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SLO-SYN® MD808 & MD808-128

Microstep Drive Module
Installation Instructions

Document Number: 400030-145

Rev E
Record of Manual Revisions
ISSUE NO. DATE BRIEF DESCRIPTION OF REVISION
A 06/26/99 Initial release
B 02/10/00 Revise corporate identity
C 10/05/01 Revise corporate identity
D 01/15/03 Updated contact information and revise corporate identity
E 07/31/03 Updated corporate style

Copyright Information
© Copyright 1997 - 2003 Danaher Motion - All rights reserved.
Printed in the United States of America.

NOTICE:
Not for use or disclosure outside of Danaher Motion except under written agreement. All rights are
reserved. No part of this book shall be reproduced, stored in retrieval form, or transmitted by any
means, electronic, mechanical, photocopying, recording, or otherwise without the written permission
from the publisher. While every precaution has been taken in the preparation of the book, the
publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for
damages resulting from the use of the information contained herein.
This document is proprietary information of Danaher Motion that is furnished for customer use
ONLY. No other uses are authorized without written permission of Danaher Motion. Information in
this document is subject to change without notice and does not represent a commitment on the part
of Danaher Motion. Therefore, information contained in this manual may be updated from time-to-
time due to product improvements, etc., and may not conform in every respect to former issues.

SAFETY
The equipment described herein has been developed, produced, tested and documented in
accordance with the corresponding standards. Use conforming with requirements means that the
safety recommendations and warnings detailed in this manual are complied with and applicable
regulations for safety (machine directives, etc.) and noise suppression (EMC Directives) are
observed while operating the drive. Comply with the applicable European standards and Directives.
At the end of its lifetime, dispose of or recycle the drive according to the applicable regulations.
This unit is designed for 20 to 80 VDC input only.
Installation and wiring of the drive must be completed only by qualified personnel having a basic
knowledge of electronics, installation of electronic and mechanical components, and all applicable
wiring regulations.
The "PWR ON" LED must be off for approximately 30 seconds before making or breaking the
motor connections. Motors powered by this drive may develop extremely high torque. Be sure to
disconnect power to this drive before doing any mechanical work.
Commissioning of the machine utilizing the drives must be done only by qualified personnel having
a broad knowledge of electronics and motion control technology.
As the user or person applying this unit, you are responsible for determining the suitability of this
product for the application. In no event is Danaher Motion responsible or liable for indirect or
consequential damage resulting from the misuse of this product.
Danaher Motion Superior Electric Table of Contents

Table of Contents

1. INTRODUCTION..........................................................................1-1
1.1. IN THIS MANUAL ....................................................................1-1
1.2. FEATURES ...............................................................................1-2
2. EXPRESS START UP...................................................................2-1

3. INSTALLATION GUIDELINES ..................................................3-1

3.1. MOUNTING ..........................................................................3-1
3.1.1. Mounting Dimensions ......................................................3-1
3.2. CONNECTORS AND PIN ASSIGNMENTS .......................3-2
3.2.1. MOTOR CONNECTIONS ................................................3-3
3.2.2. POWER INPUT................................................................3-5
4. SPECIFICATIONS ........................................................................4-1
4.1. MECHANICAL SPECIFICATIONS.....................................4-1
4.2. ELECTRICAL SPECIFICATIONS.......................................4-1
4.3. ENVIRONMENTAL SPECIFICATIONS.............................4-1
4.4. MOTOR COMPATIBILITY .................................................4-2
4.5. PREFERRED MOTORS........................................................4-3
4.6. CURRENT AND STEP RESOLUTION SETTINGS ...........4-4
4.6.1. Current Settings (Switch Positions 1 – 5) ........................4-4
4.6.2. Step Resolution (Switch Positions 6 – 8)..........................4-5
4.7. AUTO REDUCE AND
CONTROL FILTER SETTINGS.....................4-5
4.7.1. Auto Reduce (Switch Position 1)......................................4-5
4.7.2. Control Filter (Switch Positions 2 – 4) ............................4-6
4.8. SIGNAL SPECIFICATIONS.................................................4-6
4.8.1. Connector Pin Assignments .............................................4-6
4.8.2. Signal Descriptions ..........................................................4-7
4.8.3. Level Requirements ..........................................................4-8
4.8.4. Timing Requirements........................................................4-8
4.8.5. INDICATOR LIGHTS ....................................................4-10

