Intelligent Motion Systems MFM Motion Detector Operating Instructions Manual

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. TM Microstepping MForce PowerDrive Product Manual Revision R032008 Copyright © Intelligent Motion Systems, Inc. All Rights Reserved Microstepping MForce PowerDrive Product Manual Changelog Date Revision Changes 04/05/2007 R040507 Initial Release 03/20/2008 R032008 Added CW/CCW to the list of clock option labels for the differential input version. Functionality is the same as the up/down clock type. Added qualification os personnel and intended use statements to inside front. Added PWM Motor Settings to Section 2.6.

state of the art in technology and are designed to prevent any dangers. However, drives and drive controllers that are not specifically designed for safety functions are not approved for applications where the functioning of the drive could endan- ger persons. The possibility of unexpected or un-braked movements can never be totally excluded without additional safety equipment. For this reason personnel must never be in the danger zone of the drives unless additional suitable safety equip- ment prevents any personal danger. This applies to operation of the machine during production and also to all service and maintenance work on drives and the machine. The machine design must ensure personal safety. Suitable measures for prevention of property damage are also required. Qualification of personnel Only technicians who are familiar with and understand the contents of this manual and the other relevant documentation are authorized to work on and with this drive system. The technicians must be able to detect potential dangers that may be caused by setting parameters, changing parameter values and generally by the operation of mechanical, electrical and electronic equipment. The technicians must have sufficient technical training, knowledge and experience to recognise and avoid dangers. The technicians must be familiar with the relevant standards, regulations and safety regulations that must be observed when working on the drive system. Intended Use The drive systems described here are products for general use that conform to the state of the art in technology and are designed to prevent any dangers. However, drives and drive controllers that are not specifically designed for safety functions are not approved for applications where the functioning of the drive could endanger persons. The possibility of unexpected or unbraked movements can never be totally excluded without additional safety equipment. For this reason personnel must never be in the danger zone of the drives unless additional suitable safety equipment prevents any personal danger. This applies to operation of the machine during production and also to all service and maintenance work on drives and the machine. The machine design must ensure personal safety. Suitable measures for prevention of property damage are also required. In all cases the applicable safety regulations and the specified operating conditions, such as environmental conditions and specified technical data, must be observed. The drive system must not be commissioned and operated until completion of instal- lation in accordance with the EMC regulations and the specifications in this manual. To prevent personal injury and damage to property damaged drive systems must not be installed or operated. Changes and modifications of the drive systems are not permitted and if made all no warranty and liability will be accepted. The drive system must be operated only with the specified wiring and approved accessories. In general, use only original accessories and spare parts. The drive systems must not be operated in an environment subject to explosion hazard (ex area).

Getting Started: Microstepping MForce PowerDrive..................................................................1-1 Before You Begin........................................................................................................................ 1-1 Tools and Equipment Required.................................................................................................. 1-1 Connecting the Power Supply.................................................................................................... 1-1 Connect Opto Reference and Logic Inputs................................................................................ 1-2 Connecting the Motor............................................................................................................... 1-2 Part 1: Hardware Reference Section 1.1: Introduction to the Microstepping MForce PowerDrive............................................1-5 Configuring............................................................................................................................... 1-5 Features and Benefits.................................................................................................................. 1-6 Section 1.2: Microstepping MForce PowerDrive Detailed Specifications ...................................1-7 General Specifications................................................................................................................ 1-7 Setup Parameters........................................................................................................................ 1-8 Mechanical Specifications........................................................................................................... 1-8 Pin Assignment and Description................................................................................................ 1-9 P1 12-Pin Locking Wire Crimp Connector - Power, I/O and SPI Communications....... 1-9 P3 Connector - DC Power, 2-Pin Locking Wire Crimp................................................. 1-10 P4 Connector - Motor................................................................................................... 1-10 Part 2: Connecting and Interfacing Section 2.1: Mounting and Connection Guidelines ........................................................................3 Mounting Recommendations.........................................................................................................3 Securing Power Leads and Logic Leads...........................................................................................4 Layout and Interface Guidelines.....................................................................................................4 Rules of Wiring ...................................................................................................................5 Rules of Shielding ...............................................................................................................5 Recommended Wiring.........................................................................................................5 Recommended Mating Connectors and Pins.......................................................................5 Section 2.2: Interfacing DC Power..................................................................................................7 Choosing a Power Supply for Your MForce PowerDrive.................................................................7 DC Power Supply Recommendations.............................................................................................8 Recommended IMS Power Supplies.....................................................................................8 Basic DC Power Connection..........................................................................................................9 Recommended Power and Cable Configurations ...........................................................................9 Example A: DC Power Cabling Under 50 Feet....................................................................9 Example B: AC Power to Full Wave Bridge Cabling Over 50 Feet......................................10 Example C – Cabling 50 Feet or Greater, AC Power to Power Supply................................10 Section 2.3: Motor Selection and Interface ...................................................................................11 Selecting a Motor.........................................................................................................................11 Types and Construction of Stepping Motors......................................................................11 Sizing a Motor for Your System..........................................................................................11 Recommended IMS Motors ........................................................................................................12 IMS Inside Out Stepper Motors.........................................................................................13 Connecting the Motor.................................................................................................................14 8 Lead Motors ...................................................................................................................14 6 Lead Motors....................................................................................................................15 4 Lead Motors....................................................................................................................16 Recommended Motor Cabling ....................................................................................................16 Example A: Motor Cabling Less Than 50 Feet...................................................................16 Example B: Motor Cabling Greater Than 50 Feet..............................................................17 Recommended Motor Cable AWG Sizes............................................................................17 Section 2.4: Logic Interface and Connection.................................................................................19 Optically Isolated Logic Inputs.....................................................................................................19 Isolated Logic Input Pins and Connections..................................................................................19 Isolated Logic Input Characteristics..............................................................................................19

Open Collector Interface Example......................................................................................... Switch Interface Example...................................................................................................24 Minimum Required Connections.................................................................................................25 Section 2.5: Connecting SPI Communications..............................................................................26 Connecting the SPI Interface.......................................................................................................26 SPI Signal Overview.....................................................................................................................26 SPI Pins and Connections............................................................................................................27 Logic Level Shifting and Conditioning Circuit.............................................................................27 SPI Master with Multiple Microstepping MForce PowerDrive.....................................................28 Section 2.6: Using the IMS SPI Motor Interface............................................................................29 Installation...................................................................................................................................29 Configuration Parameters and Ranges..........................................................................................29 Color Coded Parameter Values.....................................................................................................29 IMS SPI Motor Interface Menu Options.....................................................................................30 Screen 1: The Motion Settings Configuration Screen...................................................................31 MSEL (Microstep Resolution Selection)............................................................................32 HCDT (Hold Current Delay Time)..................................................................................33 MRC (Motor Run Current)...............................................................................................33 MHC (Motor Hold Current).............................................................................................33 DIR (Motor Direction)......................................................................................................33 User ID..............................................................................................................................33 IMS SPI Motor Interface Button Functions.......................................................................33 Screen 2: I/O Settings Configuration Screen................................................................................34 Input Clock Type...............................................................................................................34 Input Clock Filter..............................................................................................................34 Enable Active High/Low....................................................................................................34 Warning Temperature........................................................................................................34 IMS Part Number/Serial Number Screen.....................................................................................35 Fault Indication............................................................................................................................35 Upgrading the Firmware in the Microstepping MForce PowerDrive.............................................36 The IMS SPI Upgrader Screen...........................................................................................36 Upgrade Instructions..........................................................................................................36 Initialization Screen......................................................................................................................37 Port Menu.........................................................................................................................37 Motor Settings Screen (PWM Current Control)..........................................................................38 PWM Mask ......................................................................................................................38 Maximum PWM Duty Cycle (%) Parameter.....................................................................39 PWM Frequency Range Parameter.....................................................................................39 PWM Control Bits............................................................................................................40 Example PWM Settings By Motor Specifications...............................................................40 Section 2.7: Using User-Defined SPI.............................................................................................41 SPI Timing Notes.........................................................................................................................41 Check Sum Calculation for SPI....................................................................................................41 SPI Commands and Parameters...................................................................................................42 SPI Communications Sequence.........................................................................................43 Appendices Appendix A: Optional Prototype Development Cables................................................................. A-3 MD-CC300-000: USB to SPI Parameter Setup Cable...............................................................A-3 Adapter Cables...........................................................................................................................A-3 Installation Procedure for the MD-CC300-000.........................................................................A-4 Installing the Cable/VCP Drivers.....................................................................................A-4 Determining the Virtual COM Port (VCP).....................................................................A-6 PD12-1434-FL3 — Power, I/O and SPI..........................................................................A-7 Prototype Development Cable PD02-2300-FL3........................................................................A-8 Prototype Development Cable PD04-MF34-FL3......................................................................A-8

