MS483 MICROSTEPPING DRIVE

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1 Specialists in custom precision motion control MS483 MICROSTEPPING DRIVE High Performance, customizable microstepping drive. Vertex Linears MS483 is a high performance, low cost microstepping drive that incorporates advanced surface mount and ASIC technology. The MS483 is small, easy to interface and use, yet powerfull enough to handle the most demanding applications.

2 About Us Founded in 1956, Vertex Linears has always brought the latest technologies to the marketplace. Through the years, customers have come to count on us for honest, practical answers and the most cost-effective solutions to their electro-mechanical needs.as specialists in high-tech markets such as semiconductor Capital Equipment, medical equipment, aerospace, and robotics, we provide a multitude of components, both mechanical and electrical, to address all your motion control needs. Our Team Our two California offices are staffed with sales and engineering professionals ready to respond to your design requirements as well as provide you with technical and sales information. The Northern California office is situated near the heart of Silicon Valley. Our Southern California warehouse and headquarters (3rd Party Certification to ISO 9001 and ISO 13485) is located in Aliso Viejo, Orange County. Functioning as an authorized distributor, we offer immediate deliveries of many specialty items, including one of the largest linear motion bearing inventories in the country. Matching quality parts to your specifications is our prime interest. Backing those products with engineering support and superior service reaffirms our long-time commitment to customer satisfaction. Contact us for all your electro-mechanical requirements. See for yourself why Vertex Linear has earned a reputation for high-quality MS483 Vertex Linears MS483 Microstepping drive is a from-the-ground-up stepper motor controller design and uses multiple proprietary techniques to run a stepper motor smoother, quieter and with more power than other drives in its price range. This document seeks to quickly get your MS483 up and running and will explain each new feature and its utility for your application. MS483 Key Features Push Button Self-Test User adjustable standby current Resolution upscaling at low speeds High and Low power pinout connectors Electrical Ratings: 8A Continuous / 80 VDC Max Form, fit, and function compatibility with IM483 and IM805 Midband instability and resonance is compensated for using all new algorithms, eliminating resonant frequencies at the midband Ranging from half-step to 256-microstep resolution, a stepper motor can be run with resolution of up to 51,200 pulses per revolution Backwards compatibility with decimal resolution motor controls 2

3 MS483 Microstepping drive There are two connectors on the MS483: A high power connector for motor and power supply connections called CN1 and a low power signal connector for I/O called CN2. The pinouts from left to right while facing the connector are below: Physical Dimensions and Pinout PIN NUMBER CN1 CN2 PIN 1 STANDBY OPTOISOLATOR GROUND PIN 2 CURRENT SET STEP PIN 3 GROUND DIRECTION PIN 4 SUPPLY DC+ OPTOISOLATOR +5V PIN 5 PHASE / B ENABLE PIN 6 PHASE B RESET PIN 7 PHASE / A FAULT PIN 8 PHASE A FULL STEP OUT Mechanical Drawing 3

4 Applying Power POWER SUPPLY HOOK UP CN1 PIN 4 POWER GROUND, CONNECT THE POWER SUPPLY GROUND TO THIS TERMINAL CN1 PIN 5 POWER (+), CONNECT THE POWER SUPPLY + TO THIS TERMINAL The power supply voltage must be between 18 VDC and 80 VDC. The maximum power supply current required is 67% of the motor s rated phase current. An unregulated power supply may be used as long as the voltage stays between the limits; keep the ripple voltage to 10% or less for best results. The drive has a 2 second power-on reset time before the motor is energized. CAUTION! Power supply voltage in excess of 80 VDC will damage the MS483. The choice of power supply voltage depends on the high speed performance required of the motor; doubling the voltage doubles voltage greater than 25 times the motor s rated voltage will overheat and damage the motor, even if it is not turning. Motor winding inductance should be 500uH or greater, but generally no more than 7mH for best performance. A practical limit for stepper motors is 50mH. A more accurate calculation of maximum power supply voltage is to find your motor s inductance, and put it into the following equation. 32 * ( mh inductance) = Power Supply Voltage If your motor has 2mH of inductance, the equation would look as follows. 32 * ( 2) = 45.12V That motor s maximum power supply would be 45VDC. All power supply voltages below that limit will work without unnecessarily heating the motor. Motor Connection PIN DESCRIPTION CN1 PIN 5 PHASE /B CONNECT ONE MOTOR WINDING TO THIS TERMINAL CN1 PIN 6 PHASE B CONNECT THE OTHER END OF THE WINDING TO THIS TERMINAL CN1 PIN 7 PHASE /A CONNECT THE OTHER MOTOR WINDING TO THIS TERMINAL CN1 PIN 8 PHASE A CONNECT THE OTHER END OF THE WINDING TO THIS TERMINAL

