TOXOTES MICRO STEPPER CNC Stepper Motor … MICRO STEPPER CNC Stepper Motor Controller Western Robotics Ltd. 1/9/2012 Toxotes Hardware Reference Guide PCB Rev 1.1 Page 2 Table of Contents

TOXOTES MICRO STEPPER

CNC Stepper Motor Controller

Western Robotics Ltd.

1/9/2012

Toxotes Hardware Reference Guide PCB Rev 1.1 Page 2

Table of Contents

1.0 FEATURES .................................................................................................................................... 3

2.0 HARDWARE LAYOUT .................................................................................................................... 4

3.0 QUICK SETUP GUIDE PROCEDURE................................................................................................. 5

4.0 SELECTING/CONNECTING STEPPER MOTORS ................................................................................ 5

4.1 6 & 8 Wire Stepper Motors .................................................................................................................... 5

4.1.1 6 Wire Stepper Wiring Diagram ..................................................................................................... 6

4.1.1.1 Bipolar Series Connection .............................................................................................................. 6

4.1.1.2 Unipolar Connection ...................................................................................................................... 7

4.1.2 8 Wire Stepper Motor Wiring Diagram ........................................................................................... 7

4.1.2.1 Bipolar Series Connection ............................................................................................................ 7

4.1.2.2 Bipolar Parallel Connection ......................................................................................................... 8

4.1.2.3 Unipolar Connection .................................................................................................................... 9

4.2 4 Wire Stepper Motor ........................................................................................................................... 9

5.0 HARDWARE PORT DESCRIPTION ................................................................................................. 10

5.1 Parallel Port, Limit Switch Input & Output Port Connection ................................................................. 10

5.1.1 Limit Switch Input ............................................................................................................................ 11

5.3 Step Resolution Setting ....................................................................................................................... 11

5.4 Power Input ........................................................................................................................................ 12

5.5 Motor Current Adjust .......................................................................................................................... 12

5.6 Percent Fast Decay (PFD) Adjust .......................................................................................................... 13

5.7 Stepper Motor Connection Ports ......................................................................................................... 14

6.0 ADDITIONAL SAFETY NOTES ....................................................................................................... 14

7.0 WARRANTY & LIABILITY .............................................................................................................. 15


1.0 FEATURES

• 4, 5 or 6 Axis Bi-Polar Stepper Motor Controller

• Programmable motor step resolution of full, ½, ¼ or 1/16 step

• High current capability of up to 2.5 Amperage per axis (per motor)

• Wide input power range to handle 8 to 30 Volts rating stepper motors

• Personal Computer (PC) interfaced via on board Parallel Port

• Compatible with market available Computerized Numeric Control (CNC) PC interface software

• Uses Pulse Width Modulation technology (chopper) for improved power dissipation

• On board adjustable stepper motor current setting via potentiometer

• On board adjustable PFD (Percent Fast Decay)

• Limit switch input PC controlled via parallel port

• Noise reduction filter on each input and output. (Output port not available on 6 Axis model)

• Compatible with 4, 6 and 8 wire (NEMA 17, NEMA 23 and NEMA 34) stepper motors

NEMA17

NEMA23 NEMA34

Example Motor Types


2.0 HARDWARE LAYOUT

Please read the entire manual before proceeding to operate the Toxotes.

CAUTION! Before connecting stepper motor make sure the stepper motors are wired correctly. Ensure

the motor leads are securely attached. Intermittent or loose connections can generate several kilo volts

of back EMF spikes from the attached motors; this will result in possible damage to the motor and the

Toxotes CNC controller.

Layout diagram below illustrates all the user interfaces to configure the stepper motor settings, motor ports,

setup port connections to the PC controls and power connections for the 4 & 5 Axis controller board.