SLO-SYN MD808 & MD808-128 i

Table of Contents Danaher Motion Superior Electric

5. TORQUE VERSUS SPEED CHARACTERISTICS.....................5-1

5.1. MOTOR PERFORMANCE ...................................................5-1
5.2. TORQUE VERSUS SPEED CURVES..................................5-2
6. TROUBLESHOOTING .................................................................6-1

APPENDIX A .......................................................................................A-1
A.1 TROUBLESHOOTING ELECTRICAL
INTERFERENCE PROBLEMS......................A-1
A.2 CUSTOMER SUPPORT/CONTACT INFORMATION .....................A-2

ii SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric Introduction

1. INTRODUCTION
It is important that you understand how this SLO-SYN® MD808
Microstep Drive Module is installed and operated before you attempt to
use it.
Read this manual completely before proceeding with the
installation of this unit.

1.1. In This Manual

This manual is an installation and operating guide to the SLO-SYN
MD808 Microstep Drive Module. Section 1 gives an overview of the
Drive and its features. Section 2 describes the steps necessary to place
the drive into operation. General wiring guidelines as well as the physical
mounting of the unit and connections to the drive portion are covered in
Section 3.
Complete specifications, listed in Section 4, provide easily referenced
information concerning electrical, mechanical, and environmental
specifications. The procedure for setting the motor current level is also
covered in this section.
Torque versus speed characteristics for the preferred SLO-SYN Stepper
Motors are given in Section 5. Section 6, Troubleshooting, gives
procedures to follow if the Microstep Drive Module fails to operate
properly.
Appendix A provides procedures for troubleshooting electrical
interference problems.

SLO-SYN MD808 & MD808-128 1-1

Introduction Danaher Motion Superior Electric

1.2. Features
The SLO-SYN MD808 (MD808-128) is a bi-polar, speed-adjustable,
two-phase PWM drive that uses power MOSFET devices. The MD808
can be set to operate a stepper motor in 8 step resolutions from full step
to 1/100 microstep. The MD808-128 can be set to operate a stepper
motor in 8 step resolutions from full step to 1/128 microsteps. The
maximum running speed is 3,000 rpm. To reduce the possibility of
electrical noise problems, the control signals are optically isolated from
the drive circuit.
Active mid-range stabilization control
Switch selectable current levels of 3 through 8 amperes
Full short circuit protection (phase-to-phase and phase-to-ground)
Under-voltage and transient over-voltage protection
Thermal protection
Efficient thermal design
Optically isolated inputs
Reduce current input
Switch selectable automatic current reduction or externally activated
current reduction
Windings off input
Switch selectable step resolution
Compact size
Sturdy all-aluminum case

1-2 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric EXPRESS START UP

2. EXPRESS START UP
The following instructions define the minimum steps necessary to make
your Drive operational.

Always disconnect the power to the unit and be certain

that the "PWR ON" LED is OFF before connecting or
disconnecting the motor leads. FAILURE TO DO SO
RESULTS IN A SHOCK HAZARD AND DAMAGES THE
DRIVE.
Always operate the unit with the Motor and the Drive
enclosure GROUNDED. Be sure to twist together the wires
for each motor phase as well as those for the DC input. Six
twists per foot is a good guideline.

1. Check to see that the motor used is compatible with the drive. Refer
to Section 4.4 for a list of preferred motors.

2. Set the correct current level for the motor being used per the
instructions in Section 4.6. Heat sinking is required if a current of
4 amperes or higher is used.

3. Select the appropriate step resolution and set the switches as

described in Section 4.6.

4. Wire the motor per the "Motor Connections" description in Section

3.2.1.

5. Connect the power source to the DC input terminal strip. Be sure to

follow the instructions for connecting the filter capacitor as described
in Section 3.2.2, under Power Input.