Figure GS.1: Minimum Logic and Power Connections.............................................................. 1-1 Part 1: Hardware Reference Figure 1.1.1: Microstepping MForce PowerDrive....................................................................... 1-5 Figure 1.2.1: MForce PowerDrive Mechanical Specifications...................................................... 1-8 Figure 1.2.2: P1 — 12-Pin Locking Wire Crimp Pin Configuration.......................................... 1-9 Figure 1.2.3: P3 — 2-Pin Locking Wire Crimp Pin Configuration.......................................... 1-10 Figure 1.2.4: P4 — 4-Pin Locking Wire Crimp Pin Configuration.......................................... 1-10 Part 2: Connecting and Interfacing Figure 2.1.1: Base Mounting the MForce PowerDrive....................................................................3 Figure 2.1.2: End Mounting the MForce PowerDrive....................................................................4 Figure 2.2.1: IMS ISP300 Switch Mode Power Supply...................................................................7 Figure 2.2.2: MForce PowerDrive DC Power Connection..............................................................9 Figure 2.2.3: DC Cabling - Under 50 Feet.....................................................................................9 Figure 2.2.4: AC To Full Wave Bridge Rectifier, Cabling over 50 Feet..........................................10 Figure 2.2.5: AC Cabling - 50 Feet or Greater - AC To Power Supply..........................................10 Figure 2.3.1 A & B: Per Phase Winding Inductance.....................................................................12 Figure 2.3.2: 8 Lead Motor Series Connections............................................................................14 Figure 2.3.3: 8 Lead Motor Parallel Connections........................................................................14 Figure 2.3.4: 6 Lead Half Coil (Higher Speed) Motor Connections............................................15 Figure 2.3.5: 6 Lead Half Coil (Higher Speed) Motor Connections............................................15 Figure 2.3.6: 4 Lead Motor Connections......................................................................................16 Figure 2.3.7: Motor Cabling Less than 50 Feet.............................................................................16 Figure 2.3.8: Motor Cableing Greater than 50 Feet......................................................................17 Figure 2.4.1: Isolated Logic Pins and Connections.......................................................................19 Figure 2.4.2: Input Clock Functions............................................................................................20 Figure 2.4.3: Clock Input Timing Characteristics.........................................................................21 Figure 2.4.4: Optocoupler Input Circuit Diagram........................................................................22 Figure 2.4.5: Open Collector Interface Example...........................................................................23 Figure 2.4.6: Switch Interface Example........................................................................................24 Figure 2.4.7: Minimum Required Connections............................................................................25 Figure 2.5.1: MD-CC300-000 Parameter Setup Cable.................................................................26 Figure 2.5.2: SPI Pins and Connections, 12-Pin Wire Crimp.......................................................27 Figure 2.5.3: Logic Level Shifting and Conditioning Circuit........................................................27 Figure 2.5.4: SPI Master with a Single Microstepping MForce PowerDrive..................................28 Figure 2.5.5: SPI Master with Multiple Microstepping MForce PowerDrives...............................28 Figure 2.6.1: SPI Motor Interface Color Coding..........................................................................30 Figure 2.6.2: SPI Motor Interface File Menu................................................................................30 Figure 2.6.3: SPI Motor Interface View Menu..............................................................................30 Figure 2.6.4: SPI Motor Interface Recall Menu............................................................................31 Figure 2.6.5: SPI Motor Interface Upgrade Menu........................................................................31 Figure 2.6.6: SPI Motor Interface Help Menu and About Screen.................................................31 Figure 2.6.7: SPI Motor Interface Motion Settings Screen............................................................32 Figure 2.6.8: SPI Motor Interface I/O Settings Screen..................................................................34 Figure 2.6.9: SPI Motor Interface Part and Serial Number Screen................................................35 Figure 2.6.10: SPI Motor Interface Upgrade Utility.....................................................................36 Figure 2.6.11: SPI Motor Interface Initialization..........................................................................37 Figure 2.6.12: SPI Motor Interface Port Menu.............................................................................37 Figure 2.7.1: SPI Timing..............................................................................................................38 Figure 2.7.2: Read/Write Byte Order for Parameter Settings (Default Parameters Shown)............40 Figure 2.6.13: Motor Settings Screen...........................................................................................38 Figure 2.6.14: PWM Mask Bits....................................................................................................38 Figure 2.6.15: PWM Frequency Range.......................................................................................39 Figure 2.6.16: PWM Control Bits................................................................................................40 Figure 2.7.1: SPI Timing..............................................................................................................41 Figure 2.7.2: Read/Write Byte Order for Parameter Settings (Default Parameters Shown)............43

Part 1: Hardware Reference Table 1.2.1: Electrical Specifications........................................................................................... 1-7 Table 1.2.2: Thermal Specifications............................................................................................ 1-7 Table 1.2.3: I/O Specifications................................................................................................... 1-7 Table 1.2.4: Communications Specifications.............................................................................. 1-7 Table 1.2.5: Motion Specifications............................................................................................. 1-7 Table 1.2.6: Setup Parameters..................................................................................................... 1-8 Table 1.2.7: P1 Connector – Power, I/O and SPI Communications........................................... 1-9 Table 1.2.8: P3 Connector....................................................................................................... 1-10 Table 1.2.9: P4 Connecter........................................................................................................ 1-10 Part 1: Interfacing and Configuring Table 2.2.1: Recommended Wire Gauges ....................................................................................10 Table 2.3.1: Recommended Wire Gauges.....................................................................................17 Table 2.4.1: Input Clocks Timing Table.......................................................................................21 Table 2.4.2: Optocoupler Reference Connection..........................................................................22 Table 2.6.1: Setup Parameters and Ranges....................................................................................29 Table 2.6.2: Microstep Resolution Settings...................................................................................32 Table 2.6.3: Hold and Run Current Percentage Equivalents.........................................................33 Table 2.6.4: Input Clock Filter Settings........................................................................................34 Table 2.6.5: Microstepping MForce PowerDrive Fault Codes.......................................................35 Table 2.6.6: PWM Mask Settings.................................................................................................38 Table 2.6.7: Typical PWM Mask Settings.....................................................................................39 Table 2.6.8: Maximum and Initial PWM Frequency....................................................................39 Table 2.6.9: Example PWM Settings............................................................................................40 Table 2.7.1: SPI Commands and Parameters................................................................................42 Appendices Table A.1: PD12-1434-FL3 Wire Color Codes..........................................................................A-7 Table A.2: PD04-MF34-FL3......................................................................................................A-8 Appendices Figure A.1: MD-CC300-000.....................................................................................................A-3 Figure A.2: MD-CC300-000 Mechanical Specifications.............................................................A-3 Figure A.3: Typical Setup, Adapter and Prototype Development Cable .....................................A-4 Figure A.4: Hardware Update Wizard........................................................................................A-4 Figure A.5: Hardware Update Wizard Screen 2..........................................................................A-5 Figure A.6: Hardware Update Wizard Screen 3..........................................................................A-5 Figure A.7: Windows Logo Compatibility Testing......................................................................A-5 Figure A.8: Hardware Update Wizard Finish Installation...........................................................A-6 Figure A.9: Hardware Properties.................................................................................................A-6 Figure A.10: Windows Device Manager.....................................................................................A-6 Figure A.11 PD12-1434-FL3.....................................................................................................A-7 Figure A.12: PD02-3400-FL3....................................................................................................A-8 Figure A.13: PD04-MF34-FL3..................................................................................................A-8

Note: A 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. Care should be taken so that the back EMF does not exceed the maximum input voltage rating of the MForce PowerDrive. WARNING! The MForce has components which 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 your MForce product. WARNING! Ensure that the power supply output voltage does not exceed the maximum input voltage of the MForce product that you are using! Getting Started Microstepping MForce PowerDrive Before You Begin The Getting Started Section is designed to help quickly connect and begin using your Microstepping MForce PowerDrive. The following examples will help you get a motor turning for the first time and introduce you to the basic settings of the drive. Tools and Equipment Required  Microstepping MForce PowerDrive Unit (MFM)  A NEMA 23 or 34 Size Stepping Motor  Control Device for Step/Direction  +5 to +24 VDC Optocoupler Supply (if using sinking output type)  An Unregulated +12 to +48VDC Power Supply  Basic Tools: Wire Cutters / Strippers / Screwdriver  Wire for Power Supply (18 AWG) and Motor (16 AWG)  22 AWG Wire for Logic Connections Connecting the Power Supply Using the recommended wire, connect the DC output of the power supply to the +V input of the connector appropriate for your Microstepping MForce PowerDrive model. Connect the power supply ground to the Power Ground pin appropriate for your Microstepping MForce PowerDrive. Figure GS.1: Minimum Logic and Power Connections P4 P3 P1 12-Pin Wire Crimp at P1 Shown. See Specifications for Pin Numbering for other versions. ØA ØB ØA ØB MForce PowerDrive Front Stepping Motor Step Direction +V (+12 to +48) Power Ground Opto Reference* 1 1 2 3 4 3 2 4 6 * The Opto Reference Will set the Sink/Source Configuration of the Inputs Sinking: OptoRef = +5 to +24 VDC Sourcing: OptoRef = Ground

Connect Opto Reference and Logic Inputs Using 22 AWG wire, connect the Opto Reference to the desired reference point. The reference will determine whether or not the logic input is sinking or sourcing. If Sinking Inputs are desired, connect the Opto reference to a +5 to +24 VDC Supply. If Sourcing Outputs are desired, the Opto Reference needs to be connected to the Controller Ground. Connect the Step and Direction inputs to the appropriate outputs of your PLC or controller. Connecting the Motor Using the recommended wire, connect the Motor Phases to P3 as shown in Figure GS.1. Ensure that the phases are connected correctly.

Section 1.1: Introduction to the Microstepping MForce PowerDrive Section 1.2: Microstepping MForce PowerDrive Detailed Specifications Part 1: Hardware Reference TM FORCE POWER DRIVE MICROSTEPPING

SECTION 1.1 Introduction to the Microstepping MForce PowerDrive The Microstepping MForce Pow- erDrive is a high performance, low cost microstepping driver that delivers unsurpassed smoothness and perfor- mance achieved through IMS’s advanced 2nd generation current control. By applying innovative techniques to con- trol current flow through the motor, resonance is significantly dampened over the entire speed range and audible noise is reduced. Microstepping MForce PowerDrives accept a broad input voltage range from +12 to +75 VDC, delivering enhanced performance and speed. Oversized input capacitors are used to minimize power line surges, reducing problems that can occur with long runs and multiple drive systems. An extended operating range of –40° to +85°C provides long life, trouble free service in demanding environments. The high, per phase output current of up to 5 Amps RMS, 7 Amps Peak, allows the extremely compact MForce PowerDrive to control a broad array of motors from size 23 to size 42. The microstepping drive accepts up to 20 resolution settings from full to 256 microsteps per full step, including: degrees, metric and arc minutes. These settings may be changed on-the-fly or downloaded and stored in nonvolatile memory with the use of a simple GUI which is provided. This eliminates the need for external switches or resistors. Parameters are changed via an SPI port. The versatile Microstepping MForce PowerDrive comes with dual mounting configurations to fit various system needs. All interface connections are accomplished using pluggable locking wire crimp connectors. Optional cables are avail- able for ease of connecting and configuring the MForce, and are recommended with first order. The Microstepping MForce PowerDrive is a compact, powerful and inexpensive solution that will reduce system cost, design and assembly time for a large range of applications. Configuring The IMS SPI Motor Interface software is an easy to install and use GUI for configuring the Microstepping MForce PowerDrive from a computer's USB port. GUI access is via the IMS SPI Motor Interface included on the CD shipped with the product, or from www.imshome.com. Optional cables are available for ease of connecting and configuring the MForce. The IMS SPI Motor Interface features: Easy installation. Automatic detection of MForce version and communication configuration. Will not set out-of-range values. Tool-tips display valid range setting for each option. Simple screen interfaces. • • • • • Figure 1.1.1: Microstepping MForce PowerDrive

Features and Benefits High Performance Microstepping Driver Advanced 2nd Generation Current Control for Exceptional Performance and Smoothness Single Supply: +12 to +75 VDC Low Cost Extremely Compact High Output Current: Up to 5 Amps RMS, 7 Amps Peak (Per Phase) 20 Microstep Resolutions up to 51,200 Steps Per Rev Including: Degrees, Metric, Arc Minutes Optically Isolated Logic Inputs will Accept +5 to +24 VDC Signals, Sourcing or Sinking Automatic Current Reduction Configurable: Motor Run/Hold Current Motor Direction vs. Direction Input Microstep Resolution Clock Type: Step and Direction, Quadrature, Step Up and Step Down Programmable Digital Filtering for Clock and Direction Inputs Current and Microstep Resolution May Be Switched On-The-Fly Dual Mounting Configurations Power, Motor and Signal Interface via locking wire crimp style connectors. Graphical User Interface (GUI) for Quick and Easy Parameter Setup • • • • • • • • • • • • • • • • • • •