Power Input

10 to 24volt

PFD (Percent

Fast Decay)

Adjust / Axis

Motor Current

Adjust / Axis

Limit Switch

Input

Output Control

Port (4/5 axis

versions only)

Step Resolution

Settings / Axis

Y Axis

X Axis

Parallel Port

to PC

Stepper Motor

Connection Ports

A Axis

Z Axis

B Axis Auxiliary 5

Volt Supply

T Axis (not

shown, 6 axis

version only)


3.0 QUICK SETUP GUIDE PROCEDURE

1. Ground yourself with the use of grounding wrist band.

2. Setup output pin configuration on chosen control software.

3. Connect 1 Stepper motor.

4. Connect power supply.

5. Turn power on to confirm correct connection of stepper wires - motor should lock up (if not, re-examine

stepper motor wiring diagram and re-wire)

6. Turn power off.

7. Connect remaining stepper motors.

8. Connect signal wires between computer and drive board.

9. Turn power on.

10. Attempt to jog axis with software (if axis turns in opposite direction of desired direction)

11. Attempt axis rotation reversal via software- if unable to do so switch 2 wires for one coil (i.e. switch A

with A#, do not switch wires between coils, please refer to the wiring diagrams in the manual)

12. You are now done and able to begin using your new stepper motor drive

4.0 SELECTING/CONNECTING STEPPER MOTORS

CAUTION! Incorrect wiring of the stepper motor to the Toxotes board may lead to permanent damage to

the Toxotes driver board. DO NOT CONNECT OR DISCONNECT MOTORS WHILE THE POWER IS APPLIED. It is

critical to obtain a proper motor coil diagram of your intended motor to be used with the Toxotes. Ensure

that the proper coil end wiring is properly connected to the Toxotes Axis ports, making improper connections

such as mixed cross connections on the stepper motor’s coils will destroy the Toxotes’ control circuitry.

The Toxotes Micro stepper CNC Controller is compatible with all 4, 6, and 8 wire stepper motors. It is

possible to drive these 3 different types of wired stepper motors having the motors to be rated ideally at 2.0

amps. Choosing a motor with a 1.8 degree per step resolution is recommended and is usually an industry

standard for CNC and motor automation applications.

The Toxotes driver is based on DMOS technology and despite the fact it features output protection it will be

damaged if it is not properly connected to the motor(s). Please following the 4, 6 & 8 Wire Stepper Motor

sections thoroughly before proceeding to operate the Toxotes with stepper motors connected. Note not to

connect ANY MOTOR leads directly to the ground or power supply to prevent possible damage to the

motors.

4.1 6 & 8 Wire Stepper Motors

If a 6 or 8 wire stepper motor is being used, consider them to be connected in a series wiring method. In

this case, when selecting these motors you must select the amperage rating to be doubled of that on the

motors labeled amperage rating. For example, selecting a 6 wire configured stepper motor, you will

need to select a 4 amp labeled motor, in actual fact this will result in an ideal 2 amp rating for your

Toxotes application.


4.1.1 6 Wire Stepper Wiring Diagram

If a 6 wire stepper motor is to be used, there are two methods that this motor can be connected

to the Toxotes. A 6 wire stepper motor can either be connected in a Bipolar Series Connection or

Unipolar Connection. These two methods are further discussed as follows

4.1.1.1 Bipolar Series Connection

A 6 wire stepper motor configured in a Bipolar Series Connection must have the center tap wires

of each of its coils to be left unconnected and terminated it with insulation. Remaining wires at

the ends of each phase are connected to their corresponding terminal block location on the

Toxotes Axis ports, for example the stepper motor’s A wire is connected to A connection on the

axis port of the Toxotes.

A series connection motor should be operated at only 70% of the motors rated current because

it has double the windings on each phase due to the series connection, this will result in a lower

current draw at the same rated torque. Running the motor at full rated current will saturate and

overheat the motor. The series connection is preferred method because it produces less heat in

the driver and results in higher torque.

Please refer to the following Bipolar Connection diagram for correct wiring configuration.

