstep Resolution Settings (1.8 Motor) 400 GND GND 2 GND GND OPEN GND GND GND 8 1,600 GND OPEN GND GND 16 3,200 OPEN OPEN GND GND 32 6,400 GND GND OPEN GND 64 12,800 OPEN GND OPEN GND ,600 GND OPEN OPEN GND ,200 OPEN OPEN OPEN GND Decimal Microstep Resolution Settings (1.8 Motor) 1,000 GND GND GND 5 OPEN 10 2,000 OPEN GND GND OPEN 25 5,000 GND OPEN GND OPEN 50 10,000 OPEN OPEN GND OPEN ,000 GND GND OPEN OPEN ,000 OPEN GND OPEN OPEN Invalid Resolution Settings : May Cause Erratic Operation GND OPEN OPEN OPEN OPEN OPEN OPEN OPEN Table 7.3: Microstep Resolution Select Settings 1 Bottom View RESOLUTION SELECT 0 RESOLUTION SELECT 1 RESOLUTION SELECT 2 RESOLUTION SELECT 3 SUPPLY GROUND 1 Figure 7.7: MSEL Inputs, Interface Example 45

48 I n t e r f a c i n g t h e F a u l t a n d R e s e t I n p u t s The IM483H/IM805H has a Fault input located at P1:4. This can be used to force a fault condition. When pulled low the signal is latched and the outputs will be disabled. The fault condition can only be cleared by resetting the drive or cycling the power. When interfacing this input, an open collector output or blocking diode is REQUIRED or damage may occur to the internal fault detection circuitry. The IM483H/IM805H also has a Reset Input. On power up, or if the Reset Input is Closed, the internal reset circuit will hold the input low for 100 to 300 milliseconds. The holding time does not begin until the Reset Input is Opened. (See FAULT IN MSEL 0 MSEL 1 MSEL 2 MSEL 3 SCLK DIR ENABLE RESET 1 P1 4.99k Ω 4.99k Ω 4.99k Ω 4.99k Ω 4.99k Ω 2.21k Ω 2.21k Ω 1.27k Ω Bottom View +5V P2 Figure 7.8: IM483H/IM805H Inputs RESET BUTTON Circuit Circuit Open Closes Circuit Open at T=0 Internal Reset Hold Time Starts When Circuit Opens +5 V Milliseconds Figure 7.9: Reset Timing W A R N I N G! When interfacing the FAULT IN/RESET input, an open collector, tri-state output or blocking diode is REQUIRED or damage may occur. (See Figure 7.10.) FAULT IN/RESET INPUT OR INTERFACE CIRCUIT 1N914 OR EQUIVALENT Figure 7.10: Interfacing the Fault In/Reset Inputs FAULT IN /RESET INPUT When controlling multiple drives with a single Reset you must install blocking diodes at the input (Pin 14) of each drive. Because of the slight differences in Reset timing, this will prevent the drives from latching the Reset Input in the LOW state. (See Figure 7.11.) RESET BUTTON 1N914 OR EQUIVALENT 1N914 OR EQUIVALENT 1N914 OR EQUIVALENT UNIT #1 RESET INPUT UNIT #2 RESET INPUT UNIT #3 RESET INPUT Figure 7.11: Multiple Drives - One Reset

49 M i n i m u m C o n n e c t i o n s The following figure and table illustrate the minimum connection requirements for the IM483H and IM805H drivers. IM483H/IM805H Minimum Connections Connector P2 Pin # Pin Name Description 7, 9 Phase A 1, 3 Phase B Phase A output Phase B output 4 G round Supply voltage ground (return ) 5 + V Supply voltage input 6 + 5VDC +5VDC Inpu t Connector P1 1, 2 Current Adjust 10 Direction 9 Step Clock Phase current adjust input Motor direction input Motor step clock input 5-8 MSEL 0-3 Resolution Select Lines Figure 7.9: Minimum Connections IM483H/IM805H Minimum Connections Connector P2 Pin # Pin Name Description 7, 9 Phase A 1, 3 Phase B Phase A output Phase B output 4 G round Supply voltage ground (return ) 5 + V Supply voltage input 6 + 5VDC +5VDC Inpu t Connector P1 1, 2 Current Adjust 10 Direction 9 Step Clock 5-8 MSEL 0-3 Phase current adjust input Motor direction input Motor step clock input Resolution Select Lines Table 7.4: Minimum Connections 47