SLO-SYN MD808 & MD808-128 2-1

EXPRESS START UP Danaher Motion Superior Electric

If the motor operates erratically, refer to Section 5,

"TORQUE VERSUS SPEED CHARACTERISTICS."
Clockwise and counter-clockwise directions are properly
oriented when viewing the motor from the end opposite the
mounting flange.

2-2 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric INSTALLATION GUIDELINES

3. INSTALLATION GUIDELINES
3.1. MOUNTING
The SLO-SYN Drive is mounted by fastening its mounting brackets to a
flat surface as shown in the next figure. If the Heat Sink Assembly (part
number 221576-001) is mounted against a bulkhead, be sure to apply a
thin coat of thermal compound between the heat sink and the mounting
surface before fastening the unit in place. Do not use too much thermal
compound. It is better to use too little than too much.

3.1.1. Mounting Dimensions

5.20 MAX
1.36 0.07
2.50

0.66

4.84
5.25

0.313

0.219
typical

Case temperature should not exceed +70° C (+158° F). A

heat sink, such as Danaher Motion's Superior Electric Heat
Sink Assembly (part number 221576-001) must be used
when the drive is operated at a current setting of 4
amperes or more. In this case, the unit should be mounted
upright (with the cooling fins vertical), or proper cooling
will not occur. Airflow should not be obstructed. Forced air
cooling may be required to maintain temperature within the
stated limits.

SLO-SYN MD808 & MD808-128 3-1

INSTALLATION GUIDELINES Danaher Motion Superior Electric

When selecting a mounting location, it is important to leave at least two

inches (51 mm) of space around the top, bottom and sides of the unit to
allow proper airflow for cooling.
It is also important to keep the drive away from obvious sources of
electrical noise. If possible, locate the drive in its own metal enclosure to
shield it and its wiring from electrical noise sources. If this cannot be
done, keep the drive at least three feet from any noise sources.
3.2. CONNECTORS AND PIN ASSIGNMENTS
The figure below shows the connector locations for the SLO-SYN
MD808 Microstep Drive Module.

3-2 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric INSTALLATION GUIDELINES

3.2.1. MOTOR CONNECTIONS

All motor connections are made via the 6-pin connector, part number
218397-006 (included). Pin assignments for this connector are given
below. Motor connections are shown in the next figure.
PIN ASSIGNMENT
1 M1 (Phase A)
2 M3 (Phase A)
3 M4 (Phase B)
4 M5 (Phase B)

Motor phase A is M1 and M3 and motor phase B is M4

and M5. The motor frame must be grounded.

Cabling from the drive to the motor should be done with a shielded,
twisted-pair cable. As a guideline, the wires for each motor phase should
be twisted about six times per foot.
Danaher Motion offers the following motor cable configurations. These
cables have unterminated leads on both ends.
Length Part Number
10 ft. (3 m) 216022-031
25 ft. (7.5 m) 216022-032
50 ft. (15.2 m) 216022-033
75 ft. (22.8 m) 216022-034
The next figure shows the possible motor wiring configurations.

SLO-SYN MD808 & MD808-128 3-3

INSTALLATION GUIDELINES Danaher Motion Superior Electric

MOTOR MOTOR TERMINAL "M" NUMBERS MOTOR

CONNECTOR PIN CONNECTOR PIN

1 5 WHITE/
DRIVE PIN 1 RED B D DRIVE PIN 4
BLACK

WHITE/
DRIVE PIN 2 H 3 4 F BLACK DRIVE PIN 3
RED
GREEN
4-LEAD MOTORS

DRIVE PIN 1 RED B 1 5 D GREEN DRIVE PIN 4

* N.C. BLACK G 6 2 E WHITE N.C.*

WHITE/ WHITE/
DRIVE PIN 2 H 3 4 F DRIVE PIN 3
RED GREEN
6-LEAD MOTORS

DRIVE PIN 1 RED B 1 5 D GREEN DRIVE PIN 4

BLACK G 6 7 E ORANGE

* WHITE A 2 8 C
WHITE/ *
BLACK
DRIVE PIN 2 WHITE/ H F WHITE/ DRIVE PIN 3
3 4
RED GREEN
8-LEAD MOTORS, SERIES CONNECTIONS

DRIVE PIN 1 RED B 1 5 D GREEN DRIVE PIN 4

BLACK G 6 7 E ORANGE

2 8 WHITE/
WHITE A C BLACK
DRIVE PIN 2 WHITE/ H F WHITE/
RED 3 4 DRIVE PIN 3
GREEN
8-LEAD MOTORS, PARALLEL CONNECTIONS

*These leads must be insulated and isolated from other leads or ground.

