Zikodrive ZD10LCD Stepper Motor Controller (Pump Mode) Quick Start Guide and User Manual

Transcription

1 1 Zikodrive ZD10LCD Stepper Motor Controller (Pump Mode) Quick Start Guide and User Manual

2 2 Contents IMPORTANT NOTE.3 Introduction... 4 Overview... 4 Specifications... 5 Components... 6 Top View... 6 Bottom View... 6 Setting Up... 7 Wiring Motor Phase Wires... 7 Power Wires... 7 Using the ZD10LCD... 8 Settings... 8 Modes... 9 Dispense Mode Available Dispense Settings Dose Mode Available Dose Settings Analogue Mode Potentiometer/Analogue Input Digital Inputs Available Analogue Settings Calibration Dry Calibration Wet Calibration Box Header Pin Outs Terms of Sale 23

3 3 IMPORTANT NOTE It is critically important to not exceed the recommended input voltages as this may cause unreparable damage to the Zikodrive ZD10LCD Motor Driver. The max voltage recommended for any digital or analogue inputs is 5Vdc. DO NOT APPLY Higher Voltage PWM as this will damage the board. All wires must be kept as short as possible to reduce EMC emissions from the motor phase cables and to reduce noise on both the analogue and digital inputs. If you require more information regarding good wiring practice please visit and browse our support section.

4 4 Introduction Overview This manual is intended to be used with the Zikodrive ZD10LCD Motor controller running standard firmware (2.0) and includes: Dispensing Mode Dosing Mode Analogue Control Mode The ZD10LCD in Pump Mode has been designed and optimised for stepper motors in pump applications. It will work equally well with peristaltic pumps, gear pumps or any other type of pump provided that it is driven by stepper motors. We are well aware that many companies would prefer to have this controller customised to include custom branding or specific features they require for a particular product. If this is something that you are looking for please visit and follow the links on the homepage to request a customised version of this board.

5 5 Specifications Voltage Range Current Microstep Resolution Pulse Input 0-5Vdc analogue input Onboard speed control Potentiometer Over current protection Over heat protection Reverse Polarity Protection Control Logic Inputs Max RPM Operating ambient temperature Conservation temperature Operating ambient humidity Conservation humidity Type of driver Encoder Feedback Closed Loop Feedback Onboard intelligence Setup and Programming Inputs / Outputs (IOs) Communication Options Screen User Interface 11-35Vdc 0-10A adjustable Up to 128 microsteps Optional 10bit Available Not fitted Enabled Enabled Yes -0.3 to 6Vdc Possible from RPM depending on motor used -40~+50 C - 40~+70 C 35~85% RH (no condensation) 10~90% RH (no condensation) Chopper Mode and PWM mode both available Yes Yes Fully programmable enabling set parameters or specific programmes to be stored and triggered. Standard version available or custom programming/setup by Zikodrive Motor Controllers. 4 Protected Digital Inputs, 3 unprotected digital IOs, 1 analogue input 0-5v analogue input, digital inputs, external hardware, UART, UART over RS232 (UART over RS485 plugin board), 8x2 LCD backlit 4 buttons (settable depending on application requirements)

6 6 Components Top View Bottom View

7 7 Setting Up Wiring Motor Phase Wires Wire up the Motor phase wiring according to the motor manufacturers data sheet. Below is a typical example. If you re not sure please visit for guidance on this. Terminal A2 A1 B1 B2 Wire Green Red Yellow Blue Power Wires 12-30Vdc must be applied to the board on the 2 Way terminal Block Marked GND & Vin. Although the board is protected against reverse polarity, care should be taken to ensure the wires are not reversed. Note Please ensure that the DC power supply has the proper current supply capability. Care should be taken to ensure the DC supply is clean (keep wires as short as possible, and shield where required) as any spikes in supply could damage the board. Once all these connections are complete, the ZD10LCD can be powered up.