5 Motor Connection Cont. Connect one motor winding to terminals 5 and 6. Connect the other winding to terminals 7 and 8. Turn the power supply off when connecting or disconnecting the motor. If the motor turns in the wrong direction, reverse the motor winding connections to terminals 5 and 6. 4-wire, 6-wire and 8-wire motor may be used. When 6-wire motors are used, they may be connected in half winding or full winding. This is equivalent to an 8-wire motor connected in parallel or series. If a motor is connected in series or full winding, the motor s phase current rating is half of its parallel or unipolar rating. The choice depends on the high-speed performance required; a parallel-connected motor will provide twice the power of a series-connected motor at the same power supply voltage. Setting Motor Phase Current Motor phase current may be set one of three ways: The onboard DIP switches, an external current set resistor or an external voltage input. All current settings will be in reference to the single phase peak current of the stepper motor. ONBOARD DIP SWITCH SETTING Please consult the diagram below for the proper switch setting for your motor phase current. Leave CN1 PIN2 floating if this option is being used. RESOLUTION TBD TBD SW1 SW2 SW3 SW4 LEGEND ON = OFF = CURRENT SW5 SW6 SW7 SW8 SW9 SW10 CURRENT SW5 SW6 SW7 SW8 SW9 SW10

6 External Current Set Resistor An external current set resistor can be used, which will be connected between CN1 PIN 2 (Current Set) and CN1 PIN 3 (GND). The formula for the current set resistor is below: RI = IPEAK x 500 For a 3.2A motor the equation would look like below: RI = 3.2 x 500 RI = 1600 This would mean a 1.6K resistor would be the calculated resistance value. If the calculated resistance is a nonstandard value, it is safe to use the closest 5% resistor that is less than the calculated value. For instance, a 4.6A motor would need a 2.3K resistor; the nearest 5% value is a 2.2K resistor which would result in roughly 96% of the motor s rated current (4.4A). The resistor leads should be kept as short as possible to prevent noise problems. External Voltage Input Some applications may require that current be controlled by an external voltage, either from a microcontroller or a discrete circuit. In order to do this you can calculate the required voltage by using the formula below: FORMULA For a 3.2A motor the equation would look like below: VIN = 3.2 x WHATEVER VIN = VOLTAGE It is not recommended to change operating current to less than 70% of the motor s rated current. Although no damage will come to the motor or the MS483, there will be inconsistent performance from the motor due to insufficient winding saturation. Setting Standby Current After the MS483 has not received step pulses for one second it will enter standby mode, where it will limit current to a user-set percentage of maximum current. The MS483 will enter reduced-heating switching mode during this time to further decrease motor temperature during times of inactivity. There are two ways to set the standby current value.