Circled letters identify terminals for connector motors; numbers identify

those for terminal box motors.

3-4 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric INSTALLATION GUIDELINES

3.2.2. POWER INPUT

The DC input power is connected to pins 5 and 6 of the power connector.
Pin 5 [Vm(+)] is the power supply plus (+) connection and pin 6
[Vom(-)] is the power supply minus (-) connection.
An unregulated supply is preferable. If a regulated supply is used, it
must be a linear regulated supply and must be capable of operating
with the added filter capacitor. A switching regulated supply is not
recommended for use with this drive. It is important that capacitor
C1 be connected within three feet (0.9 meter) of the input terminals.
The capacitor must be of the correct value and have the proper
current and voltage parameters (see list of components).
It is recommended that the power supply leads be twisted together (6
twists per foot).

If the power supply is grounded, it must only be

grounded on the negative side or the short circuit
protection will not operate properly.

T1
F1

CT
115 VAC

R1 F2 DRIVE
AC +
5 Vm(+)
+
CT C1 R2
6 Vm(-)
AC -

The cable between the filter capacitor C1 and the drive

should be twisted (six twists per foot). Maximum wire
length is three feet.
Use #16 AWG or larger wire.

SLO-SYN MD808 & MD808-128 3-5

INSTALLATION GUIDELINES Danaher Motion Superior Electric

Components for circuit shown in previous figure:

5 ampere or lower setting
F1 3 amp time delay, Bussman MDA-3 or equivalent
F2 15 amp very fast-acting, Bussman GBB-15 or
equivalent
R1 5 Ω surge limiter, Phillips 2322-654-61508 or
equivalent
R2 4.7 kΩ, 2 watt, ±5%
T1 160 VA, Bicron Electronics BU216AS040D, Signal
Transformer 80-2 or equivalent
BR1 General Instrument GBPC3502 or equivalent
C1 4700 µf, 6.9 amp ripple current, 100 VDC United
ChemiCon 36DA472F100AL2A or equivalent
6 through 8 ampere setting
F1 6 amp time delay, Bussman MDA-6 or equivalent
F2 15 amp very fast-acting, Bussman GBB-15 or
equivalent
R1 4 Ω surge limiter, Phillips 2322-654-61408 or
equivalent
R2 4.7 kΩ, 2 watt, ±5%
T1 320 VA, Bicron Electronics BU233AS040D, Signal
Transformer 80-4 or equivalent
BR1 General Instrument GBPC3502 or equivalent
C1 6800 µf, 9.4 amp ripple current, 100 VDC United
ChemiCon 36DA682F100AD2A or equivalent

3-6 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric SPECIFICATIONS

4. SPECIFICATIONS
4.1. MECHANICAL SPECIFICATIONS
Size
(inches) 5.25 H x 1.36 W x 5.6 D
(mm) 133 H x 35 W x 142 D
Weight 1.5 pounds (680 grams)

4.2. ELECTRICAL SPECIFICATIONS

DC Input Range 20 VDC min., 80 VDC max.
DC Current see Motor Table
Drive Power Dissipation
(Worse Case) 40 watts

4.3. ENVIRONMENTAL SPECIFICATIONS

Temperature
Operating +32° F to +122° F (0° C to +50° C) free air ambient,
Natural Convection. Maximum heat sink temperature
of +158° F (+70° C) must be maintained. Forced air
cooling may be required.
Storage -40° F to +167° F (-40° C to +75° C)
Humidity 95% max. non-condensing
Altitude 6,562 feet (2000 m) max.

