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Contact Technical Support

G203V REV-7

Versions:

Standard
Click here to download this manual
(PDF)

Vacuum
Click here to download this manual
(PDF)

G203V Revision 7
Manual
Last Update: January 7, 2010

Thank you for
purchasing the G203V drive. The G203V is Geckodrive’s new generation CPLD-based
microstep drive. It has short-circuit protection for the motor outputs,
over-voltage and under-voltage protection, over-temperature protection, reversed
power supply polarity protection and will survive accidental motor disconnects
while powered-up. The “V” in G203V stands for “Vampire” as it is an unkillable
drive.

The G203V uses a synchronous PWM design that is absolutely silent
when the motor is stopped or turning slowly. It virtually eliminates
stopped-motor heating regardless of power supply voltage. The G203V is a
jumper-free drive. There are no internal user settings at all so there is no
need to ever remove the drive cover at all.

The STEP, DIRECTION and
DISABLE inputs are opto-isolated. All three inputs work with 2.5V, 3.3V or 5V
logic drive signals. The input drive current is now 2.5mA at 2.5V so almost all
logic family (74LS, 74HC, etc.) can be used to drive these inputs. The COMMON
return for the signals is controller ground referenced instead of +5VDC. This
greatly eases the drive to controller interface.

There are no unusual
STEP to DIRECTION timing restrictions. Stepping occurs on the positive edge of
the STEP pulse. The DIRECTION input must be true 200nS before and after this
STEP pulse edge.

The G203V microstep drive is warranted to be free of
manufacturing defects for 1 year from the date of purchase. Anyone who is
dissatisfied with it or is unable to make it work to their satisfaction for any
reason will be cheerfully refunded the purchase price if the G203V is returned
within 15 days of the purchase date in a cosmetically and electrically undamaged
condition.

PLEASE READ FIRST BEFORE USING THE
G203V

Before you start you must have a 2-phase hybrid PM step
motor (ordinary 1.8 or 0.9 degree per step motor), a DC power supply suitable
for the motor and a current set resistor. The motor’s rated phase current must
not be more than 7 Amps. The power supply voltage must be between 15VDC and
80VDC unregulated. The current set resistor may be a 1/4-Watt, 5% part. Finally
have a STEP, DIRECTION and DISABLE (if needed) source
available.

G203V TERMINAL WIRING

The G203V uses a
2-piece modular main connector. The connector is split in two pieces; terminals
1 through 6 (power supply and motor leads) and terminals 7 through 12 (control
interface). Each can be removed separately by pulling the connector body upwards
and off of the mating header pins on the G203V. The connectors must initially be
removed to mount the G203V to a heatsink or chassis.

TERMINAL 1
Power Ground
Connect the negative (black) lead of your power supply
to this terminal.

TERMINAL 2 Power (+)
Connect the
positive (red) lead of your power supply to this terminal. It must be between
+18VDC to +80VDC.

TERMINAL 3 Motor Phase A
Connect
one end of your “Phase A” motor winding here.

TERMINAL 4
Motor Phase /A
Connect the other end of your “Phase A” motor winding
here.

TERMINAL 5 Motor Phase B
Connect one end of
your “Phase B” motor winding here.

TERMINAL 6 Motor
Phase /B
Connect the other end of your “Phase B” motor winding
here.

TERMINAL 7 Disable
This terminal will force the
winding currents to zero when tied to the step and direction controller +5V.

TERMINAL 8 Direction
Connect the DIRECTION signal to
this terminal.

TERMINAL 9 Step
Connect the STEP
signal to this terminal.

TERMINAL 10 Common
Connect
the controller’s GROUND to this terminal.

TERMINAL 11
Current Set
Connect one end of your current set resistor to this
terminal.

TERMINAL 12 Current Set
Connect the other
end of your current set resistor to this terminal.