7 Onboard Standby Trimpot One of the two trimpots on the MS483 is dedicated to setting the standby current value. Turning this fully CCW (8 o clock) will reduce current to 0% of the set value, while turning it fully CW (4 o clock) will set the standby current to 100% of set current. This trimpot is a single turn component with a total range of approximately 270 of motion. A diagram of the adjustment trimpot is below: External Standyby Resistor An external resistor can be used to set the standby current on the MS483 in lieu of using the onboard trimpot. If any method of current set but the DIP switch is used then this is the mandatory way of setting standby current. This resistor will be placed between CN1 PIN 1 (Standby Set) and CN1 PIN 3 (GND) The formula for the resistor is below: R2 = 500 * (Run Amps * Standby Amps) / (Run Amps Standby Amps) If a motor is rated for 6A and a standby current of 2A is required, the formula would be worked out as below: R2 = 500 * (6A * 2A) / (6A 2A) R2 = 500 * 12 / 4 R2 = 1500 In this example you would want to use a 1.5K resistor between CN1 PIN 1 (Standby Set) and CN1 PIN 3 (GND). Component tolerance for this setting can be 5%, so the nearest 5% resistor value to the calculated value is acceptable. As with the current set resistor, the component leads should be kept as short as possible to prevent noise problems.

8 Push-Button Self-Test to Verify Motor Connections Once the motor is connected to the MS483 power may be applied to the drive. The motor should have holding torque (resist being rotated by hand) and the green indicator LED should be blinking. You may now begin self-test and tuning. In order to use the onboard self-test you will need to locate the button near TRIM1. The button should be pushed with either a finger (without the cover) or with a blunt nonconductive rod (like a ceramic screwdriver or plastic dowel). As long as the button is depressed the motor will move one revolution CW and one revolution CCW; the speed of the motor is such that you can use it to tune out any low speed vibration with the ADJUST trimpot. With the motor tuned and verified to run correctly, you may move on to the fourth and final step to getting the drive to run. CONNECTING STEP AND DIRECTION SIGNALS CN2 PIN 1 CN2 PIN2 CN2 PIN3 CN2 PIN4 Signal GND This pin is optional. This pin must connect to the controller ground terminal if the drive s FAULT a nd FULL-STEP outputs are going to be used; otherwise it can be left unconnected. Step This input pin connects to the controller s STEP output. The input accepts 3.3V and 5V logic level signals; if 3.3V logic is used, a 3.3VDC supply voltage from the controller must be connected to Pin 4. The maximum step pulse frequency is 2.5 MHz, the minimum logic 0 time is 200ns and the minimum logic 1 time is 200ns. The STEP input current is -2.5 ma with 3.3V logic and -5 ma when 5V logic is used. Stepping occurs on the positive going edge of the STEP input. Direction This input pin connects to the controller s DIRECTION output. The input accepts 3.3V and 5V logic level signals; if 3.3V logic is used, a 3.3VDC supply voltage from the controller must be connected to Pin 4. The minimum setup time is 0ns and the minimum hold time is 500ns. The DIRECTION input current is -2.5mA with 3.3V logic and -5mA when 5V logic is used. Common This pin connects to the controller s +5VDC supply terminal if 5V logic is used or a +3.3VDC supply terminal if 3.3V logic signals are used. The maximum current draw from the supply is 15mA at +5VDC or 8mA at +3.3VDC. The absolute maximum voltage limits to this pin is -0.3VDC and +6VDC.

9 Understanding Inputs STEP, DIRECTION, COMMON, FAULT, AND ENABLE All control inputs on the MS483 are optoisolated for protection. The user may connect +3.3VDC or +5VDC to control supply inputs and the maximum current draw will be 15mA on all inputs. An explanation for each input is below: RESET: This pin is optional. This pin connects to the controller s RESET output; otherwise it can be left unconnected. A logic 1 on this pin allows the drive to run the motor if the ENABLE input is a logic 1 or unconnected. A logic 0 resets the drive s internal microstep counter to zero, phase A off and phase B on. The RESET input should be used if it s necessary to have an emergency stop input. Cycling the RESET input (hold at logic 0 for one second, then at logic 1 ) also clears latched fault conditions such as short-circuit and over-temperature protection provided the triggering cause has been cleared. If no latched faults exist, the minimum RESET logic 0 time is 20us. ENABLE: Freewheels motor and stops all motor switching when a logic 0 is applied. The motor will have no holding torque and can be manually manipulated. Upon a logic 1 being applied the MS483 will move the motor to the nearest full step location. STEP: A step pulse frequency is applied to this input to move the motor. The frequency and speed will depend on the microstep resolution chosen. The maximum frequency input is 2.5 MHz, allowing for a maximum speed of 2,929 RPM at the highest resolution of the MS483. A chart for pulses per revolution on a standard 1.8 degree stepper motor is below. Binary Resolutions Pulses Per Revolution , , , , , , , , , , , ,200