SECTION 1.2 Microstepping MForce PowerDrive Detailed Specifications General Specifications Electrical Specifications Input Voltage (+V) Range* +12 to +75 VDC Max Power Supply Current (Per MForce PowerDrive)* 4 Amps Output Current RMS 5 Amps Output Current Peak (Per Phase) 7 Amps * Actual Power Supply Current will depend on Voltage and Load. Table 1.2.1: Electrical Specifications Thermal Specifications Heat Sink Temperature -40°C to +85°C Table 1.2.2: Thermal Specifications I/O Specifications Isolated Inputs — Step Clock, Direction and Enable Resolution 10 Bit Voltage Range (Sourcing or Sinking) +5 to +24 VDC Current (+5 VDC Max) 8.7 mA Current (+24 VDC Max) 14.6 mA Table 1.2.3: I/O Specifications Communications Specifications Protocol SPI Table 1.2.4: Communications Specifications Motion Specifications Microstep Resolution Number of Resolutions 20 Available Microsteps Per Revolution 200 400 800 1000 1600 2000 3200 5000 6400 10000 12800 20000 25000 25600 40000 50000 51200 360001 216002 254003 1=0.01 deg/µstep 2=1 arc minute/µstep 3=0.001 mm/µstep Digital Filter Range 50 nS to 12.9 µS (10 MHz to 38.8kHz) Clock Types Step/Direction, Quadrature, Clock Up/ Clock Down Step Frequency (Max) 5.0 MHz Step Frequency Minimum Pulse Width 100 nS Table 1.2.5: Motion Specifications

Mechanical Specifications - Dimensions in Inches (mm) Figure 1.2.1: MForce PowerDrive Mechanical Specifications Microstepping MForce PowerDrive Setup Parameters Name Function Range Units Default MHC Motor Hold Current 0 to 100 percent 5 MRC Motor Run Current 1 to 100 percent 25 MSEL Microstep Resolution 1, 2, 4, 5, 8, 10, 16, 25, 32, 50, 64, 100,108, 125, 127,128, 180, 200, 250, 256 µsteps per full step 256 DIR Motor Direction Override 0/1 – CW HCDT Hold Current Delay Time 0 or 2-65535 mSec 500 CLK TYPE Clock Type Step/Dir. Quadrature, Up/Down (CW/CCW) – Step/Dir CLK IOF Clock and Direction Filter 50 nS to 12.9 µS (10 MHz to 38.8kHz) nS (MHz) 200nS(2.5 MHz) USER ID User ID Customizable 1-3 characters IMS WARN TEMP Warning Temperature 0 to +125 ºC 80 EN ACT Enable Active High/Low High or Low — High PWM MSK PWM Mask 0 to 255 — 102 PWM PER PWM Duty Cycle 0 to 95 Percent 90% PWM FREQ PWM Frequency Range 0 to 255 — 170 (20kHz to 60 kHz) PWM CTL PWM Control See Section 2.4 See Section 2.4 0-10010 Table 1.2.6: Setup Parameters Setup Parameters The following table illustrates the setup parameters. These are easily configured using the IMS SPI Motor Interface configuration utility. An optional Parameter Setup Cable is available and recommended with the first order. 3.473 (88.21) 2X 0.580 (2X 14.73) Ø 0.187 ±0.01 (Ø 4.75 ±0.25) 2X #8 Screws for End Mount 3.00 ±0.01 (76.2 ±0.25) 2.116 (53.75) 0.225 (5.72) P4 P3 P1 3.473 (88.21) Ø 0.160 ±0.01 Thru (Ø 4.06 ±0.25 Thru) 4X #6 Screws for Flat Mount 0.308 TYP. (7.82 TYP.) 2.931 TYP. (74.45 TYP.) 3.897 (98.98) 0.417 TYP. (10.59 TYP.) 0.160 ±0.01 (4.06 ±0.25) 2.950 (74.93)

Pin Assignment and Description P1 12-Pin Locking Wire Crimp Connector Option - Power, I/O and SPI Communications Pin Assignment - P1 Power, I/O and SPI Connections Pin # Function Description Pin 1 N/C No Connect Pin 2 N/C No Connect Pin 3 Opto Reference The Signal applied to the Optocoupler Reference will determine the sinking/ or sourcing configuration of the inputs. To set the inputs for sinking operation, a +5 to +24 VDC supply is connected. If sourcing, the Reference is connected to Ground. Pin 4 Step Clock/Channel A/ Clock Up Step Clock input. The step clock input will receive the clock pulses which will step the motor 1 step for each pulse. It may also receive quadrature and clock up type inputs if so configured. Pin 5 Enable Enable/Disable Input will enable or disable the driver output to the motor. In the disconnected state the driver outputs are enabled in either sinking or sourcing configuration. Pin 6 Direction/Channel B/ Clock Down Direction input. The axis direction will be with respect to the state of the Direction Override Parameter. It may also receive quadrature and clock up type inputs if so configured. Pin 7 +5 VDC Output Supply voltage for the MD-CC300-000 Cable ONLY! Pin 8 SPI Clock The Clock is driven by the SPI Master. The clock cycles once for each data bit. Pin 9 GND Communications Ground. Pin 10 MISO Master-In/Slave-Out. Carries output data from the MFM back to the SPI Master. Pin 11 CS SPI Chip Select. This signal is used to turn communications on multiple MFM units on or off. Pin 12 MOSI Master-Out/Slave-In. Carries output data from the SPI Master to the MFM. Table 1.2.7: P1 Connector – Power, I/O and SPI Communications NEED A CABLE? The following cables and converters are available to interface with P1: 12-Pin Locking Wire Crimp PD12-1434-FL3 P3 P1 1 3 5 7 9 11 2 4 6 8 10 12 NEED A CABLE? The following cables and converters are available to interface communications with USB to SPI: MD-C300-000 10-Pin IDC to 12-Pin Locking Wire Crimp Adapter All SPI Communications will connect to the P1 Connector. An adapter is available to interface the MD-CC300-000 to the 12-Pin Locking Wire Crimp connector. MD-ADP-1723C This adapter may be used in conjunction with the following Prototype Development cables to interface power and logic: PD12-1434-FL3 (10') ADP-3512-FL (12") See Appendix A for details. Figure 1.2.2: P1 — 12-Pin Locking Wire Crimp Pin Configuration Recommended Connector Shell and Pins Shell: AMP P/N 1-794617-2 Pins: 12 x AMP P/N 794610-1 Wire: 22 AWG Shielded Twisted Pair

P3 Connector - DC Power, 2-Pin Locking Wire Crimp Pin Assignment - P3 Power 2-Pin Locking Wire Crimp Function Description Pin 1 +V +12 to +75 VDC, 4 Amps Maximum per MDrive34Plus. Pin 2 GND Power Supply Return. Table 1.2.8: P3 Connector P3 12 10 8 6 4 2 11 9 7 5 3 1 1 2 Figure 1.2.3: P3 — 2-Pin Locking Wire Crimp Pin Configuration Pin Assignment - P4 Motor 5-Pin Locking Wire Crimp Function Description Pin 1 Phase A Phase A Motor Output Pin 2 Phase A Phase A Motor Return Pin 3 Phase B Phase B Motor Output Pin 4 Phase B Phase B Motor Return Recommended Cable PD04-MF34-FL3 Table 1.2.9: P4 Connecter P4 Connector - Motor P4 12 10 8 6 4 2 11 9 7 5 3 1 1 1 2 2 3 4 Figure 1.2.4: P4 — 4-Pin Locking Wire Crimp Pin Configuration Recommended Connector Shell and Pins Shell: Molex P/N 39-01-2045 Pins: 4 x Molex P/N 44476-3112 Wire: 16 AWG Shielded Twisted Pair Recommended Connector Shell and Pins Shell: Molex P/N 510-67-0200 Pins: 2 x Molex P/N 502-17-9101 Wire: 18 AWG Shielded Twisted Pair NEED A CABLE? The following cables and converters are available to interface with P3: 2-Pin Locking Wire Crimp PD02-3400-FL3 WARNING! Do not plug or unplug DC Power with power applied. NEED A CABLE? The following cables and converters are available to interface with P4: 4-Pin Locking Wire Crimp PD04-MF34-FL3

Options and Accessories Parameter Setup Cable and Adapters The optional 12.0' (3.6m) parameter setup cable part number MD-CC300-000 facilitates communications wiring and is recommended with first order. It connects from the 10-Pin IDC Connector located at P2 to a PC's USB port. If the12-pin pluggable locking wire crimp connector is used at P1, adapter MD-ADP-1723C is required to use the MD-CC300-000. USB to SPI...........................................................................................................MD-CC300-000 Prototype Development Cable To speed prototype development, these cables connect to user interface via flying leads with MForce mating connector on opposite end. Mating connector to 12-pin pluggable locking wire crimp plugs into MForce or adapter MD-ADP-1723C. Choose from 2 lengths: 12.0" (30.5cm)...........................................................................................................ADP-3512-FL 10.0' (3.0m)........................................................................................................... PD12-1434-FL3 Mating connector to MForce 4-pin motor interface: 10.0' (3.0m)......................................................................................................... PD04-MF17-FL3

Section 2.1: Mounting and Connection Recommendations Section 2.2: Logic Interface and Connection Section 2.3: Connecting SPI Communications Section 2.4: Using the IMS SPI Motor Interface Section 2.5: Using User-Defined SPI Part 2: Interfacing and Configuring TM FORCE MICRO DRIVE MICROSTEPPING

SECTION 2.1 Mounting and Connection Guidelines Mounting Recommendations The Microstepping MForce PowerDrive may be mounted two ways: end mounted or flat mounted End mount- ing will use #8 hardware, flat mounting will use standard #6 hardware. Do not exceed the recommended mount- ing torque specification. The diagrams in Figures 2.1.1 and 2.1.2 illustrate the mounting methods. Figure 2.1.1: Base Mounting the MForce PowerDrive 4 x #6-32 Screw 4 x #6 Split Lockwasher 4 x #6 Flat Washer Mounting Hardware 4 x M3.5 - 0.60 Screw 4 x M3.5 Split Lockwasher 4 x M3.5 Flat Washer Mounting Hardware (Metric) MForce PowerDrive Mounting Surface 2.931 TYP (74.45 TYP) 2.950 (74.93 Use #36 Drill Size (2.9 mm) Tap to #6-32 (M3.5 - 0.60) 4 PL Mounting Hole Pattern (Not to Scale) Recommended Tightening Torque: 7 - 8 lb-in (78.4 - 89.6 N-cm) NOTE: Mounting Hardware is not supplied.