8 8 Using the ZD10LCD Settings Once the ZD10LCD has been powered up, the required settings can be programmed into the driver. To access the settings, press and hold the Settings button for at least 2 seconds. Once you have accessed the settings Menu, you need to press the Up button to scroll through the various options. The following Menu items are located within settings: Mode - Selects running Mode Current - Selects Max Phase Current Enter Calibration - Calibration for Dosing and Dispensing Modes (Not available in Analogue Mode) Dose Speed - Selects Dosing Speed (Only available in Dose Mode) Dose Timing - Selects the time interval between doses (Only available in Dose Mode) Dose No. - Selects the number of doses to be performed(only available in Dose Mode) SuckBack - Selects the reversing feature performed on every motor stop (Not available in Analogue Mode) Acce Val - Selects how fast the motor accelerates up to set speed Dece Val - Selects how fast the motor decelerates down to stop Change Dir - Selects main operating direction

9 9 Modes There are 3 Modes that can be used (dispense mode, dose mode and analogue mode): Dispense Mode In dispense mode the controller controls the motor (and therefore pump) in real time. The user interface includes simple commands such as start, stop, reset and more. The screen will display the amount of fluid dosed (once the unit has been calibrated). Dose Mode In dose mode, the user can set the amount of required fluid to be dosed. This can then be repeated for any number of times or modified as required. Time intervals for dose timing are also an option enabling the unit to be preset to continuously dose at fixed intervals as required by the user. Analogue Mode In analogue mode the unit can be controlled by 0-5V external signal input as well as stop/go and CW/CCW direction inputs. It is important to select which mode you are wanting to operate in before attempting to modify any other settings.

10 10 Dispense Mode This is the default mode of the ZD10LCD and is the easiest Mode to use. The Dispense mode can be controlled by using either the onboard buttons or triggered externally through I/O from the Box connector. The default calibration is set to 10mm/rev*. If you are using a standard 1.8 degree stepper motor (200 steps per revolution), and the OK button is pressed, the motor will accelerate from 0 to the pre-set 300RPM 1. The motor will continue running at 300RPM and continue running at this speed until the OK button in pressed again to stop the motor. As the motor is running, the dispensed amount is shown on the screen. To ensure this value is correct, the ZD10LCD must first be calibrated. When the OK button is pressed the motor will decelerate (using the deceleration value ( DECE Val ) to govern the rate of deceleration. This value can be changed in the settings. The motor will then come to a stop while still displaying the dispensed amount as it decelerates. If OK is pressed again the dispensed amount will continue to grow unless the SETTINGS button is pressed in which case the dispensed value will be re-set. The speed can be changed at any time, either while the motor is stationary or when the motor is turning. The OK button can be pressed again at any time to STOP the motor. 1 These values are set as default and can be changed at any time through the settings or with the UP and DOWN buttons.

11 11 Available Dispense Settings Press and hold the SETTINGS button for at least 2 seconds. You will now access the Settings menu. The MODE screen is the first to be displayed. This can be ignored if you want to remain in Dispense mode or select an alternate mode and switch to that part of the ZD10LCD manual. Press the UP button to access the Current settings. The Max PHASE CURRENT for the motor is now displayed. Press the OK button to change the pre-set current setting and press the UP or the DOWN buttons to view the available options. Once the correct current has been selected press the OK button to save the setting. The value required will be shown in your motor data sheet. If the motor current is set too low the there is a possibility the motor will be underpowered, if the current is set too high both the motor and the driver may be permanently damaged and dangerously over heat (if you are unsure please contact us and we will be happy to advise). After pressing the UP button again, you will access the CALIBRATION setting. This setting is discussed in more detail in the CALIBRATION section of this user manual. The SUCKBACK is a feature used to reverse the motor at the end of a dose. This feature prevents fluids remaining in the pump and dripping. The SUCKBACK feature can be set in increments of 0.1 motor revolutions (when 1.8 degree stepper motor is used). The ACCE Val is a value that sets the acceleration value of the motor. The ACCE Val can be set from a value of 1 (slow acceleration) up to No acceleration (instant start). DECE Val is a value that sets the deceleration value of the motor. The DECE Val can be set from a value of 1 (slow deceleration) up to No deceleration (instant stop). The Change Dir is the software direction control of the motor. Ie, if the normal running of the motor is in a clockwise direction, SuckBack will be Counterclockwise, if the Change

12 12 Dir is used the motor will run normally in the Counterclockwise direction with the SuckBack feature running Clockwise. EXIT SETTINGS there are two ways to exit the settings of the ZD10LCD, the firstly by scrolling to the EXIT SETTINGS and pressing the OK button, or at any point (as long as no settings are currently being changed Flashing heading ) the Settings button can be pressed.