10 Understanding Inputs Cont. DIRECTION: When a logic 0 is applied the MS483 will move clockwise. When a logic 1 is applied the MS483 will move counter clockwise. This input is a non-latching input and must be held at the desired logic level for as long as the motor must move that direction. Understanding Outputs The two outputs on the MS483, FULLSTEP and FAULT, are covered below. EXPLAINATION OF FEATURES Sub-Microstepping: At certain microstep resolutions the MS483 will interpolate microsteps between rougher resolution choices. This means that the motor will move with the smoothness of a higher resolution option but will still have the lower input frequency requirement of the selected resolution. When operating in 2uStep, 4uStep and 8uStep modes the drive will interpolate to 16uStep motor smoothness. When operating at 5uStep the MS483 will interpolate to 10uStep smoothness. Higher levels of interpolation have significantly diminished returns, which is why this affects only lower resolution choices. Resonance Compensation: Using an entirely new method of motor control allows the MS483 to eliminate nearly all resonance. The two-tier system the drive uses eliminates resonance at the 1st and 2nd harmonic and at the midband, increasing torque and motor stability in unstable step motor regions. Full Step Morphing: The MS483 has full step morphing. Between 3 6 RPS the drive will morph from microstepping to a true full step output to the motor, increasing high speed motor torque by 40% over a microstepping only driver. This requires no input from the user and the drive will not need any modifications in the software controlling it to take advantage of this. Soft Start: Step motors without a soft start drive operating them can draw significant inrush current. The MS483 ramps up current to the motor to avoid startup noise and premature tripping of protection circuitry due to sudden current loads. Spread Spectrum PWM: Most stepper controls have a fixed switching frequency which leads to motor harmonics and large EMI outputs. With spread spectrum PWM the MS483 switches randomly between switching frequencies at every step, eliminating harmonic knocking and EMI interference. Self-Test: A push button is used on the MS483 to allow for quick in-the-field testing of the drive s core functionality. With a motor and power supply connected correctly the motor will turn at 1 RPS clockwise and counter-clockwise as long as the button is held down. This button input will take priority over all other input signals, meaning if STEP and DIRECTION are connected and the button is held down the MS483 will move in self-test mode.

11 Protection Circuitry: The MS483 has rugged protection features to prevent damage in the majority of catastrophic events. It is protected against short-circuit, under-voltage, over-voltage, and over-temperature. The protection circuit will also detect an open motor phase and an unconnected motor. To clear a FAULT state the RESET input must be cycled to logic 0 for one second and then returned to a floating or logic 1 state. MS483 Featured Manual Data Electrical: 0 to 7 Amps per phase +18 to +80 VDC power supply range 15 Watt drive heat dissipation at 7 Amps per phase Current Set: Phase current set via external resistor (500 Ohms per Amp) or internal DIP switch Standby current set via external resistor or internal trimpot (0 to 100%) Standby uses reduced motor heating switching mode Test: Self test push-button runs motor 1 revolution CW / CCW (no STP/DIR input needed) Detect and Protection: Short-circuit detect and protection; cleared by cycling RESET input Under-voltage detect and protection Over-temperature detect and protection Fuse protection on power supply input Open motor phase detect* No motor detect* Indicators: Blown power fuse indicator LED 2 indicator LEDs (green and red) can show up to 10 different drive conditions* Control Outputs: All control outputs are opto-isolated and CMOS buffered Outputs are compatible 5VDC and 3.3VDC logic Zero microstep state on FULL-STEP output FAULT output indicates errors; can be set as 4800 baud TTL-level UART*

