Leadshine DM860 - User Manual

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Summary

Introduction, Features and Applications

Introduction

Provides an overview of the DM860 digital stepper drive and its advanced DSP control algorithm.

Features

Highlights key features like anti-resonance, multi-stepping, wide voltage/current range, and protections.

Applications

Details suitable applications for machines requiring precision, low noise, and low heating.

Specifications

Electrical Specifications

Lists electrical parameters such as output current, input voltage, logic signal current, and pulse characteristics.

Operating Environment and other Specifications

Covers cooling, ambient/operating temperature, humidity, vibration, and weight.

Mechanical Specifications

Presents dimensional drawings and mounting details for the DM860 driver unit.

Elimination of Heat

Offers recommendations for managing driver and motor temperatures and improving heat dissipation.

Pin Assignment and Description

Connector P1 Configurations

Describes the pin functions for PUL, DIR, and ENA control signals on the P1 connector.

Connector P2 Configurations

Details the pin functions for power and motor connections on the P2 connector.

Control Signal Connector (P1) Interface

Connecting the Motor

Connections to 4-lead Motors

Provides wiring instructions for 4-lead motors and output current setting guidance.

Connections to 6-lead Motors

Covers half coil (speed) and full coil (torque) configurations for 6-lead motors.

Connections to 8-lead Motors

Details series and parallel connection methods for 8-lead motors.

Power Supply Selection

Regulated or Unregulated Power Supply

Discusses the pros and cons of regulated vs. unregulated power supplies and current ratings.

Multiple Drivers

Guidance on sharing a power supply for multiple drivers and preventing interference.

Selecting Supply Voltage

Advises on choosing the correct supply voltage for optimal performance and safety.

Selecting Microstep Resolution and Driver Output Current

Microstep Resolution Selection

Details DIP switch settings (SW5-SW8) for selecting microstep resolution.

Dynamic Current Setting

Explains DIP switch settings (SW1-SW3) for selecting the peak operating current.

Standstill Current Setting

Covers the use of SW4 for setting the current when the motor is idle.

Sequence Chart of Control Signals

Frequently Asked Questions

Problem Symptoms and Possible Causes

A troubleshooting guide linking common symptoms to potential causes and solutions.

Summary

Introduction, Features and Applications

Introduction

Provides an overview of the DM860 digital stepper drive and its advanced DSP control algorithm.

Features

Highlights key features like anti-resonance, multi-stepping, wide voltage/current range, and protections.

Applications

Details suitable applications for machines requiring precision, low noise, and low heating.

Specifications

Electrical Specifications

Lists electrical parameters such as output current, input voltage, logic signal current, and pulse characteristics.

Operating Environment and other Specifications

Covers cooling, ambient/operating temperature, humidity, vibration, and weight.

Mechanical Specifications

Presents dimensional drawings and mounting details for the DM860 driver unit.

Elimination of Heat

Offers recommendations for managing driver and motor temperatures and improving heat dissipation.

Pin Assignment and Description

Connector P1 Configurations

Describes the pin functions for PUL, DIR, and ENA control signals on the P1 connector.

Connector P2 Configurations

Details the pin functions for power and motor connections on the P2 connector.

Control Signal Connector (P1) Interface

Connecting the Motor

Connections to 4-lead Motors

Provides wiring instructions for 4-lead motors and output current setting guidance.

Connections to 6-lead Motors

Covers half coil (speed) and full coil (torque) configurations for 6-lead motors.

Connections to 8-lead Motors

Details series and parallel connection methods for 8-lead motors.

Power Supply Selection

Regulated or Unregulated Power Supply

Discusses the pros and cons of regulated vs. unregulated power supplies and current ratings.

Multiple Drivers

Guidance on sharing a power supply for multiple drivers and preventing interference.

Selecting Supply Voltage

Advises on choosing the correct supply voltage for optimal performance and safety.

Selecting Microstep Resolution and Driver Output Current

Microstep Resolution Selection

Details DIP switch settings (SW5-SW8) for selecting microstep resolution.

Dynamic Current Setting

Explains DIP switch settings (SW1-SW3) for selecting the peak operating current.

Standstill Current Setting

Covers the use of SW4 for setting the current when the motor is idle.

Sequence Chart of Control Signals

Frequently Asked Questions

Problem Symptoms and Possible Causes

A troubleshooting guide linking common symptoms to potential causes and solutions.

The DM860 is a fully digital 2-phase microstep driver designed for controlling stepping motors. It incorporates an advanced DSP control algorithm, leveraging the latest motion control technology to deliver smooth motor movement, optimal torque, and effective nullification of mid-range instability. This makes it a superior alternative to traditional analog drives, offering significantly lower noise, reduced heating, and smoother operation. The DM860 is particularly well-suited for applications demanding high precision, high speed, low noise, and minimal heating.

Function Description

The DM860 driver is designed to interface with a controller (pulse generator) and a stepping motor, along with a power supply, to form a complete stepping system. It accepts control signals from the controller and translates them into precise current pulses to drive the motor. The driver supports both 2-phase and 4-phase hybrid stepping motors, making it versatile for various motor types.