Figure 2.1.2: End Mounting the MForce PowerDrive Securing Power Leads and Logic Leads Some applications may require that the MForce and/or the connected motor to move with the axis motion. If this is a requirement of your application, the motor leads must be properly anchored. This will prevent flexing and tugging which can cause damage at critical connection points on the MForce connectors. Layout and Interface Guidelines Logic level cables must not run parallel to power cables. Power cables will introduce noise into the logic level cables and make your system unreliable. Logic level cables must be shielded to reduce the chance of EMI induced noise. The shield needs to be grounded at the signal source to earth. The other end of the shield must not be tied to anything, but allowed to float. This allows the shield to act as a drain. Power supply leads to the MForce PowerDrive need to be twisted. If more than one driver is to be connected to the same power supply, run separate power and ground leads from the supply to each driver. 2 x #8-32 Screw 2 x #8 Split Lockwasher 2 x #8 Flat Washer Mounting Hardware 2 x M4 - 0.70 Screw 2 x M4 Split Lockwasher 2 x M4 Flat Washer Mounting Hardware (Metric) Mounting Surface 3.000 TYP (76.20 TYP) Use #29 Drill Size (3.3 mm) Tap to #8-32 2 PL (M4 - 0.70) Mounting Hole Pattern Recommended Tightening Torque: 8 - 9 lb-in (89.6 - 100.8 N-cm) NOTE: Ensure that proper clearance is allowed for wiring and cabling. Especially when end mounting the device. NOTE: Mounting Hardware is not supplied.

Rules of Wiring • Power Supply and Motor wiring should be shielded twisted pairs, and run separately from signal- carrying wires. • A minimum of one twist per inch is recommended. • Motor wiring should be shielded twisted pairs using 20 gauge, or for distances of more 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 of 18 gauge for less than 4 amps DC and 16 gauge for more than 4 amps DC. Rules of Shielding • The shield must be tied to zero-signal reference potential. It is necessary that the signal be earthed or grounded, for the shield to become earthed or grounded. Earthing or grounding the shield is not effective if the signal is not earthed or grounded. • Do not assume that Earth ground is a true Earth ground. Depending on the distance from the main power cabinet, it may be necessary to sink a ground rod at the 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. Recommended Wiring The following wiring/cabling is recommended for use with the MForce PowerDrive: Logic Wiring.......................................................................................................................22 AWG Wire Strip Length....................................................................................................0.25” (6.0 mm) Power and Ground .........................................................................18 AWG Shielded Twisted Pair* Motor................................................................................................16 AWG Shielded Twisted Pair *See Table 2.2.1 if using a power cable longer than 10 feet. The Gauge used is dependant upon supply current and legnth. Recommended Mating Connectors and Pins Logic and SPI Communications (P1) 12-pin Locking Wire Crimp Connector Shell.......................................................AMP 1-794617-2 Crimp Pins...............................................................................................................AMP 794610-1 Power (P3) 2-pin Locking Wire Crimp Connector Shell...................................................... Molex 51067-0200 Crimp Pins............................................................................................... Molex 50217-9101 Brass Motor (P4) 4-pin Locking Wire Crimp Connector Shell........................................................ Molex 3901-2045 Crimp Pins........................................................................................................ Molex 44476-3112

SECTION 2.2 Interfacing DC Power Choosing a Power Supply for Your MForce PowerDrive When choosing a power supply for your MForce PowerDrive there are performance and sizing issues that must be addressed. An undersized power supply can lead to poor performance and even possible damage to the device, which can be both time consum- ing and expensive. However, The design of the MForce PowerDrive is quite efficient and may not require as large a supply as you might suspect. Motors have windings that are electrically just inductors, and with inductors comes re- sistance and inductance. Winding resistance and inductance result in a L/R time constant that resists the change in current. It requires five time constants to reach nominal current. To effectively manipulate the di/dt or 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, and though nothing can be done about back EMF, we can give a path of low impedance by supplying enough output capacitance. Back EMF is a source of current that can push the output of a power supply beyond the maximum operating voltage of the driver and as a result could damage the MForce PowerDrive over time. The MForce PowerDrive 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 re-circulate within the bridge, and in and out of each phase reservoir. While one phase is in the decaying stage of the variable chopping oscillator, the other phase is in the charging stage, this results in a less than expected current draw on the supply. The MForce PowerDrive is designed with the intention that a user’s power supply output will ramp up to greater or equal to the minimum operating voltage. The initial current surge is quite substantial and could damage the driver if the supply is undersized. If a power supply is undersized, upon a current surge the supply could fall be- low the operating range of the driver. This could cause the power supply to start oscillating in and out of the volt- age range of the driver and result in damaging either the supply, driver or both. There are two types of supplies commonly used, regulated and unregulated, both of which can be switching or linear. All have their advantages and disadvantages. An unregulated linear supply is less expensive and more resilient to current surges, however, voltage decreases with increasing current draw. This can cause serious problems if the voltage drops below the working range of the drive. Also of concern is the fluctuations in line voltage. This can cause the unregulated linear supply to be above or below the anticipated voltage. A regulated supply maintains a stable output voltage, which is good for high speed performance. They are also not bothered 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 lead to damage. Back EMF can cause problems for regulated supplies as well. The current regeneration may be too large for the regulated supply to absorb and may lead to an over voltage condition. Switching supplies are typically regulated and require little real-estate, which makes them attractive. However, their output response time is slow, making them ineffective for inductive loads. IMS has designed a series of low cost miniature non-regulated switchers that can handle the extreme varying load conditions which makes them ideal for the MForce PowerDrive. Figure 2.2.1: IMS ISP300 Switch Mode Power Supply

DC Power Supply Recommendations The power requirements for the Microstepping MForce PowerDrive are: Output Voltage....................................................................+12 to +75 VDC (Includes Back EMF) Current (max. per unit)................................................................................................................4A (Actual power supply current requirement will depend upon voltage and load) Recommended IMS Power Supplies IMS unregulated linear and unregulated switching power supplies are the best fit for IMS drive products. IP804 Unregulated Linear Supply Input Range 120 VAC Versions............................................................................................102-132 VAC 240 VAC Versions............................................................................................204-264 VAC Output (All Measurements were taken at 25˚C, 120 VAC, 60 Hz) No Load Output Voltage........................................................................76 VDC @ 0 Amps Half Load Output...................................................................................65 VDC @ 2 Amps Full Load output.....................................................................................58 VDC @ 4 Amps IP806 Unregulated Linear Supply Input Range 120 VAC Versions............................................................................................102-132 VAC 240 VAC Versions............................................................................................204-264 VAC Output (All Measurements were taken at 25˚C, 120 VAC, 60 Hz) No Load Output Voltage........................................................................76 VDC @ 0 Amps Half Load Output...................................................................................68 VDC @ 3 Amps Full Load Output....................................................................................64 VDC @ 6 Amps ISP300-7 Unregulated Switching Supply Input Range 120 VAC Versions............................................................................................102-132 VAC 240 VAC Versions............................................................................................204-264 VAC Output (All Measurements were taken at 25˚C, 120 VAC, 60 Hz) No Load Output Voltage........................................................................68 VDC @ 0 Amps Continuous Output Rating.....................................................................63 VDC @ 2 Amps Peak Output Rating................................................................................59 VDC @ 4 Amps

P3 Unregulated Linear or Switching Power Supply Power Ground +VDC Shield to Earth Ground + – ! WARNING! Do not connect or disconnect cabling while power is applied! Optional Prototype Development Cable: PD02-3400-FL3 Pin 1 Pin 2 Basic DC Power Connection Figure 2.2.2: MForce PowerDrive DC Power Connection Recommended Power and Cable Configurations Cable length, wire gauge and power conditioning devices play a major role in the performance of your MForce PoweDrive. Example A demonstrates the recommended cable configuration for DC power supply cabling under 50 feet long. If cabling of 50 feet or longer is required, the additional length may be gained by adding an AC power supply cable (see Examples B & C). Correct AWG wire size is determined by the current requirement plus cable length. Please see Table 2.2.1 for recommended wire gauges. Example A: DC Power Cabling Under 50 Feet Shield to Earth Ground on Supply End Only DC Voltage from Power Supply 500 µf Per Amp + - Ferrite Beads P Type RFI Filter r Required Current + - Shielded Twisted Pair Cable Length less than 50 Feet P3:2 P3:1 Figure 2.2.3: DC Cabling - Under 50 Feet WARNING! DO NOT connect or disconnect power leads when power is applied! Disconnect the AC power side to power down the DC power supply.

WARNING! DO NOT connect or disconnect power leads when power is applied! Disconnect the AC power side to power down the DC power supply. Example C – Cabling 50 Feet or Greater, AC Power to Power Supply Figure 2.2.4: AC To Full Wave Bridge Rectifier, Cabling over 50 Feet Figure 2.2.5: AC Cabling - 50 Feet or Greater - AC To Power Supply Shield to Earth Ground on Supply End Only P Type RFI Filter r Required Current Transformer - 10 to 28 VAC RMS for 48 VDC Systems 20 to 48 VAC RMS for 75 VDC Systems Full Wave Bridge + - Shielded Twisted Pair Cable Length as required NOTE: Connect the cable illustrated in Figure 2.2.2 to the output of the Full Wave Bridge Example B: AC Power to Full Wave Bridge Cabling Over 50 Feet Shield to Earth Ground on Supply End Only P Type RFI Filter r Required Current 120 or 240 VAC Dependent on Power Supply Power Supply + - DC Volts Out Shielded Twisted Pair Cable Length as required NOTE: Connect the cable illustrated in Example A to the output of the Power Supply MForce PowerDrive Recommended Power Supply Cable AWG 1 Amperes (Peak) 3 Amperes (Peak) Length (Feet) 10 25 50* 75* 100* Length (Feet) 10 25 50* 75* 100* Minimum AWG 20 20 18 18 16 Minimum AWG 18 16 14 12 12 2 Amperes (Peak) 4 Amperes (Peak) Length (Feet) 10 25 50* 75* 100* Length (Feet) 10 25 50* 75* 100* Minimum AWG 20 18 16 14 14 Minimum AWG 18 16 14 12 12 *Use the alternative methods illustrated in examples B and C when cable length is ≥ 50 feet. Also, use the same current rating when the alternate AC power is used. Table 2.2.1: Recommended Wire Gauges

SECTION 2.3 Motor Selection and Interface Selecting a Motor When selecting a stepper motor for your application, there are several factors that need to be taken into consider- ation:  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 affect everything from the power supply voltage to the type and wiring configuration of your stepper motor. The current and microstepping settings of your Microstepping MForce PowerDrive will also be affected. Types and Construction of Stepping Motors 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 MForce PowerDrive is designed to work with the following types of stepping motors: 1) Permanent Magnet (PM) 2) Hybrid Stepping Motors 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). VR motors are low torque and load capacity motors which are typically used in instrumentation. The MForce PowerDrive 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 com- monly used. Torque capacity in hybrid steppers ranges from 5 - 8000 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. Sizing a Motor for Your System The MForce PowerDrive 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 MForce PowerDrive chops the voltage using a variable chopping fre- quency 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. Winding Inductance Since the MForce PowerDrive 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 MForce PowerDrive is set to the motor’s rated current. 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. There- fore, 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.