POWER SUPPLY
WIRING

TERMINAL 1 Power Ground
Connect the
power supply ground to term.1

TERMINAL 2 Power
(+)
Connect the power supply “+” to this terminal

The power supply
voltage must be between 15 VDC and 80 VDC. The maximum power supply current
required is equal to the motor’s rated phase current. An unregulated power
supply may be used so long as the voltage stays between the specified limits;
keep the power supply ripple voltage to 10% or less for best
results.

CAUTION! Power supply voltage in excess of 80 VDC will
blow the G203V internal fuse.

CAUTION! Reversed power
supply polarity will blow the G203V internal
fuse.

CAUTION! Never put a switch on the DC side of the
power supply! This will damage, if not destroy, your drive!

The
choice of power supply voltage depends on the required high-speed performance
from the motor; doubling the voltage doubles the motor’s high-speed power. In
all cases the power supply voltage should be no less than 4 times or no more
than 20 times the motor’s rated voltage. The motor may not run as smoothly as
possible if the power supply voltage is less than 4 times or more than 20 times
the motor’s rated voltage. A power supply voltage greater than 20 times the
motor’s rated voltage may overheat and damage the motor. Motor winding
inductance should be 500uH or greater.

A more accurate calculation of
power supply voltage is to find your motor’s inductance, and put it into the
following equation.

32 * (√mH inductance) = Power Supply
Voltage

If your motor has 2mH of inductance, the equation would look as
follows.

32 * (√2) = 45.12V

MOTOR
CONNECTION

TERMINAL 3 Phase A
Connect one
motor winding to this terminal

TERMINAL 4 Phase
/A
Connect the other end of the winding to this
terminal

TERMINAL 5 Phase B
Connect the other motor
winding to this terminal

TERMINAL 6 Phase /B
Connect
the other end of the winding to this terminal

One motor winding connects
to terminals 3 and 4 and the other winding connects to terminals 5 and 6. Turn
the power supply off when connecting or disconnecting the motor. If the motor
turns in the wrong direction, reverse the motor winding connections to terminals
3 and 4.

CAUTION! Avoid shorting the motor leads to each other or
to ground or the G203V will enter protective shut-down.

4-wire,
6-wire and 8-wire motor may be used. If 6-wire motors are used, they may be
connected in half winding or full winding. This is equivalent to an 8-wire motor
connected in parallel or series. If a motor is connected in series or full
winding, the motor’s phase current rating is half of its parallel or unipolar
rating. The choice depends on the high-speed performance required; a
parallel-connected motor will provide twice the power of a series-connected
motor at the same power supply voltage.

DISABLE
PIN

TERMINAL 7 Disable
This terminal will
force the winding currents to zero when tied to the step and direction
controller +5V.

The DISABLE input on the G203V is optically isolated and
requires logic “1” to DISABLE and logic “0” to ENABLE the drive. Once it is
disabled, the motor windings are unergenized and the motor
freewheels.

STEP AND DIRECTION
INPUTS

TERMINAL 8 Direction
Connect the
DIRECTION line to this terminal.

TERMINAL 9 Step

Connect the STEP line to this terminal.

TERMINAL 10
Common
Connect this terminal to the controller GROUND

These 3 inputs
are optically isolated from the rest of the drive. They will operate with 2.5V,
3.3V or 5V logic outputs with 2.5mA minimum source drive current. The STEP
input’s maximum rated frequency is 350kHz with a 50% duty-cycle waveform. The
G203V steps the motor on the 0 to 1 logic (positive) edge of the STEP
signal.

CURRENT SET RESISTOR

TERMINAL
11 Current Set
Connect the current set resistor to this
terminal

TERMINAL 12 Current Set
Connect the other
end of the current set resistor to this terminal

This input matches the
G203V’s current output to the motor windings. The G203V will accommodate motor
winding currents from 0 to 7A. Use the following equation to calculate the
value, (in kilo-Ohms) of the current set resistor:
R (in kilo-ohms) = 47 * I
/ (7 – I) Use the nearest standard value 5% tolerance, 1/4W resistor for this
setting.