12 MS483 Featured Manual Data Cont. Mechanical: Drive dimensions are 3.00" W, 2.75" D, 0.75" H Drive dimensions are 76.2mm W, 69.9mm D, 19.1mm H Mounting hole pattern is 2.42" W, 2.45" D, 0.2" diameter, 4 places Mounting hole pattern is 61.5mm W, 62.2mm D, 5mm diameter, 4 places Modular 10 Amp rated terminal block connectors (5mm or optional 0.2" pitch)* Environmental: 0C to 75C operating temperature Humidity 0 to 95%, non-condensing *Not implemented yet Please see the Motor Wiring Guide for how to connect 6-wire and 8-wire motors to the drive. Please use a multimeter to verify there is continuity between pins 5 and 6, then pins 7 and 8 before powering up the drive. Control Interface Connector NOTE: All 8 pins on this connector are optoisolated and there is no galvanic connection from them to the drive. PIN 1 GND: This pin is optional. This pin must connect to the controller ground terminal if the drive s FAULT and FULL-STEP outputs are going to be used; otherwise it can be left unconnected. PIN 2 STEP: This input pin connects to the controller s STEP output. The input accepts 3.3V and 5V logic level signals; if 3.3V logic is used, a 3.3VDC supply voltage from the controller must be connected to Pin 4. The maximum step pulse frequency is 2.5 MHz, the minimum logic 0 time is 200ns and the minimum logic 1 time is 200ns. The STEP input current is -2.5 ma with 3.3V logic and -5 ma when 5V logic is used. Stepping occurs on the positive going edge of the STEP input. PIN 3 DIRECTION: This input pin connects to the controller s DIRECTION output. The input accepts 3.3V and 5V logic level signals; if 3.3V logic is used, a 3.3VDC supply voltage from the controller must be connected to Pin 4. The minimum setup time is 0ns and the minimum hold time is 500ns. The DIRECTION input current is -2.5mA with 3.3V logic and -5mA when 5V logic is used. PIN 4 +5VDC: This pin connects to the controller s +5VDC supply terminal if 5V logic is used or a +3.3VDC supply terminal if 3.3V logic signals are used. The maximum current draw from the supply is 15mA at +5VDC or 8mA at +3.3VDC. The absolute maximum voltage limits to this pin is -0.3VDC and +6VDC.

13 PIN 5 ENABLE: This pin is optional. This pin connects to the controller s ENABLE output; otherwise it can be left unconnected. A logic 1 on this pin enables the drive and allows it to operate the motor. The drive is disabled when a logic 0 is applied to this pin. During disable, the motor current goes to zero, freewheeling the motor and all switching activity stops on the motor connections. The internal microstep counter retains its contents while disabled. PIN 6 RESET: This pin is optional. This pin connects to the controller s RESET output; otherwise it can be left unconnected. A logic 1 on this pin allows the drive to run the motor if the ENABLE input is a logic 1 or unconnected. A logic 0 resets the drive s internal microstep counter to zero, phase A off and phase B on. The RESET input should be used if it s necessary to have an emergency stop input. Cycling the RESET input (hold at 0 for one second, then 1 ) also clears latched fault conditions such as short-circuit and over-temperature protection provided the triggering cause has been cleared. If no latched faults exist, the minimum RESET logic 0 time is 20us. PIN 7 FAULT: This pin is optional. The controller ground must be connected to pin 1 if this output is used. The totem-pole output is a logic 0 if a short-circuit or over-temperature FAULT exists. Optionally the FAULT output can operate as a TTL level UART output to indicate other drive conditions such as missing motor connectivity to phase A or B, standby or run state, motor direction, short-circut, over-temperature and other information about the state of the drive. The UART is 9600 Baud, 8-bit data, single stop bit, no parity, Tx only. The UART sends a single status byte that updates continuously. PIN 8 FULL-STEP: This pin is optional. The controller ground must be connected to pin 1 if this output is used. The FULL-STEP totem-pole output is a logic 0 when the motor is at a full-step location, otherwise the output is a logic 1. Onboard Switches, Trimpots and LED Indicators SELF TEST BUTTON: The motor will continuously turn 1 revolution CW and CCW at 1 revolution per second using 256 microstep resolution while the SELF TEST switch is depressed. The STEP, DIRECTION, ENABLE, RESET inputs and the microstep resolution DIP switch settings are ignored and the while the SELF-TEST switch is pushed. The motor will return to its original position when the SELF TEST switch is released. STANDBY CURRENT SET: This trimpot setting only applies when no external current set resistors are used. The trimpot setting is a percentage of the DIP switch RUN CURRENT settings. A fully CCW trimpot makes the standby current 0%, half-scale is 50% and a fully CW setting makes the standby current 100% of the RUN current DIP switch settings. This is fully covered in the MOTOR/POWER CONNECTOR, Pin 2 section of this manual. LOW-SPEED RESONANCE COMPENSATION: Most step motors will vibrate at some speed between 1 to 3 revolutions per second.