The per phase winding inductance specified may be different than the per phase inductance seen by your MForce PowerDrive driver depending on the wiring configuration used. Your calculations must allow for the actual induc- tance that the driver will see based upon the wiring configuration. Figure 2.3.1A 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 2.3.1B shows an 8 lead motor wired in parallel. Using this configuration the per phase inductance seen by the driver will be as specified. Using the following equation we will show an example of sizing a motor for a MForce PowerDrive used with an unregulated power supply with a minimum voltage (+V) of 18 VDC: .2 X 18 = 3.6 mH The recommended per phase winding inductance we can use is 3.6 mH. Recommended IMS Motors IMS also carries a series of 23 and 34 frame enhanced stepping motors that are recommended for use with the MForce PowerDrive. 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. Each frame size is available in 3 stack sizes, single or double shaft, with or without encoders. They handle currents up to 2.4 Amps in series or 6 Amps parallel, and holding torque ranges from 90 oz.-in. (M-2218-2.4) to 1303 oz.-in (M- 3447-6.3) (64 N-cm to 920 N-cm). These CE rated motors are ideal for applications where higher torque is required. For more detailed information on these motors, please see the IMS Full Line catalog or the IMS web site at http://www.imshome.com. PHASE A PHASE A PHASE B PHASE B 8 Lead Stepping Motor Series Configuration 8 Lead Stepping Motor Parallel Configuration PHASE A PHASE A PHASE B PHASE B (Note: This example also applies to the 6 lead motor full copper confguration and to 4 lead stepping motors) (Note: This example also applies to the 6 lead motor half copper confguration) Specified Per Phase Inductance Specified Per Phase Inductance Actual Inductance Seen By the Driver Actual Inductance Seen By the Driver A B Figure 2.3.1 A & B: Per Phase Winding Inductance 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.

23 Frame Enhanced (2.4A - Not Available with Double Shaft) Single Shaft Double Shaft M-2218-2.4S.............................................................................................................................N/A M-2222-2.4S.............................................................................................................................N/A M-2231-2.4S.............................................................................................................................N/A 23 Frame Enhanced (3.0A) Single Shaft Double Shaft M-2218-3.0S.............................................................................................................M-2218-3.0D M-2222-3.0S.............................................................................................................M-2222-3.0D M-2231-3.0S.............................................................................................................M-2231-3.0D 23 Frame Enhanced (6.0A) Single Shaft Double Shaft M-2218-6.0S.............................................................................................................M-2218-6.0D M-2222-6.0S.............................................................................................................M-2222-6.0D M-2231-6.0S.............................................................................................................M-2231-6.0D 34 Frame Enhanced (6.3A) Single Shaft Double Shaft M-3424-6.3S............................................................................................................M-3424-6.3-D M-3431-6.3S.............................................................................................................M-3431-6.3D M-3447-6.3S.............................................................................................................M-3447-6.3D IMS also offers 23 and 34 Frame hybrid linear actuators for use with the MForce PowerDrive. Please see the IMS Full Line catalog or the IMS web site at http://www.imshome.com. IMS Inside Out Stepper Motors 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 damping between the motor and the load. The induced backlash from the gearbox is eliminated providing improved bidirectional position accuracy.  Electrical or pneumatic lines can be directed through the center of the motor enabling the motors to be stacked end-to-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 23 Frame....................................................................................................................M3-2220-IOS 34 Frame....................................................................................................................M3-3424-IOS Connecting the Motor The motor leads are connected to the following connector pins: Phase Connector: Pin Phase A.................................................................................................................................... P4: 1 Phase A.................................................................................................................................... P4: 2 Phase B.................................................................................................................................... P4: 3 Phase B.................................................................................................................................... P4: 4 8 Lead Motors 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. Series Connection A series motor configuration would typically be used in applications where a higher torque at lower speeds is required. 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. Parallel Connection 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. Figure 2.3.2: 8 Lead Motor Series Connections 1 3 4 2 Splice Splice P4 PHASE A PHASE A B PHASE PHASE B Figure 2.3.3: 8 Lead Motor Parallel Connections 1 3 4 2 P4 PHASE A PHASE A B PHASE PHASE B

6 Lead Motors 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. Half Coil Configuration 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 mo- tor, 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 unipo- lar) current rating by 1.4 to determine the peak output current. Full Coil Configuration 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. Figure 2.3.4: 6 Lead Half Coil (Higher Speed) Motor Connections 1 3 4 2 P4 PHASE A PHASE A B PHASE PHASE B No Connect No Connect 1 3 4 2 P4 PHASE A PHASE A B PHASE PHASE B No Connect No Connect Figure 2.3.5: 6 Lead Half Coil (Higher Speed) Motor Connections

Figure 2.3.6: 4 Lead Motor Connections 1 3 4 2 P4 PHASE A PHASE A B PHASE PHASE B 4 Lead Motors 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 deter- mine the peak output current. Recommended Motor Cabling 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. Cable length, wire gauge and power conditioning devices play a major role in the performance of your MForce PowerDrive and Stepper Motor. NOTE: The length of the DC power supply cable between the MForce PowerDrive and the Motor should not exceed 50 feet. Example A demonstrates the recommended cable configuration for the MForce PowerDrive to Motor cabling under 50 Feet long. If cabling of 50 feet or longer is required, the additional length can be gained with the cable configuration in Example B. Correct AWG wire size is determined by the current requirement plus cable length. Please see Table 2.3.1 on the following page. Example A: Motor Cabling Less Than 50 Feet Shield to Earth Ground on Supply End Only Ferrite Beads Cable Length less than 50 Feet MForce PowerDrive Phase Outputs Motor Connections Shielded/Twisted Pair A A B B A A B B Figure 2.3.7: Motor Cabling Less than 50 Feet

Shield to Earth Ground on Supply End Only Ferrite Beads *L z 0.5 MH * 0.5 MH is a typical starting point for the Common Mode Line Filters. By increasing or decreasing the value of L you can set the drain current to a minimum to meet your application’s requirements. Common Mode Line Filters (2x) From MicroLYNX Shielded/Twisted Pair Cable Length as required Motor Connections A A B B A A B B MForce PowerDrive Phase Outputs Example B: Motor Cabling Greater Than 50 Feet Figure 2.3.8: Motor Cableing Greater than 50 Feet Recommended Motor Cable AWG Sizes MForce PowerDrive Recommended Motor Cable AWG 1 Amperes (Peak) 5 Amperes (Peak) Length (Feet) 10 25 50* 75* 100* Length (Feet) 10 25 50* 75* 100* Minimum AWG 20 20 18 18 16 Minimum AWG 16 16 14 12 12 2 Amperes (Peak) 6 Amperes (Peak) Length (Feet) 10 25 50* 75* 100* Length (Feet) 10 25 50* 75* 100* Minimum AWG 20 18 16 14 14 Minimum AWG 14 14 14 12 12 3 Amperes (Peak) 7 Amperes (Peak) Length (Feet) 10 25 50* 75* 100* Length (Feet) 10 25 50* 75* 100* Minimum AWG 18 16 14 12 12 Minimum AWG 12 12 12 12 12 4 Amperes (Peak) *Use the alternative methods illustrated in example B when cable length is ≥ 50 feet. Also, use the same current rating when the alternate AC power is used. Length (Feet) 10 25 50* 75* 100* Minimum AWG 18 16 14 12 12 Table 2.3.1: Recommended Wire Gauges

SECTION 2.4 Logic Interface and Connection Optically Isolated Logic Inputs The Microstepping MForce PowerDrive has three optically isolated logic inputs which are located on connector P1. These inputs are isolated to minimize or eliminate electrical noise coupled onto the drive control signals. Each input is internally pulled-up to the level of the optocoupler supply and may be connected to sinking or +5 to +24 VDC sourcing outputs on a controller or PLC. These inputs are: 1] Step Clock (SCLK)/Quadrature (CH A)/Clock UP 2] Direction (DIR)/Quadrature (CH B)/ Clock DOWN 3] Enable (EN) Of these inputs only step clock and direction are required to operate the Microstepping MForce PowerDrive. Isolated Logic Input Pins and Connections The following diagram illustrates the pins and connections for the Microstepping MForce PowerDrive family of products. Careful attention should be paid to verify the connections on the model Microstepping MForce Power- Drive you are using. Isolated Logic Input Characteristics Enable Input This input can be used to enable or disable the driver output circuitry. Leaving the enable switch open (Logic HIGH, Disconnected) for sinking or sourcing configuration, the driver outputs will be enabled and the step clock pulses will cause the motor to advance. When this input switch is closed (Logic LOW) in both sinking Figure 2.4.1: Isolated Logic Pins and Connections Pin 3: Opto Supply Pin 5: Enable Pin 4: Step/Clock Pin 6: Direction Inputs Configured as Sinking +5 to +24VDC Inputs Configured as Sourcing Controller I/O Ground Pin 3 Pin 3

and sourcing configurations, the driver output circuitry will be disabled. Please note that the internal sine/cosine position generator will continue to increment or decrement as long as step clock pluses are being received by the Microstepping MForce PowerDrive. Clock Inputs The Microstepping MForce PowerDrive features the ability to configure the clock inputs based upon how the user will desire to control the drive. By default the unit is configured for the Step/Direction function. Step Clock The step clock input is where the motion clock from your control circuitry will be connected. The motor will advance one microstep in the plus or minus direction (based upon the state of the direction input) on the ris- ing edge of each clock pulse. The size of this increment or decrement will depend on the microstep resolution setting. Direction The direction input controls the CW/CCW direction of the motor. The input may be configured as sinking or sourcing based upon the state of the Optocoupler Refer- ence. The CW/CCW rotation, based upon the state of the input may be set using the IMS Motor Interface software included with the Microstepping MForce PowerDrive. Quadrature The Quadrature clock function would typically be used for following applications where the Microstepping MForce PowerDrive would be slaved to an MForce PowerDrive Microstepping (or other controller) in an electronic gearing application. Up/Down The Up/Down clock would typically be used in a dual- clock direction control application. Input Timing The direction input and the microstep resolution inputs are internally synchronized to the positive going edge of the step clock input. When a step clock pulse goes HIGH, the state of the direction input and microstep resolution settings are latched. Any changes made to the direction and/or microstep resolution will occur on the rising edge of the step clock pulse following this change. Run and Hold Current changes are updated immediately. The following figure and table list the timing specifications. Input Filtering The clock inputs may also be filtered using the Clock IOF pull down of the IMS SPI Motor Interface. The filter range is from 50 nS (10 MHz) to 12.9 µSec. (38.8 kHz). The configuration parameters for the input filtering is covered in detail in Section 2.4: Configuring the Microstepping MForce PowerDrive. Step Clock Direction Channel A Channel B CW CCW Step/Direction Function Quadrature Function Up/Down Function Figure 2.4.2: Input Clock Functions