BiPolar 6Wire Stepper Motor Series Connection


4.1.1.2 Unipolar Connection

A 6 wire stepper motor configured in a unipolar connection has one end of each phase should be

unconnected and insulated. The other end and center tap are connected to their corresponding

terminal block location on the Toxotes Axis ports. In this case the attached motor could run at its

full current rating. This type of connection works better at higher RPM speeds.

Please refer to the following Unipolar Connection diagram for correct wiring configuration.

4.1.2 8 Wire Stepper Motor Wiring Diagram

If an 8 wire stepper motor is to be used, there are three methods that this motor can be connected to

the Toxotes. An 8 wire stepper motor can either be connected in a Bipolar Series Connection, Bipolar

Parallel Connection or Unipolar Connection. These three methods are further discussed as follows.

4.1.2.1 Bipolar Series Connection

An 8 wire stepper motor configured in a bipolar-series connection gives more torque at lower

RPM speeds and less torque at higher RPM speeds. A series connection motor should be

operated at only 70% of the motors rated current because it has double the windings on each

phase due to the series connection, this will result in a lower current draw at the same rated

torque. Running the motor at full rated current will saturate and overheat the motor.

UniPolar 6Wire Stepper Motor Connection


Please refer to the following Bipolar Series Connection diagram for correct wiring configuration.

4.1.2.2 Bipolar Parallel Connection

An 8 wire stepper motor configured in a bipolar-parallel connection should run at 1.41 rated

current. This connection is not recommended because higher current is generated in this

configuration that will result in more heat buildup in the Toxotes driver and it’s connected motor.

Please refer to the following Bipolar Parallel Connection diagram for correct wiring configuration.

Bipolar 8 Wire Stepper Motor Series Connection

Bipolar 8 Wire Stepper Motor Parallel Connection


4.1.2.3 Unipolar Connection

An 8 wire stepper motor configured in a unipolar connection has only one pair of each phase is

used. This connection works better at higher RPM speeds. Please refer to the following Unipolar

Connection diagram for correct wiring configuration.

4.2 4 Wire Stepper Motor

If a 4 wire stepper motor is to be used, then a motor rated from 2 to 2.5 amps per phase will yield the best

performance with the Toxotes micro stepper driver. The 4 wire configuration on these motors can only be

configured in one way and it connects directly to the motor axis port on the Toxotes. Each wire is connected

to its corresponding terminal block location example the stepper motor’s A wire is connected to the A

connection on the axis port of the Toxotes. If the rotation of the attached stepper motor turns the opposite

of the desired direction, then swapping the wires of just one phase will cause the motor to rotate in opposite

direction.

Unipolar 8 Wire Stepper Motor Connection

4 Wire Stepper Motor Connection


5.0 HARDWARE PORT DESCRIPTION

This section describes all user interface ports on the Toxotes driver board as shown on section 2.0

Hardware Layout.

5.1 Parallel Port, Limit Switch Input & Output Port Connection

A DB25 male to female extension should be used to interconnect the driver board to your PC. This

connection does not require any kind of adaptors or hubs. The use of adapters and hubs is not

recommended and will prevent communication problems between the PC and Toxotes controller.

It is critical that the connection between the computer parallel port and motor driver board be direct

without the use of adapters. If your computer does not feature a 25 pin parallel port such as a laptop

computer, you must install one by adding a PMCIA card.

The following table labels all the corresponding PC DB25 parallel port pins with respect with the Toxotes

DB25 parallel port pins. Limit Switch Input and Output Control Port from the Toxotes board reflects the

same pin connections as the DB25 Parallel port Input and Output pins as displayed below.

Categorized Printer Port Pins:

DB25 PC Printer Port Output Pin from PC to TOXOTES Input Pin from TOXOTES to PC

1 Direction B Axis

2 Direction X Axis

3 Step X Axis

4 Direction Y Axis

5 Step Y Axis

6 Direction Z Axis

7 Step Z Axis

8 Direction A Axis

9 Step A Axis

10 HOME B

11 HOME A

12 HOME X

13 HOME Y

14 Step B Axis

15 HOME Z

16 Output 1 or Direction T Axis

17 Output 2 or Step T Axis

18-to-25 GROUND GROUND


o Blue pins represent output control signals to the Toxotes Micro stepper CNC controller.

o Red pins represent input control signals for the limit and home switch.

o Green pins represent ground.