50 S e c t i o n 8 S e c t i o n O v e r v i e w This section will cover the following: Tr o u b l e s h o o t i n g Basic Troubleshooting Common Problems/Solutions Contacting Application Support Product Return Procedure 24-Month Limited Warranty B a s i c Tr o u b l e s h o o t i n g In the event that your IM483H/IM805H 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 one of our application engineers in determining the problem should you need assistance. Many of the problems that effect motion control systems can be traced to electrical noise, software errors, or mistakes in wiring. P r o b l e m S y m p t o m s a n d P o s s i b l e C a u s e s S y m p t o m Motor does not move. P o s s i b l e P r o b l e m No power. Unit is in a reset condition. Invalid microstep resolution select setting. 48

51 Current adjust resistor is wrong value or not in place. Fault condition exists. Unit is disabled. S y m p t o m Motor moves in the wrong direction. P o s s i b l e P r o b l e m Motor phases may be connected in reverse. S y m p t o m Unit in fault. P o s s i b l e P r o b l e m Current adjust resistor is incorrect value or not in place. Motor phase winding shorted. Power input or output driver electrically overstressed. Unit overheating. S y m p t o m Erratic motor motion. P o s s i b l e P r o b l e m Motor or power wiring unshielded or not twisted pair. Logic wiring next to motor/power wiring. Ground loop in system. Open winding of motor. Phase bad on drive. Invalid microstep resolution select setting. S y m p t o m Motor stalls during acceleration. 49

52 P o s s i b l e P r o b l e m Incorrect current adjust setting or resistor value. Motor is undersized for application. Acceleration on controller is set to high. Power supply voltage too low. S y m p t o m Excessive motor and driver heating. P o s s i b l e P r o b l e m Inadequate heat sinking / cooling. Current reduction not being utilized. Current set too high. S y m p t o m Inadequate holding torque. P o s s i b l e P r o b l e m Incorrect current adjust setting or resistor value. Increase holding current with the current reduction adjust resistor. 50

53 C o n t a c t i n g A p p l i c a t i o n S u p p o r t In the event that you are unable to isolate the problem with your IM483H/ IM805H, the first action you should take is to contact the distributor from whom you originally purchased your product or IMS Application Support at or by fax at Be prepared to answer the following questions: What is the application? In detail, how is the system configured? What is the system environment? (Temperature, Humidity, Exposure to chemical vapors, etc.) What external equipment is the system interfaced to? T h e I M S W e b S i t e Another product support resource is the IMS website located at This site is updated monthly with tech tips, applications and new product updates. R e t u r n i n g Yo u r P r o d u c t t o I M S If Application Support determines that your IM483H/IM805H needs to be returned the factory for repair or replacement you will need to take the following steps: Obtain an RMA (Returned Material Authorization) number and shipping instructions from Customer Service. Fill out the Reported Problem field in detail on the RMA form that Customer Service will fax you. Enclose the product being returned, and the RMA form in the box. Package product in its original container if possible. If original packaging is unavailable ensure that the product is enclosed in approved antistatic packing material. Write the RMA number on the box. The normal repair lead time is 10 business days, should you need your product returned in a shorter time period you may request that a HOT status be placed upon it while obtaining an RMA number. Should the factory determine that the product repair is not covered under warranty, you will be notified of any charges. 51

54 A p p e n d i x A T h e I M H / I M H D e v e l o p e r s K i t S e c t i o n O v e r v i e w This appendix covers the optional developer s kit for the IM483H and IM805H Microstepping Hybrids. (IMS Part Numbers IM483H-DK1 and IM805H-DK1). The Developer s Kit provides all of the tools needed for rapid prototyping and product evaluation by eliminating the need of laying out and testing a PC board and heat sink proofing. The included interface board Figure A.1: IM483H/IM805H-DK1 features an onboard +5V supply, fault protection, opto isolation for logic inputs, and screw terminals for easy prototyping. The inclusion of the interface board schematic provides a useful guide for PC board layout when completing a system design using the IM483H/IM805H Hybrid. Included in the Developer s Kit are: IM483H or IM805H Hybrid Driver. INT-483H/805H Interface Board. HFC-22 Heat Sink/Fan/Clip Assembly. Interface Board Schematic. A s s e m b l i n g t h e I M H / I M H - D K 1 To assemble the IM483H/IM805H-DK1: 1) Placing the heat sink on the driver, align so that the dot on the heat sink is on the same side as the dot on the driver, with the TN-22H thermal pad sandwiched between them. 2) Insert two of the arms from the fan/clip assembly into the corresponding slots in the driver, aligning the curved fingers on the clip between the posts of the heat sink. Insert the other two locking tabs into the opposite slots and snap into place. The locking tabs on all four arms should be completely through the slots on the driver. 3) Plug assembled HFC-22/driver into interface board. 52