TDSU TDH TSH TSL Direction Step TDC TCHL TCHL Channel A Channel B Direction Change TSH TSL TDC TSH TSL TDC Step Up Step Down STEP/DIRECTION TIMING QUADRATURE TIMING UP/DOWN TIMING Figure 2.4.3: Clock Input Timing Characteristics Clock Input Timing Symbol Parameter Type and Value Step/Direction Step Up/Down Quadrature Units TDSU T Direction Set Up 50 — — nS min TDH T Direction Hold 100 — — nS min TSH T Step High 100 100 — nS min TSL T Step Low 100 100 — nS min TDL T Direction Change — 200 200 nS min TCHL T Channel High/Low — — 400 nS min FSMAX F Step Maximum 5 5 — MHz Max FCHMAX F Channel Maximum — — 1.25 MHz Max FER F Edge Rate — — 5 MHz Max Table 2.4.1: Input Clocks Timing Table

Optocoupler Reference The Microstepping MForce PowerDrive Logic Inputs are optically isolated to prevent electrical noise being coupled into the inputs and causing erratic operation. There are two ways that the Optocoupler Reference will be connected depending whether the Inputs are to be configured as sinking or sourcing. Optocoupler Reference Input Type Optocoupler Reference Connection Sinking +5 to +24 VDC Sourcing Controller Ground Table 2.4.2: Optocoupler Reference Connection NOTE: When connecting the Optocoupler Supply, it is recommended that you do not use MForce Power Ground as Ground as this will defeat the optical isolation. Constant Current Source Optocoupler +5 VDC To Drive Logic Optocoupler Reference Input (Step Clock, Direction, Enable) Microstepping MForce PowerDrive Figure 2.4.4: Optocoupler Input Circuit Diagram

+ Microstepping MForce PowerDrive +5 to +24VDC Optocoupler Reference Input Controller Output Controller Ground + +5 to +24VDC Optocoupler Reference Input Controller Output Controller Ground NPN Open Collector Interface (Sinking) PNP Open Collector Interface (Sourcing) Microstepping MForce PowerDrive Input Connection Examples The following diagrams illustrate possible connection/application of the Microstepping MForce PowerDrive Logic Inputs. Figure 2.4.5: Open Collector Interface Example

Switch Interface Example Switch Interface (Sinking) Switch Interface (Sourcing) + +5 to +24VDC Optocoupler Reference Enable Input SPST Switch GND + Enable Input +5 to +24VDC Optocoupler Reference GND SPST Switch Enable Input Microstepping MForce PowerDrive Microstepping MForce PowerDrive Figure 2.4.6: Switch Interface Example

Minimum Required Connections The connections shown are the minimum required to operate the Microstepping MForce PowerDrive. These are illustrated in both Sinking and Sourcing Configurations. Please reference the Pin Configuration diagram and Specification Tables for the Microstepping MForce PowerDrive connector option you are using. Figure 2.4.7: Minimum Required Connections P4 P3 P1 12-Pin Wire Crimp at P1 Shown. See Specifications for Pin Numbering for other versions. ØA ØB ØA ØB MForce PowerDrive Front Stepping Motor Step Direction +V (+12 to +48) Power Ground Opto Reference* 1 1 2 3 4 3 2 4 6 * The Opto Reference Will set the Sink/Source Configuration of the Inputs Sinking: OptoRef = +5 to +24 VDC Sourcing: OptoRef = Ground

SECTION 2.5 Connecting SPI Communications Connecting the SPI Interface The SPI (Serial Peripheral Interface) is the com- munications and configuration interface. For prototyping we recommend the purchase of the parameter setup cable MD-CC300-000. If using the Microstepping MForce PowerDrive with the 10-Pin IDC on P2, this cable will plug directly into the P2 Connector. If using the model with a 12-Pin Locking Wire Crimp connector, adapters are available to interface the parameter setup cable to P1. For more information on prototype development cables, please see Appendix: Prototype Development Cables. SPI Signal Overview +5 VDC (Output) This output is a voltage supply for the setup cable only. It is not designed to power any external devices. SPI Clock The Clock is driven by the Master and regulates the flow of the data bits. The Master may transmit data at a variety of baud rates. The Clock cycles once for each bit that is transferred. Logic Ground This is the ground for all Communications. MISO (Master In/Slave Out) Carries output data from the Microstepping MForce PowerDrive units back to the SPI Master. Only one MForce PowerDrive can transmit data during any particular transfer. CS (SPI Chip Select) This signal is used to turn multiple Microstepping MForce PowerDrive units on or off. MOSI (Master Out/Slave In) Carries output data from the SPI Master to the Microstepping MForce PowerDrive. Figure 2.5.1: MD-CC300-000 Parameter Setup Cable

SPI Pins and Connections +5 VDC OUT 19 15 2 3 4 PC Parallel/SPI Port P1 10 12 7 9 11 MASTER OUT/SLAVE IN MASTER IN/SLAVE OUT SPI CLOCK 8 CHIP SELECT COMM GND 12-Pin Locking Wire Crimp For Use ONLY with IMS Parameter Setup Cable Figure 2.5.2: SPI Pins and Connections, 12-Pin Wire Crimp Logic Level Shifting and Conditioning Circuit The following circuit diagram is of a Logic Level shifting and conditioning circuit. This circuit should be used if you are making your own parameter cable and are using a laptop computer with 3.3 V output parallel ports. U1:A U1:B U1:D U1:C HCT125 HCT125 HCT125 HCT125 2 1 14 4 5 7 13 12 11 10 8 9 6 3 2 R1 100 +5V R2 49.9 P2: 8 CLK +5V P2: 4 P2: 7 P2: 10 P2: 6 P2: 5 CS MOSI MISO +5 VDC GND 5 6 10 7 4 8 3 4 19 DB25: 2 DB25: 3 DB25: 4 DB25: 19 DB25: 15 15 C3 330pF R9 100K R10 100K R4 49.9 R6 49.9 C4 330pF R3 100 R5 100 C5 330pF R11 100K +5V R12 100K +5V R8 4.9K R7 49.9 +5V C1 C2 .1µF 1µF 25V + Figure 2.5.3: Logic Level Shifting and Conditioning Circuit NOTE: If making your own parameter setup cable, be advised the 3.3V output parallel ports on some laptop PC’s may not be sufficient to communicate with the device without use of a logic level shifting and conditioning Interface.

Figure 2.5.4: SPI Master with a Single Microstepping MForce PowerDrive SPI Master with Multiple Microstepping MForce PowerDrive It is possible to link multiple Microstepping MForce PowerDrive units in an array from a single SPI Master by wiring the system and programming the user interface to write to multiple chip selects. Each MForce on the bus will have a dedicated chip select. Only one system MForce can be communicated with/Parameters changed at a time. Figure 2.5.5: SPI Master with Multiple Microstepping MForce PowerDrives SPI Master SPI Clock MOSI MISO CS SPI Clock MOSI MISO CS1 CS2 SPI Master Microstepping MForce PowerDrive Microstepping MForce PowerDrive #1 Microstepping MForce PowerDrive #2

SECTION 2.6 Using the IMS SPI Motor Interface Installation The IMS SPI Motor Interface is a utility that easily allows you to set up the parameters of your Microstepping MForce PowerDrive. It is available both on the CD that came with your product and on the IMS web site at http://www.imshome.com/software_interfaces.html. 1. Insert the CD into the CD Drive of your PC. If not available, go to http://www.imshome.com/software_interfaces.html. 2. The CD will auto-start. 3. Click the Software Button in the top-right navigation Area. 4. Click the IMS SPI Interface link appropriate to your operating system. 5. Click SETUP in the Setup dialog box and follow the on-screen instructions. 6. Once IMS SPI Motor Interface is installed, the Microstepping MForce PowerDrive settings can be checked and/or set. Configuration Parameters and Ranges Microstepping MForce PowerDrive Setup Parameters Name Function Range Units Default MHC Motor Hold Current 0 to 100 percent 5 MRC Motor Run Current 1 to 100 percent 25 MSEL Microstep Resolution 1, 2, 4, 5, 8, 10, 16, 25, 32, 50, 64, 100,108, 125, 127,128, 180, 200, 250, 256 µsteps per full step 256 DIR Motor Direction Override 0/1 – CW HCDT Hold Current Delay Time 0 or 2-65535 mSec 500 CLK TYPE Clock Type Step/Dir. Quadrature, Up/Down – Step/Dir CLK IOF Clock and Direction Filter 50 nS to 12.9 µS (10 MHz to 38.8kHz) nS (MHz) 50nS (10 MHz) USER ID User ID Customizable 1-3 characters IMS EN ACT Enable Active High/Low High/Low — High WARN TEMP Warning Temperature 0 to + 125 °C 80 Table 2.6.1: Setup Parameters and Ranges Color Coded Parameter Values The SPI Motor Interface displays the parameter values using a predefined system of color codes to identify the status of the parameter. Black: the parameter settings currently stored in the device NVM will display as black. Blue: Blue text indicates a changed parameter setting that has not yet been written to the device. Red: Red text indicates an out-of-range value which cannot be written to the device. When an out-of-range parameter is entered into a field, the "set" button will disable, preventing the value to be written to NVM. To view the valid parameter range, hover the mouse pointer over the field. The valid range will display in a tool tip. The color coding is illustrated in Figure 2.5.1. 1. 2. 3.