Key functional features include:

Anti-Resonance: This feature optimizes torque output and eliminates mid-range instability, ensuring stable and efficient motor operation across different speeds.
Multi-Stepping: The DM860 can convert low-resolution step inputs into higher microstep outputs. This capability results in smoother motor movement, reducing vibrations and improving overall system performance.
Microstep Resolution Selection: The driver offers a wide range of selectable microstep resolutions, allowing users to fine-tune the motor's step angle for specific application requirements. This is configured via DIP switches.
Current Control: The DM860 provides selectable peak current settings, enabling users to match the driver's output current to the motor's specifications. This is crucial for achieving optimal torque and preventing motor overheating.
Automatic Idle-Current Reduction: This intelligent feature automatically reduces the motor current when the motor is at a standstill. This significantly reduces both motor and driver heating, improving efficiency and extending component lifespan.
Protection Functions: To enhance reliability and prevent damage, the DM860 includes built-in over-voltage and over-current protections. These safeguards automatically activate if the peak current exceeds limits or if the drive working voltage becomes too high.
Optically Isolated Inputs: The control signal inputs (PUL, DIR, ENA) are optically isolated. This isolation minimizes or eliminates electrical noise coupled onto the drive control signals, improving noise immunity, especially in environments with interference.
Pulse/Direction Control: The driver operates in a single pulse (pulse/direction) mode, where a pulse signal dictates movement and a direction signal determines the motor's rotation. An enable signal allows for activating or deactivating the driver.

Usage Features

The DM860 is designed for ease of use and flexibility in various applications:

Wide Motor Compatibility: It is suitable for a broad range of stepping motors, from NEMA size 17 to 42, making it adaptable for different machine sizes and power requirements.
Application Versatility: The driver can be integrated into various machines, including X-Y tables, engraving machines, labeling machines, laser cutters, and pick-place devices.
DIP Switch Configuration: Microstep resolution and current settings are easily configured using an 8-bit DIP switch, providing a straightforward method for customization without complex software.
Motor Connection Flexibility: The DM860 supports 4-lead, 6-lead, and 8-lead motors. For 6-lead motors, users can choose between half-coil (higher speed) or full-coil (higher torque) configurations. For 8-lead motors, both series (higher torque at lower speeds) and parallel (more stable, higher torque at higher speeds) connections are supported, offering a high degree of flexibility to system designers.
Power Supply Selection: Both regulated and unregulated power supplies can be used. Unregulated power supplies are generally preferred due to their ability to withstand current surges. The manual provides guidance on selecting appropriate supply voltages to optimize high-speed performance, reduce noise, and manage heating.
Multiple Driver Support: Multiple DM860 drivers can share a single power supply, provided the supply has sufficient capacity. This helps reduce overall system cost. It is recommended to connect each driver separately to the power supply to avoid cross-interference.
Control Signal Interface: The DM860 can accept differential and single-ended inputs (open-collector and PNP output), accommodating various controller types.

Maintenance Features

Proper installation and adherence to wiring guidelines are crucial for the longevity and reliable operation of the DM860:

Heat Dissipation: Effective heat management is vital. The driver's reliable working temperature should be below 70°C (158°F), and the motor's working temperature below 80°C (176°F).
- Automatic Idle-Current Mode: Utilizing the automatic idle-current reduction feature is highly recommended. This reduces current to 50% when the motor stops, significantly decreasing driver and motor heating.
- Mounting Orientation: Mounting the driver vertically maximizes the heat sink area, aiding in natural cooling. For systems with higher heat loads, forced cooling methods (e.g., fans) may be necessary.
- Side Mounting: The manual specifically recommends using side mounting for better heat dissipation.
Wiring Recommendations:
- Twisted Pair Shield Cable: To improve anti-interference performance, using twisted pair shield cables for wiring is recommended.
- Signal Separation: Pulse/direction signal wires and motor wires should be kept separate, ideally by at least 10 cm. This prevents disturbing signals from the motor from interfering with control signals, which could lead to motor position errors or system instability.
- Power Supply Connections: When multiple drivers share a power supply, connect each driver separately to the supply rather than daisy-chaining them to prevent cross-interference.
- Hot-Plugging Prohibition: It is strictly prohibited to connect or disconnect the motor (connector P2) while the driver is powered ON. High currents flowing through the motor coils, even at standstill, can generate extremely high back-EMF voltage surges, potentially damaging the driver.
Troubleshooting: The manual includes a comprehensive section on frequently asked questions and problem symptoms with possible causes. This aids in diagnosing issues such as the motor not rotating, rotating in the wrong direction, erratic motion, stalling, or excessive heating.
- Systematic Diagnosis: When a problem occurs, the first step is to determine if it's electrical or mechanical. Then, isolate the faulty component by testing individual parts. Documenting each step is important for future reference and for technical support.
- Resetting Protections: If over-current or over-voltage protections are activated (indicated by a blinking red LED), the motor shaft will be free. The driver can be reset by repowering it after resolving the underlying problem.
Current Setting Considerations: Due to motor inductance, the actual current in the coil might be lower than the dynamic current setting, especially at high speeds. This should be considered when setting the current to ensure optimal performance without overheating.

Leadshine DM860 Specifications

General

Control Method	Pulse/Direction
Protection Features	Over-voltage, Over-current
Pulse Input Frequency	up to 200 kHz
Logic Signal Current	7-16mA
Storage Temperature	-20°C to +70°C
Control Signal	Pulse and direction
Humidity	90% non-condensing