13 13 Dose Mode Once this mode has been selected the first screen you will see is below. The Dose mode can be operated via either the onboard buttons or triggered externally through I/O from the Box connector. The default calibration is set to 10mm/rev 2. If you are using a standard 1.8 degree stepper motor (200 steps per revolution) and the OK button is pressed, the motor will accelerate from 0 to the pre-set 300RPM. The motor will continue running at 300RPM, then decelerate and stop after 10 motor revolutions (100ml / 10mm/rev = 10rev). Once the motor has stopped, you can then press OK again to repeat this dose, or you can press either the UP or the DOWN buttons to increase or decrease the required dose amount. The OK button can be pressed again at any time to STOP the motor. Available Dose Settings Press and hold the SETTINGS button for at least 2 seconds. You will now access the Settings menu. The MODE screen is the first to be displayed. This can be ignored if you want to remain in Dose mode or select alternate mode and switch to that part of the ZD10LCD manual. Press the UP button to access the Current settings. The Max PHASE CURRENT for the motor is now displayed. Press the OK button to change the pre-set current setting and press the UP or the DOWN buttons to view the available options. Once the correct current has been selected press the OK button to save the setting. The value required will be shown in your motor data sheet. If the motor current is set too low the there is a possibility the motor will be underpowered, if the current is set too high both the motor and the driver may be permanently damaged and dangerously over heat. If you are unsure on the right setting please contact us and we will be happy to 2 These values are set as default and can be changed at any time through the settings.

14 14 help. After pressing the UP button again, you will access the CALIBRATION setting. This setting is discussed in more detail in the CALIBRATION section of this user manual. The next option is the DOSE SPEED setting. Press the OK button again to enter and edit this speed using the UP and DOWN buttons. The Max speed will be saved once the OK button is pressed. DOSE TIMING is used to select the time between doses (if multiple doses are required). You first need to set the number of required hours, select 0 if anything less than an hour is required. Press OK to proceed to Minutes, again set to 0 of anything less than one minute is required. Then select the total number of seconds needed, select OK to store the timing value or leave on 0 if no repeats are required. Note The time must be set to at least 1sec if multiple doses are required. The DOSE NUMBER is the total number of sequential doses the motor will perform, separated by the DOSE TIMING. This value can be set anywhere from 1 up to 254 cycles, 255 being set as infinite doses. The SUCKBACK is a feature used to reverse the motor at the end of a dose. This feature prevents fluids remaining in the pump and dripping. The SUCKBACK feature can be set in increments of 0.1 motor revolutions (when 1.8 degree stepper motor is used). The ACCE Val is a value that sets the acceleration value of the motor. The ACCE Val can be set from a value of 1 (slow acceleration) up to No acceleration (instant start). DECE Val is a value that sets the deceleration value of the motor. The DECE Val can be set from a value of 1 (slow deceleration) up to No deceleration (instant stop). The Change Dir is the software direction control of the motor. Ie, if the normal running of

15 15 the motor is in a clockwise direction, SuckBack will be Counterclockwise, if the Change Dir is used the motor will run normally in the Counterclockwise direction with the SuckBack feature running Clockwise. EXIT SETTINGS there are two ways to exit the settings of the ZD10LCD, the firstly by scrolling to the EXIT SETTINGS and pressing the OK button, or at any point (as long as no settings are currently being changed Flashing heading ) the Settings button can be pressed.

16 16 Analogue Mode In Analogue Mode the 10Bit analogue input can be accessed through the 12Way box header. The analogue input requires a 0-5V input that is used to control the speed of the motor. In the Analogue Mode, there are also two digital inputs that can be used. A direction control (also connected to the UP button) and a STOP/RUN control (also connected to the OK button). When the Analogue input has a Voltage greater than 0V, the motor will accelerate (using ACCE Val ) from 0RPM up to a speed proportional to the analogue voltage. The proportional value can be set in the Change Anl Res Value accessible through the settings. This enables the speed range controlled by the 0-5V input to be changed according to your project s needs. As the analogue voltage increases and decreases, the ACCE Val and DECE Val values are used between the voltage values. When the STOP/RUN (or OK button) is triggered, the motor will decelerate at the DECE Val to a stop and remain there until the STOP/RUN is released, at which point the motor will accelerate back up to the Analogue value using the ACCE Val acceleration rate. When the Direction (or UP button) is triggered, the motor will decelerate at the DECE Val rate down to a stop, then the motor will change direction and accelerate back up the Analogue value using the ACCE Val acceleration rate.