IMS SPI Motor Interface Menu Options File > Open: Opens a saved *.mot (Motor Settings) file. > Save: Saves the current motor settings as a *.mot file for later re-use > Save As > Exit - Disconnects from the device and opens the Initialization Dialog. View > Motion Settings: Displays the Motion Settings screen > IO Settings: Displays the IO Settings Screen > Part and Serial Number: Displays the part and serial number Red: Out of Range Value. The Set Button will disable as the the Motor Interface will not allow an out of range value to be stored. Blue: New Value which has not yet been set to NVM. Black: This is the value Currently Stored in NVM Figure 2.6.1: SPI Motor Interface Color Coding Perform File Operation Open Motor Settings File (*.mot) Save Motor Settings Save Motor Settings As Exit the Motor Interface Figure 2.6.2: SPI Motor Interface File Menu View Settings Screen Motion Settings Screen I/O Settings Screen Read-Only Part and Serial Number Screen Figure 2.6.3: SPI Motor Interface View Menu

Recall! Retrieves the settings from the Microstepping MForce PowerDrive. Upgrade! Upgrades the Microstepping MForce PowerDrive firmware by placing the device in Upgrade Mode and launching the firmware upgrader utility. Help > IMS Internet Tutorials: Link to an IMS Web Site page containing Interactive flash tutorials. > About: Opens the About IMS and IMS SPI Motor Interface Screen. Recall Last Stored Parameter Settings Figure 2.6.4: SPI Motor Interface Recall Menu Toggle MForce into Upgrade Mode for Firmware Upgrade Figure 2.6.5: SPI Motor Interface Upgrade Menu Figure 2.6.6: SPI Motor Interface Help Menu and About Screen Links to the Software Tutorial page of the IMS Website

1. MSEL: Microstep Resolution Select. 2. HCDT: Holding Current Delay Time. 3. MRC: Motor Run Current 4. Motor Holding Current 5. User ID: 3-character ID 6. Direction Override: Allows the user to set the CW/CCW direction of the motor in relation to the Direction Input from the SPI Motor Interface. MSEL (Microstep Resolution Selection) The Microstepping MForce PowerDrive features 20 microstep resolutions. This setting specifies the number of microsteps per step the motor will move. The MForce PowerDrive uses a 200 step (1.8°) stepping motor which at the highest (default) resolution of 256 will yield 51,200 steps per revolution of the motor shaft. See Table 2.3.2 for available Microstep Resolutions. Microstep Resolution Settings Binary µStep Resolution Settings Decimal µStep Resolution Settings MS=<µSteps/Step> Steps/Revolution MS=<µSteps/ Step> Steps/Revolution 1 200 5 1000 2 400 10 2000 4 800 25 5000 8 1600 50 10000 16 3200 100 20000 32 6400 125 25000 64 12800 200 40000 128 25600 250 50000 256 51200 Additional Resolution Settings 180 36000 (0.01°/µStep) 108 21600 (1 Arc Minute/µStep) 127 25400 (0.001 mm/µStep) Table 2.6.2: Microstep Resolution Settings Figure 2.6.7: SPI Motor Interface Motion Settings Screen Load Factory Default Settings Exit Program Store Settings to NVM Three Character User ID Microstep Resolution Selection Holding Current Delay Time Direction Override Motor Run Current Motor Holding Current Fault/Checksum Error

HCDT (Hold Current Delay Time) The HCDT Motor Hold Current Delay sets time in milliseconds for the Run Current to switch to Hold Current when motion is complete. When motion is complete, the Microstepping MForce PowerDrive will reduce the current in the windings of the motor to the percentage specified by MHC when the specified time elapses. MRC (Motor Run Current) The MRC Motor Run Current parameter sets the motor run current to a percentage of the full output current of the MForce PowerDrive driver section. MHC (Motor Hold Current) The MHC parameter sets the motor holding current as a percentage of the full output current of the driver. If the hold current is set to 0, the output circuitry of the driver section will disable when the hold current setting becomes active. The hold current setting becomes active HCDT setting mS following the last clock pulse. Run and Hold Current Settings HC=(%) RC=(%) MForce PowerDrive (Amps RMS) 10 0.5 20 1.0 30 1.5 40 2.0 50 2.5 60 3.0 70 3.5 80 4.0 90 4.5 100 5.0 Table 2.6.3: Hold and Run Current Percentage Equivalents DIR (Motor Direction) The DIR Motor Direction parameter changes the motor direction relative to the direction input signal, adapting the direc- tion of the MForce PowerDrive to operate as your system expects. User ID The User ID is a three character (viewable ASCII) identifier which can be assigned by the user. Default is IMS. IMS SPI Motor Interface Button Functions The following appear on all of the IMS SPI Motor Interface screens, but will only be documented here. Factory Clicking the Factory button will load the Microstepping MForce PowerDrive unit's factory default settings into the IMS SPI Motor Interface. Connected/Disconnected Indicator Displays the connected/disconnected state of the software , and if connected, the port connected on. Set Set writes the new settings to the MForce PowerDrive . Un-set settings will display as blue text in the setting fields. Once set they will be in black text. Setting the Parameters will also clear most Fault Conditions. Exit Disconnects and opens the Initialization dialog.

Screen 2: I/O Settings Configuration Screen The I/O Settings screen may be accessed by clicking View > IO Settings on the menu bar. This screen is used to configure the Input Clock type, the filtering and the Active High/Low State of the Enable Input. Input Clock Type The Input Clock Type translates the specified pulse source that the motor will use as a reference for establishing stepping resolution based on the frequency. The three clock types supported are: 1. Step/Direction 2. Quadrature 3. Up/Down The Clock types are covered in detail in Section 2.2: Logic Interface and Connection.­ Input Clock Filter The clock inputs may also be filtered using the Clock IOF pull down of the IMS SPI Motor Interface. The filter range is from 50 nS (10 MHz) to 12.9 µSec. (38.8 kHz). Table 2.4.3 shows the filter settings. Input Clock Filter Settings Min. Pulse Cutoff Frequency 50 nS 10 MHz 150 nS 3.3 MHz 200 nS 2.5 MHz 300 nS 1.67 MHz 500 nS 1.0 MHz 900 nS 555 kHz 1.7 µS 294.1 kHz 3.3 µS 151 kHz 6.5 µS 76.9 kHz 12.9 µS 38.8 kHz Table 2.6.4: Input Clock Filter Settings Enable Active High/Low The parameter sets the Enable Input to be Active when High (Default, Disconnected) or Active when Low. Warning Temperature The parameter sets the temperature at which a TW, or temperature warning fault code will be generated. In the warning condition the MForce PowerDrive will continue to operate as normal. The thermal shutdown is +85°C. Input Clock Type (Step/Dir, Quadrature or Up/Down) Input Clock Filter Active High/Low State of the Enable Input Warning Temperature Figure 2.6.8: SPI Motor Interface I/O Settings Screen

IMS Part Number/Serial Number Screen The IMS Part Number and Serial Number screen is accessed by clicking "View > Part and Serial Numbers". This screen is read-only and will display the part and serial number, as well as the fault code if existing. IMS may require this information if calling the factory for support. Fault Indication All of the IMS SPI Motor Interface Screens have the Fault field visible. This read-only field will display a 2 charac- ter error code to indicate the type of fault. The table below shows the error codes. MForce34Plus Microstepping Fault Codes Binary Case* Error Code Description Action To Clear — None No Fault — — 4 CS SPI Checksum Error Error Displayed Write to MDM (Set Button) 8 SC/CS SPI Checksum Error/ Sector Changing Error Displayed Write to MDM (Set Button) 16 DFLT Defaults Checksum Error Error Displayed Write to MDM (Set Button) 32 DATA Settings Checksum Error Error Displayed Write to MDM (Set Button) 64 TW Temperature Warning Error Displayed Write to MDM (Set Button) *All Fault Codes are OR'ed together Table 2.6.5: Microstepping MForce PowerDrive Fault Codes IMS Part # IMS Serial Number Figure 2.6.9: SPI Motor Interface Part and Serial Number Screen

Upgrading the Firmware in the Microstepping MForce PowerDrive The IMS SPI Upgrader Screen New firmware releases are posted to the IMS web site at http://www.imshome.com. The IMS SPI Motor Interface is required to upgrade your Microstepping MForce PowerDrive product. To launch the Upgrader, click "Upgrade!" on the IMS SPI Motor Interface menu. The Upgrader screen has 4 read-only text fields that will display the necessary info about your Microstepping MForce PowerDrive. 1. Previous Version: this is the version of the firmware currently on your Microstepping MForce PowerDrive. 2. Serial Number: the serial number of your unit. 3. Upgrade Version: will display the version number of the firmware being installed. 4. Messages: the messages text area will display step by step instructions through the upgrade process. Upgrade Instructions Below are listed the upgrade instructions as they will appear in the message box of the IMS SPI Upgrader. Note that some steps are not shown as they are accomplished internally, or are not relevant to the model IMS product you are updating. The only steps shown are those requiring user action. Welcome Message: Welcome to the Motor Interface UPGRADER! Click NEXT to continue. Step 2: Select Upgrade File When this loads, an explorer dialog will open asking you to browse for the firmware upgrade file. This file will have the extension *.ims. Step 3: Connect SPI Cable Step 4: Power up or Cycle Power to the MForce Step 6: Press Upgrade Button Progress bar will show upgrade progress in blue, Message box will read "Resetting Motor Interface" Step 8: Press DONE, then select Port/Reconnect. NOTE: Once entered into Upgrade Mode, you MUST complete the upgrade. If the upgrade process is incomplete the IMS SPI Motor Interface will continue to open to the Upgrade dialog until the process is completed! Figure 2.6.10: SPI Motor Interface Upgrade Utility

Initialization Screen This screen will be active under five conditions: When the program initially starts up and seeks for a compatible device. The User selects File > Exit when connected to the device. The User clicks the Exit button while connected to the device. The Upgrade Process completes. The SPI Motor Interface is unable to connect to a compatible device. Port Menu The Port Menu allows the user to select the COM Port that the device is connected to, either a parallel (LPT) Port, or a Hardware Serial or Virtual Serial Port via USB. The Reconnect option allows the user to reconnect to a unit using the previously used settings. On open or reconnect, the SPI Motor Interface will also try to auto seek for a connected device. 1. 2. 3. 4. 5. Figure 2.6.11: SPI Motor Interface Initialization Communications Port Operations Select Parallel (LPT) Port Select Serial or USB (VCP) Auto-seek Port and Reconnect to device Figure 2.6.12: SPI Motor Interface Port Menu