Here are the current set resistor values for motor current in
.5A increments. Round the appropriate answer to the nearest 5% resistor value.

a. 1A – 7.8K
b. 1.5A – 12.8K
c. 2A – 18.8K
d. 2.5A –
26.1K
e. 3A – 35.25K
f. 3.5A – 47K
g. 4A – 62.67K
h. 4.5A –
84.6K
i. 5A – 117.5K
j. 5.5A – 172.33K
k. 6A – 282K
l. 6.5A –
611K
m. 7A – OPEN

OTHER
CONSIDERATIONS

HEATSINKING: The G203V needs heatsinking for
current settings greater than 3 amps. The case temperature (measured on the
bottom plate) should not exceed 70 degrees C, and for best life should be kept
at 50C degrees or less. Use heatsink compound between the G203V and your
heatsink.

CAUTION! Current settings above 3A without a heatsink
may result in the G203V entering thermal shutdown.

AUTO CURRENT
REDUCTION: The G203V reduces motor phase current to 71% of the set current value
1 second after the last step pulse is sent. The G203V also changes to a special
recirculating current mode to nearly eliminate motor heating.

ADJUST:
This trimpot adjusts the motor for the smoothest possible low-speed operation.
Set the motor speed to about 1/2 revolution per second and then turn the trimpot
until a distinct null is noted in the motor’s vibration. This will result in the
most even microstep placement for a given motor and power supply voltage. The
default setting for this trimpot is at ½ -turn and the setting for your motor
will be within +/- ¼-turn of the default setting.

MAIN CONNECTOR: The
G203V uses a 2-piece modular main connector. The connector is split in two
pieces; terminals 1 thru 6 (power supply and motor leads) and terminals 7 thru
12 (control interface). Each can be removed separately by pulling the connector
body up and away from the top surface of the G203V. Remove the connectors to
access the G203V front mounting screw locations in order to mount it to a
heatsink or chassis.

G203V INDICATORS

POWER LED:
The GREEN POWER indicator is lit whenever the G203V has power supply voltage
applied.

FULL POWER LED: The YELLOW FULL POWER indicator is lit when the
motor is turning fast enough to generate maximum possible mechanical power.
Power is torque times RPM and power output reaches its maximum value when this
indicator is lit. Use this indicator to verify your motor is optimally geared to
the load.

ERROR LED: The RED ERROR indicator is lit when:
1) During
power-on reset for 1 second when power is first applied to the G203V.
2)
While the DISABLE input is active.
3) When there is a short-circuit on any
motor output. Momentarily activate the DISABLE input to reset.
4) During
over-temperature shutdown. The LED automatically resets when the drive
temperature drops.

INTERNAL FUSE: The G203V uses a socketed,
user-replaceable internally mounted fuse (Littlefuse Inc. part # 0251005.MXL).
Reversing the power supply polarity or a power supply voltage over 114VDC will
cause the internal fuse to blow.

CAUTION! Do not use any other
type of fuse, do not bridge a blown fuse with wire and do not solder the fuse in
place. Doing so will void the drive’s warranty.

REMOVING
AND REPLACING THE COVER

REMOVING THE COVER:

1) Remove the
two 2-56 phillips-head screws on the bottom of the drive.
2) Slide the cover
backwards until it clears the drive.

REPLACING THE COVER:

1) Slide
the cover forward over the drive while lifting the back of the cover.
2)
Replace the screws on the bottom of the drive.

It is recommended to use
small needle-nose pliers or tweezers to move the jumpers on the internal
headers.

MAIN CONNECTOR: The G203V uses a 2-piece modular main connector.
The connector is split in two pieces; terminals 1 thru 6 (power supply and motor
leads) and terminals 7 thru 12 (control interface). Each can be removed
separately by pulling the connector body upwards and off of the mating header
pins on the G203V. The connectors must initially be removed to mount the G203V
to a heatsink or
chassis.

TROUBLESHOOTING

EVERYTHING IS CONNECTED,
NOTHING HAPPENS: Is the GREEN LED lit? If not, either the G203V has no power
supply voltage connected or something very bad caused its internal fuse to blow.
Check the power supply voltage using a multimeter set to ‘DC VOLTS’ on terminal
screw heads 1,2 of the drive.