14 CONFIGURATION DIP SWITCHES: These 10 switches are used to set the drive s microstep resolution (SW1 to SW4) and set the RUN current for the motor (SW5 to SW10). Please see the Quick Start guide for the MICROSTEP RESOLUTION and MOTOR CURRENT SETTINGS tables. INDICATOR LED 7, 8: Indicator 7 is a green LED and indicator 8 is a red LED. These two indicators work together to generate a blink code to display up to 10 different drive conditions and faults. The LEDs blink 3 times, pause and repeat (green blink = GRN, red blink = RED). The assigned blink codes are: LED Indicators CONTINUOUS GREEN: The motor is running GRN - GRN - GRN - PAUSE: The motor is stopped GRN - GRN - RED - PAUSE: Winding A is not connected GRN - RED - GRN - PAUSE: Winding B is not connected GRN - RED - RED - PAUSE: No motor connected to drive RED - RED - RED - PAUSE: Over-temperature shutdown CONTINUOUS RED: Short-circuit shutdown INDICATOR LED 9: The drive has an internal ultra fast blow fuse. Conditions that will blow the fuse are power supply over-voltage, reversed power supply polarity, spilled liquids, conductive foreign object contamination and some short-circuit conditions. The indicator LED will light when power is applied if the fuse is blown. Replace the fuse only with MXL. Using any other type of fuse or jumpering the fuse with wire will void the drive s warrantee. DC SPECIFICATIONS: Min Typ Max Power Supply Voltage +18 VDC VDC Output Phase Current 0 Amps Amps Quiescent Current - 20 ma Dissipation (no motor) 0.36 W at 18V W at 80V Dissipation (with motor) 1.8 W at 1A 4.5 W at 3.5A 14 W at 7A Current per I/O Input 2.5 ma at 3.3V - 5 ma at 5V Current per I/O Output - +/-24 ma - - Control I/O Supply Voltage Control I/O Supply Current Control I/O Opto Isolation +3VDC VDC 1 ma ma +/-500 V - - -

15 TIMING SPECIFICATIONS: Min Typ Max Step Pulse Frequency 0 Hz MHz Step Pulse '0' Time 200ns - - Step Pulse '1' Time 200ns - - Step Pulse Active Edge '0' to '1' - - Direction Setup Time 0 ns - - Direction Hold Time 500 ns - - Reset/Run Delay Time us Enable/Disable Delay Time us Fault Delay Time us Full-Step Delay Time us Motor Speed 0 RPM - 6,000 RPM THERMAL SPECIFICATIONS: Min Typ Max Storage Temperature -40 C C Operating Temperature 0 C C Thermal Shutdown - 85 C -

16 Specialists in custom precision motion control Vertex Linears specialises in high-tech markets such as semiconductor fabrication equipment, medical equipment, aerospace, and robotics, we provide a multitude of components, both mechanical and electrical, to address all your motion control needs. Call us at Custom Solutions Contract Manufacturing Motion Control Machine Automation Linear Motion Sensors Safety Bearings and Hardware Visit Vertex Linears online store to purchase actuators, linear stages, motors, drives, and linear components. VLMS483.V01.0 VERTEX LINEAR 21 Argonaut Aliso Viejo, CA 92656