Motor Settings Screen (PWM Current Control) The Motor settings screen allows the user to fine tune the settings of the PWM to optimize the current output for a variety of stepping motors. There are four parameters that may be set: PWM Mask PWM Period (Duty Cycle) PWM Frequency Range PWM Control PWM Mask The PWM mask parameter prevents the premature end of the forward period caused by switching transients when the motor phase current is at low levels. Adjusting this value can impact the zero-crossing performance of the motor. If experiencing the “tick” which is inherit in stepper motor systems, this may be minimized or eliminated by adjusting this value. The range of this value is 0 to 255d and will be entered as a decimal value. The Mask will act as a filter on the PWM signal to allow time for any ringing in the output circuitry to settle. This range represents a 8-bit Hex value that specifies the Bridge Reverse Measure Time (REVTM) and the Minimum Bridge Forward On Time (FORTM) ranging from 600 nS to 3.4 µS each (see table and diagram below). Typically these values would be balanced. The table below shows the decimal value for each time. Note that these are typical values and the currents may be unbalanced to fine tune the motor performance. The default value for this parameter is 204 (0xCC), which represents a Reverse Measure Time and Minimum Forward On Time of 2.5 µS. Reverse Measure Time/Minimum Forward On Time Hex Time Hex Time Hex Time Hex Time 0x0 600 ns 0x4 1.0 µs 0x8 1.6 µs 0xC 2.5 µs 0x1 700 ns 0x5 1.1 µs 0x9 1.8 µs 0xD 2.8 µs 0x2 800 ns 0x6 1.2 µs 0xA 2.0 µs 0xE 3.1 µs 0x3 900 ns 0x7 1.4 µs 0xB 2.2 µs 0xF 3.4 µs Table 2.6.6: PWM Mask Settings 1. 2. 3. 4. PWM Mask PWM Frequency Range PWM Period (Duty Cycle) Control Bits Figure 2.6.13: Motor Settings Screen Reverse Measure Time Min. Forward On Time 1 1 0 1 1 1 0 1 0xD (2.8 µS) 0xD (2.8 µS) 0xDD PWM Mask Value = 221 Convert to Decimal Figure 2.6.14: PWM Mask Bits

Typical PWM Mask Settings (Currents Balanced) Mask (hex) Mask (dec) REVTM FORTM Mask (hex) Mask (dec) REVTM FORTM 0x00 0 600 ns 600 ns 0x88 135 1.6 µs 1.6 µs 0x11 17 700 ns 700 ns 0x99 153 1.8 µs 1.8 µs 0x22 34 800 ns 800 ns 0xAA 170 2.0 µs 2.0 µs 0x33 51 900 ns 900 ns 0xBB 187 2.2 µs 2.2 µs 0x44 68 1.0 µs 1.0 µs 0xCC 204 2.5 µs 2.5 µs 0x55 85 1.1 µs 1.1 µs 0xDD 221 2.8 µs 2.8 µs 0x66 102 1.2 µs 1.2 µs 0xEE 238 3.1 µs 3.1 µs 0x77 119 1.4 µs 1.4 µs 0xFF 255 3.4 µs 3.4 µs Table 2.6.7: Typical PWM Mask Settings Maximum PWM Duty Cycle (%) Parameter This parameter sets the maximum duty cycle as a percentage of the bridge PWM oscillator period. The range for this parameter is 0 to 95%. The default value for this parameter is 95%. PWM Frequency Range Parameter The PWM Frequency Parameter sets the initial and maximum frequencies for the PWM. As with the MASK parameter, the PWM Frequency is a two part 8-bit hex number which is entered as a decimal value ranging from 0 to 255. The default for this 170 (0xAA) with an initial PWM Frequency of 20 kHz and a Maximum of 60 kHz. Maximum PWM Frequency (kHz) Hex Freq. Hex Freq Hex Freq Hex Freq 0x0 40 0x4 48 0x8 56 0xC 64 0x1 42 0x5 50 0x9 58 0xD 66 0x2 44 0x6 52 0xA 60 0xE 68 0x3 46 0x7 54 0xB 62 0xF 70 Initial PWM Frequency (kHz) Hex Freq. Hex Freq Hex Freq Hex Freq 0x0 10 0x4 14 0x8 18 0xC 22 0x1 11 0x5 15 0x9 19 0xD 23 0x2 12 0x6 16 0xA 20 0xE 24 0x3 13 0x7 17 0xB 21 0xF 25 Table 2.6.8: Maximum and Initial PWM Frequency PWM Max. Frequency PWM Initial Frequency 0 1 0 1 1 1 1 0 0x5 (50 kHz) 0xE (24 kHz) 0x5E PWM SFREQ = 94 PWM Frequency Range 24 to 50 kHz Convert to Decimal Figure 2.6.15: PWM Frequency Range

PWM Control Bits Bit 7 – QUIET This bit changes PWM operation. When quiet is set, the bridge logic does not enter the reverse measure period, therefore there are fewer transitions. The bridge is disabled during zero cross. This mode is used at rest or when moving very slowly. When quiet is cleared, normal bridge operation is selected. Bit 6 – Not used Bit 5 – SYNC_EN This bit controls the synchronization of the bridge PWM with the zero cross. When the sync_en bit is set, the bridge PWM will be synchronized with the positive front slope of the sin phase at each zero cross. Bit 4 – RECIR This bit controls where the motor current will recirculate within the bridge during the recirculate period. When recirc is set, the motor current will recirculate in the high portion of the bridge. When recir is cleared, the motor current will recirculate in the low portion of the bridge. Bits 3..1 – TODLY - Turn on Delay This value sets the bridge control turn on delay to prevent shoot through if a discrete FET bridge is in use. The range is 0 to 350 nS with 50 nS resolution. Each LSB is 50 nS. The default setting for a bridge driver is 50 nS (0x1). Bit 0 – ENABLE Bridge Enable, this bit is set at the factory and is inaccessible to the user. Example PWM Settings By Motor Specifications The following settings are based upon IMS settings per motor specifications and should serve as a baseline to work from with regard to the manufacturer specifications of the motor being utilized. Note that these are example settings ONLY! Example PW Settings Frame Size Stack Size Phase Current (ARMS) Phase Resistance (Ω) Phase Inductance (mH) MASK Duty Cycle Frequency Checksum 14 Single 0.75 4.30 4 102 90 170 106 17 Single 1.5 1.30 2.1 136 90 170 140 Double 1.5 2.10 5.0 136 90 170 140 Triple 1.5 2.00 3.85 136 90 170 140 23 Single 2.4 0.95 2.4 136 90 170 140 Double 2.4 1.20 4.0 136 90 170 140 Triple 2.4 1.50 5.4 136 90 170 140 MForce Default — — — 204 95 170 — Table 2.6.9: Example PWM Settings       7 6 5 4 3 2 1 0 PWMCTL Bit 0x0203 Read/Write Initial Value R/W 0 R/W 0 R/W 1 R/W 0 R/W 0 R/W 0 R/W 1 R/W 0 QUIET SYNC_EN RECIR TODLY[2:0] ENABLE Figure 2.6.16: PWM Control Bits

SECTION 2.7 Using User-Defined SPI The MForce can be configured and operated through the end-user's SPI interface without using the IMS SPI Mo- tor Interface software and optional parameter setup cable. An example of when this might be used is in cases where the machine design requires parameter settings to be changed on-the-fly by a software program or multiple system Microstepping MForce PowerDrive units parameter states being written/read. SPI Timing Notes 1. MSb (Most Significant bit) first and MSB (Most Significant Byte) first. 2. 8 bit bytes. 3. 25 kHz SPI Clock (SCK). 4. Data In (MOSI) on rising clock. 5. Data Out (MISO) on falling clock. Check Sum Calculation for SPI The values in the example below are 8-bit binary hexadecimal conversions for the following SPI parameters: MRC=25%, MHC=5%, MSEL=256, HCDT=500 mSec, WARNTEMP=80. The Check Sum is calculated as follows: (Hex) 80+19+05+00+00+01+F4+50 Sum = E3 1110 0011 1’s complement = 1C 0001 1100 (Invert) 2’s complement = 1D 0001 1101 (Add 1) Send the check sum value of 1D Note: 80 is always the first command on a write. Note: Once a write is performed, a read needs to be performed to see if there is a fault. The fault is the last byte of the read. Figure 2.7.1: SPI Timing

SPI Commands and Parameters Use the following table and figure found on the following page together as the Byte order read and written from the MDrivePlus Microstepping, as well as the checksum at the end of a WRITE is critical. SPI Commands and Parameters Command/ Parameter HEX (Default) Range Notes READ ALL 0x40 — Reads the hex value of all parameters MSB Device (M) 0x4D — M Character precedes every READ Version_MSB 0x10 <1-8>.<0-9> Firmware Version.Sub-version, eg 1.0 Version_LSB 0x00 <0-99> Firmware Version Appends to Version_ MSB, eg.00 USR_ID1 0x49 — Uppercase Letter USR_ID2 0x4D — Uppercase Letter USR_ID3 0x53 — Uppercase Letter MRC 0x19 1-67% Motor Run Current MHC 0x05 0-67% Motor Hold Current MSEL 0x00 0*, 1-259 *0=256 Microstep Resolution (See Table in Section 2.4 for settings) DIR_OVRID 0x00 0=no override 1=override dir Direction Override HCDT_HI 0x01 0 or 2-65535 Hold Current Delay Time High Byte HCDT_LO 0xF4 Hold Current Delay Time Low Byte CLKTYP 0x00 0=s/d, 1=quad, 2=u/d Input Clock Type CLKIOF 0x00 <0-9> Clock Input Filtering WARNTEMP 0x50 OVER_TEMP - 5° C EN_ACT 0x01 0=Low 1=High, Enable Active High/Low LSB FAULT 0x00 — See Fault Table, Section 2.4 WRITE ALL 0x80 — Writes the hex value to the following parameters. MSB USR_ID1 0x49 — Uppercase Letter USR_ID2 0x4D — Uppercase Letter USR_ID3 0x53 — Uppercase Letter MRC 0x19 1-100% Motor Run Current MHC 0x05 0-100% Motor Hold Current MSEL 0x00 0*, 1-259 *0=256 Microstep Resolution (See Table in Section 2.4 for settings) DIR_OVRID 0x00 0=no override 1=override dir Direction Override HCDT_HI 0x01 0 or 2-65535 Hold Current Delay Time High Byte HCDT_LO 0xF4 Hold Current Delay Time Low Byte CLKTYP 0x00 0=s/d, 1=quad, 2=u/d Input Clock Type CLKIOF 0x00 <0-9> Clock Input Filtering WARNTEMP 0x50 OVER_TEMP - 5° C EN_ACT 0x01 0=Low 1=High Enable Active High/Low LSB CKSUM 34 Table 2.7.1: SPI Commands and Parameters