5.1.1 Limit Switch Input

The Limit Switch Input allows you to add end and home switches to your CNC application. Total

of 5 switches can be added to limit your movement of the CNC motion controlled by the stepper

motors. Refer to diagram below on the switch connection on the Limit Switch Input port on the

Toxotes board.

NOTE: OUTPUT PORTS NOT AVAILABLE ON 6 AXIS MODEL


5.2 Step Resolution Setting There are 4 individual resolution jumper settings on the Toxotes board to set the four individual stepper

motor connection axis. The Step Resolution Setting jumpers correspond in line with the respective

motor axis.

The Step Resolution Setting sets the stepper motor step increment resolution to be either full, ½, 1/4, or

1/16 step. . For example, if you have 1.8 degree precision stepper motor and have it configured for a full

step resolution, then you will get 200 steps in one full 360 degree turn (1 revolution) , if it is configured

with a 1/16 step resolution then you will get 3200 steps in one full turn. Please refer to the following

diagram on how to set the jumpers for the desired step resolution. Solid fill represents a jumper plug.

5.3 Power Input This is the DC power input that supplies power to the Toxotes. The Toxotes has a wide input range that

takes 8 to 30 Volts DC. Please ensure the correct polarity and voltage is applied to the Power Input pins.

Refer to the Toxotes board labeling for correct polarity connection.

5.4 Motor Current Adjust The Motor Current Adjust potentiometer allows the operator to adjust the current setting for each

individual stepper motor. Each Motor Current Adjust corresponds in line with the respective motor axes.

Use a small Philips screwdriver to adjust the potentiometer as required.

CAUTION! Do not connect or disconnect any attached motors or any of the motor’s wire while

power is applied to the Toxotes board, by doing so will cause immediate damage to the Toxotes

driver board. Remove all power to the Toxotes before removing or adding stepper motor

connection(s).

All Axis current must be adjusted on the Motor Current Adjust potentiometers with the aid of a

voltmeter; each potentiometer corresponds in line with the respective motor axis. The voltage reading

from the current adjust potentiometers corresponds to a current setting. The voltage can be monitored

on the corresponding TPx1 pin on the Toxotes with a use of a voltmeter while adjusting the Stepper

Motor Current Adjust potentiometer.

To adjust the stepper motor current, apply power to the Toxotes board with the proper connected

stepper motor and measure the voltage at the corresponding TPx1 axis point (on the round pad) of each


potentiometer with respect to the black or negative point of the Power supply GND. Please refer to the

following example diagram that shows where to measure the voltage points with Y AXIS of the Toxotes

board.

Use the following formula to translate the voltage reading to a current setting.

Vref = 2*(DESIRED CURRENT), therefore DESIRED CURRENT (A) = Vref/2

For example, for a desired current of 1.8 Amp you will adjust the V-REF potentiometer until you get the

3.6volt.

CAUTION! It is proper and safe to adjust the V-REF potentiometer while the power is applied to

the Toxotes board with the stepper motor properly connected. Make sure to adjust the

potentiometer slowly to slowly increase/decrease the current setting. If you find the motor is

overheating, this means that the motor current is too high and should be set lower.

It is recommended to use a series configured wiring if 6 or 8 wire motors are used. This reduces

the amperage rating by 50%. A 3 Amp motor wired in this way should consider as a 1.5amp

motor.

5.5 Percent Fast Decay (PFD) Adjust It is possible that the attached stepper motors on the Toxotes board to produce a high pitched resonance

noise; this is normal and is caused by the current pulse control circuitry. This is imperceptible in high

quality motors. It is possible to reduce the resonance noise by adjusting the Toxotes’ Percent Fast

Decay(PFD) adjust potentiometer as shown on the Hardware Layout section 2.0. The PFD adjust sets the

Toxotes driver output current decay when the PWM circuit switches the control current.