17 17 Potentiometer/Analogue Input The ZD10LCD board is fitted with a 12 way Box header for all IO. If you are using a potentiometer you will need all three pins in order for the input to work correctly. If you are connecting the ZD10LCD to an external power source, only the GND black wire and analogue input pins are required. Pin Colour Black Yellow Function GND Analogue In Red +5V Digital Inputs These are the digital inputs used only on Analogue Mode Pin Colour Black Blue White Function GND Reverse STOP/GO Available Analogue Settings Press and hold the SETTINGS button for at least 2 seconds. You will now access the Settings menu.

18 18 The MODE screen is the first to be displayed. This can be ignored if you want to remain in Analogue mode. Press the UP button to access the Current setting The Max PHASE CURRENT for the motor is now displayed. Press the OK button to change the pre-set current setting and press the UP or the DOWN buttons to view the available options. Once the correct current has been selected press the OK button to save the setting. The value required will be shown in your motor data sheet. If the motor current is set too low the there is a possibility the motor will be underpowered, if the current is set too high both the motor and the driver may be permanently damaged and dangerously over heat. If you re not sure on this value please contact us and we will be happy to help. The ACCE Val is a value that sets the acceleration value of the motor. The ACCE Val can be set from a value of 1 (slow acceleration) up to No acceleration (instant start). DECE Val is a value that sets the deceleration value of the motor. The DECE Val can be set from a value of 1 (slow deceleration) up to No deceleration (instant stop). The Change Anl Res value allows you to change the speed resolution of the analogue input, therefore allowing the Max Motor speed to be set. For example, if a Low value of 10 is used, the Max speed of the motor is 49.1RPM allowing a speed resolution of 49.1/1024 ~ 0.05RPM. If a Value of 100 is used, the Max speed increases to 460RPM allowing a speed resolution of 0.45RPM. EXIT SETTINGS there are two ways to exit the settings of the ZD10LCD, the firstly by scrolling to the EXIT SETTINGS and pressing the OK button, or at any point (as long as no settings are currently being changed Flashing heading ) the Settings button can be pressed.

19 19 Calibration The calibration value is used in both the Dispense and Dose modes. The calibration must be done prior to accepting any values of fluid measurements. There are two ways to change the calibration values. There is a dry calibration where you can store a new value manually, or a wet calibration where the ZD10LCD will guide you through the calibration procedure. To perform a Dry calibration you will need to press the OK button dictated on the screen by showing the > arrow. To perform a Wet calibration procedure press the Settings button dictated on the screen by showing the < arrow. Dry Calibration Once you have entered the Dry mode, press the UP or DOWM buttons to increase or decrease the value. Once the value has been chosen press the OK button and the screen will inform you that the new Calibration value has been saved. Wet Calibration Once you have entered the WET calibration procedure by pressing the Settings button, the first thing you will be asked is to set the speed. Use the UP and the DOWN buttons to select the required speed. It is recommended that the calibration procedure be performed at the same speed that the motor/pump will be running most of the time with the same equipment layout (Ie, valves, splitters, flow sensors, tube lengths, head height etc...) to ensure the most accurate calibration. Put a beaker on a set of scales for the fluid to be pumped into, ensure the scales are reset to 0

20 20 and that the tube is not touching the beaker. You will then have a screen that says Start?. This screen allows you to start the calibration procedure only once you are sure your set up is correct. If you are sure you are ready to start, press the OK button. The motor will now start turning at the speed set. The screen will now ask if you want it to STOP, when you want the motor to stop, press the OK button again. Once the Motor has stopped, you will then see the following screen asking for the total amount of fluid dosed. Use the UP and DOWN buttons to set the correct value displayed on the scales 3. Press the OK button once the correct value has been entered. You will now be shown the CAL VAL (calibration value). Press OK button again to get to the next screen that will give you the option to either Save, or Discard the new calibration value. Press the OK button again (dictated by using the > arrow) to save the new calibration value, or 3 This calibration has been done with a fluid with the same specific gravity of water. If scales are being used as mentioned above, please ensure the relevant calculations have been performed to ensure the actual amount of fluid dosed is correct.