The internal fuse is the G203V’s final line
of protection. It blows only under the most extreme circumstances. Those are
reversed power supply polarity; AC voltage instead of DC voltage on terminals 1
and 2 and power supply voltages in excess of 114VDC. Correct the problem and
replace the fuse with the only approved type. It is the only kind that blows
fast enough to protect the G203V. Anything else voids the
warranty.

EVERYTHING IS CONNECTED, RED INDICATOR STAYS LIT: If the RED
and GREEN indicator LEDs are lit then the motor is miswired, the motor has a
wire shorted to ground, is shorted to another motor wire or the motor is bad.
Secondarily: Everything ran OK but the RED LED lit a while later. Check the
drive temperature; it may have overheated because of inadequate heatsinking.
Also see that the DISABLE input isn’t being activated (+5VDC on
DISABLE).

MOTOR HAS NO HOLDING TORQUE: If the RED LED is off and the
GREEN LED is on, check the CURRENT SET resistor with a multimeter. Re-calculate
the resistor value. Check to see if the motor is connected to the
G203V.

MOTOR HAS HOLDING TORQUE BUT WON’T MOVE: Check your STEP,
DIRECTION, DISABLE (if used) and COMMON interface. Verify COMMON goes to your
controller GND.

MY MOTOR RUNS ROUGH AT LOW SPEEDs: Try adjusting the
ADJUST trimpot setting. Verify you are using the correct CURRENT SET resistor. A
round stepper motor will not operate as well as a square stepper motor as they
were not designed for microstepping.

MY YELLOW LED NEVER LIGHTS: You are
not going fast enough to get full power from your motor. If you don’t need to go
any faster, use a lower power supply voltage. This indicator is a good
application diagnostic for motor gearing and power supply voltage choice. Using
it correctly will help you to optimize your
system.

DISCLAIMER

CERTAIN APPLICATIONS USING
POWER PRODUCTS MAY INVOLVE POTENTIAL RISKS OF DEATH, PERSONAL INJURY OR SEVERE
DAMAGE TO PROPERTY. GECKODRIVE INC. PRODUCTS ARE NOT DESIGNED, AUTHORIZED OR
WARRANTED TO BE SUITABLE FOR USE IN LIFE-SUPPORT DEVICES OR OTHER CRITICAL
APPLICATIONS. INCLUSION OF GECKODRIVE INC. PRODUCTS IN SUCH APPLICATIONS IS
UNDERSTOOD TO BE FULLY AT THE PURCHASER’S OWN RISK

In order to minimize
risks associated with the purchaser’s application, adequate design and operating
safeguards must be provided by the purchaser to minimize inherent or procedural
hazards. GECKODRIVE INC. assumes no liability for applications assistance or the
purchaser’s product design. GECKODRIVE INC. does not warrant or represent that
any license, either express or implied, is granted under any patent right,
copyright or other intellectual property right of GECKODRIVE
INC.

SPECIFICATIONS

Supply Voltage:

15 to 80 VDC

Phase Current:

0 to 7 Amps
Auto Current Reduction:

71% of set current, 1 second after last Step Pulse
Size:

2.5”W, 2.5”D,
.85”H (63.5mm, 63.5mm, 21.5mm)
Mounting Pattern:

4 6-32 screws, 1.75” by 2.375” (44.5 mm, 60
mm)
Weight:

3.6 oz. (100
gm)
Quiescent Current:

20 Ma or less (drive disabled)
Short-circuit trip current:

10A, 3uS response time
Step Frequency:

0 to 333 kHz
Step
Pulse “0” Time:
2uS min (Step on rising
edge)
Step Pulse “1” Time:
1 uS min

Temperature Range:
0 to 70 C

Humidity:

0 to 95 %
(non-condensing)
Direction Setup:

200nS before step pulse rising edge

200nS hold after step pulse rising edge
Power Dissipation:

1 to 13 W (0 to 7 Amps)

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