The PFD voltage can be monitored with the aid of a voltmeter by measuring the voltage at the

corresponding labeled TPx2 axis point (on the round pad) of each potentiometer with respect to the

Example Voltage Measuring Points for Current Adjust


black or negative point of the Power supply GND. Please refer to the following example diagram that

shows where to measure the voltage points with one of the Toxotes board. For most stepper motors,

setting the PFD to 2.5VDC is a good reference to start point for minimal resonance noise

NOTE: It is proper and safe to adjust the PFD voltage while the power is applied to the Toxotes board

having the stepper motors properly connected.

5.6 Stepper Motor Connection Ports All stepper motor connections are made to the 4, 5 and 6 Axis connections on the Toxotes board as

shown on section 2.0 Hardware Layout. The corresponding X, Y, Z, A, B and T axis are as displayed on the

Hardware Layout diagram. These ports are controlled by the corresponding axis as in the PC CNC

software. Refer to section 3.1 and 3.2 for the proper stepper motor wiring.

6.0 ADDITIONAL SAFETY NOTES Always properly ground one-self when handling the Toxotes stepper motor drive board. It is highly

recommend that the stepper motor driver board is properly enclosed in an instrument case before use

(contact with debris may cause damage to the board). Do not connect or disconnect any attached motors

or any of the motor’s wire while power is applied to the Toxotes board, by doing so will cause immediate

damage to the Toxotes driver board. Remove all power to the Toxotes before removing or adding

stepper motor connection(s).

Example Voltage Measuring Points for PFD Adjust


7.0 WARRANTY & LIABILITY

Disclaimer and Limitation of Liability

Western Robotics Ltd. shall have no liability or responsibility to the user of any other party or entity with respect

to any liability, injuries, loss or damage, cause or alleged to be caused, directly or indirectly, for equipment sold,

furnished or supplied by Western Robotics Ltd.

Notwithstanding the above limitations, Western Robotics Ltd. is not liable for damages incurred by customers or

to the customers. Western Robotics Ltd. is not liable for the particular equipment involved.

Neither Western Robotics Ltd. nor this document makes any expressed or implied warranty, including, but not

limited to the implied warranties of merchantability, quality or fitness for a particular purpose.

Specifications are subject to change without notice.

Limited Warranty (North America Only)

The TOXOTES MICROSTEPPER is guaranteed to be free from defects in material and workmanship for a period of

90 days from the date of purchase accompanied by the proof of purchase or invoice. Warranty does not cover

damage due to improper use or incorrect installation.

During the 90 day warranty period, if the product shows defects caused by abuse, accident or misuse, it will

repaired or replaced upon Western Robotics Ltd. sole discretion, at a service charge not greater than 40% of the

current retail list price. Please ensure to include your contact information before any repair(s) or replacement(s)

can be conducted. Under no circumstances or condition will the purchaser be entitled to consequential or

incidental damages. In no case shall our liability exceed the product's original cost. We reserve the right to

modify warranty provision without notice. Because Western Robotics Ltd. has no control over connection and

use of this product, no liability may be assumed nor will be accepted for damage resulting from the use of this

product, user accepts all resulting liability. If you attempt to disassemble, modify or repair this unit yourself, it

may void the warranty.

For warranty service on Western Robotics product(s) in, out or off warranty period, please send the defective

unit(s) along with the proof of purchase and a description of the problem, postage paid, to the given address

below.

Customer Service,

Western Robotics Ltd.

215-12837 76th Avenue

Surrey, BC

V3W 2V3 Canada

Phone: 778-565-1332

[email protected]

www.western-robotics.com

Documents

TOXOTES MICRO STEPPER CNC Stepper Motor … MICRO STEPPER CNC Stepper Motor Controller Western Robotics Ltd. 1/9/2012 Toxotes Hardware Reference Guide PCB Rev 1.1 Page 2 Table of Contents