21 21 press the Settings button (dictated as the < arrow) to discard this new calibration value.

22 22 Box Header Pin Outs

23 23 Terms of Sale Zikodrive Motor Controllers is a registered trademark of Round Bank Engineering Ltd. All Zikodrive Motor Controllers are designed to be a component incorporated within equipment manufactured by our customers and are not suitable for use by an end user. As such, none of our motor controllers are CE marked. It is entirely the buyer s responsibility to ensure that all Zikodrive Motor Controllers and other related products meet the required specification and safety requirements for applications in which they are used. The use of Zikodrive products in safety critical applications is entirely at the buyers risk, and the buyer agrees to defend, indemnify and hold harmless Round Bank Engineering ltd from any and all damages, claims, suits, or expenses resulting from such use. Round Bank Engineering ltd. is not responsible for injury or damage of any kind, including but not limited to, injury, death, damage, property damage/loss or any other type of loss which may arise in whole or in part from the use of Zikodrive Motor Controllers. Returns Policy Subject to the terms provided herein, all returns for exchange, refund or credit must be made within fourteen (14) days from the date of delivery All questions or comments relating to returns should be sent directly to enquiries@zikodrive.com or by calling us direct on +44 (0) In order to qualify for an exchange, refund or credit, the product must be in re-sellable condition, which shall be determined at Zikodrive Motor Controller s sole discretion. Factors affecting the resellable condition of a controller/motor/accessory include, but are not limited to: obvious signs of use or abuse; customer negligence; excessive wear and tear and/or damaged/missing product or parts. Where it is determined, at Zikodrive Motor Controller s sole discretion, that the controller/accessory is, in fact, re-sellable, Customer will be given a full refund or credit for the product, less the cost of shipping. Customer should expect a refund within 30 business days of Zikodrive Motor Controller s receipt of the controller/accessory. CUSTOM PARTS AND PRODUCTS DO NOT QUALIFY FOR REFUND OR CREDIT. Warranty Zikodrive Motor Controllers warrants to the original purchaser that any part of its controller/accessory purchased will be free of defects in workmanship and parts for a period of twelve (12) months from the date of delivery (hereinafter Warranty Period ). During the Warranty Period, Zikodrive Motor Controllers will, at its option: (1) provide replacement parts

24 24 necessary to repair the product; (2) replace the product with a comparable product; or (3) refund the amount Customer paid for the product upon its return. Replacement parts or products will be new or serviceably used, comparable in function and performance to the original part or product, and warranted for the longer of thirty days for the US or the remainder of the warranty period. Any additional purchases or upgrades will not extend this warranty. This product warranty covers normal use only. This product warranty does not cover damage caused during shipment and any damage caused by: actions that are beyond Zikodrive Motor Controller s control, including (but not limited to) impacts, fluids, fire, flood, wind, earthquake, lightning or similar disaster, war, lockout, epidemic, destruction of production facilities, riot, insurrection, or material unavailability; unauthorized modifications, attachments or peripherals; improper use, environment, installation or electrical supply; improper maintenance; any other misuse, abuse or mishandling. EXCEPT FOR THE WARRANTIES EXPRESSED IN THIS AGREEMENT, ZIKODRIVE MOTOR CONTROLLERS DISCLAIMS ALL OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, INCLUDING IMPLIED WARRANTIES OF MERCHANT ABILITY OR FITNESS FOR A PARTICULAR PURPOSE, OTHER THAN THOSE WARRANTIES IMPLIED BY AND INCAPABLE OF EXCLUSION, RESTRICTION OR MODIFICATION UNDER THE APPLICABLE LAW. THE TERM OF ANY IMPLIED WARRANTIES THAT CANNOT BE DISCLAIMED ARE LIMITED TO THE TERM OF THIS AGREEMENT.