SLO-SYN MD808 & MD808-128 4-1

SPECIFICATIONS Danaher Motion Superior Electric

4.4. MOTOR COMPATIBILITY

Motor Types Superior Electric M and KM Series
Frame Sizes
M Series M061 (NEMA 23D) - M092 (NEMA 34)
KM Series KML060 (NEMA 23) - KML093 (NEMA 34)
Number of Connections 4, 6, 8
Minimum Inductance 1 millihenry
Maximum Resistance 0.25 x VDC Supply/I Setting
Example:
VDC = 60 I Setting = 7
R max. = 0.25 x 60/7 = 2.1 Ω

Maximum resistance is total of motor plus cable.

Duty cycle limiting or external motor cooling may be

required to keep the motor shell temperature below its
rating.
Do not use larger frame size motor than those listed, or
the drive may be damaged. If a larger frame size must be
used, consult the factory for recommendations.

4-2 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric SPECIFICATIONS

4.5. PREFERRED MOTORS

Control Filter Switch Settings Current Power Supply Current
Setting Standstill Maximum
Motor 4 3 2 (Amps) (ADC) (ADC)
KML060F05 DOWN UP UP 3 1.0 2.0
KML061F05 DOWN UP UP 3 1.0 2.0
KML062F07 DOWN UP UP 4 1.0 3.5
KML062F13 UP DOWN DOWN 8 1.5 4.5
KML063F07 DOWN UP UP 4 1.0 2.0
KML063F13* DOWN UP UP 8 2.0 4.5
KML091F07 DOWN UP UP 4 1.5 2.5
KML091F13* DOWN UP UP 8 1.5 4.0
KML092F13* DOWN UP UP 8 2.0 4.5
KML093F10 UP DOWN DOWN 7 2.0 4.5
KML093F14* UP DOWN DOWN 8 2.0 4.5
*Recommended motor

Power supply currents shown are measured at the output of the rectifier
bridge.
Motors with windings other than those listed can be used as long as the
current ratings listed on the motors are not exceeded.

SLO-SYN MD808 & MD808-128 4-3

SPECIFICATIONS Danaher Motion Superior Electric

4.6. CURRENT AND STEP RESOLUTION

SETTINGS

4.6.1. Current Settings (Switch Positions 1 – 5)

The proper current setting for each motor is shown on the torque vs.
speed curves. Use this current level to obtain the torque shown. The
access hole for the switches that set the motor current level is located on
the back of the unit. Switches 1 through 5 are used to select a current
level. Select the desired operating current by setting the appropriate
switch. Only one switch should be Down at a time. If two or more
switches are Down, the higher current level is the active level. The
switch settings are:
Switch Position Peak Current (Amps) RMS Current (Amps)
All Up 3.0 2.1
1 Down 4.0* 2.8
2 Down 5.0* 3.5
3 Down 6.0* 4.2*
4 Down 7.0* 5.0*
5 Down 8.0* 5.6*
* Heat sinking is recommended at current settings of 4 amperes or higher. The
drive case temperature MUST NOT exceed +70° C.

4-4 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric SPECIFICATIONS

4.6.2. Step Resolution (Switch Positions 6 – 8)

The number of pulses per revolution is selected using positions 6 through
8 of the switch. The following chart shows the correct switch settings for
each available step resolution.
MD808 MD808-128
Switch* Position* Resolution Pulses/Ref Resolution Pulses/Ref
All Up Full 200 Full 200
7 Down 1/2 400 1/2 400
8 Down 1/5 1,000 1/4 800
7&8 Down 1/10 2,000 1/8 1,600
6 Down 1/20 4,000 1/16 3,200
6&7 Down 1/25 5,000 1/32 6,400
6&8 Down 1/50 10,000 1/64 12,800
6, 7, & 8 Down 1/100 20,000 1/128 25,600
* Switches not listed must be in the Up position

4.7. AUTO REDUCE AND CONTROL FILTER

SETTINGS

4.7.1. Auto Reduce (Switch Position 1)

Refer to the next figure for the location of the Auto reduce switch.
Up - 50% Standstill current activated after 0.5 to 1.5 seconds.
Down - Auto reduce inactive.

Reduce is controlled by an external signal.

4 3 2 1

1 2 3 4 5 6 7 8

Current Selection and Control Filter and Auto

Step Resolution Switches Reduce Switches

SLO-SYN MD808 & MD808-128 4-5

SPECIFICATIONS Danaher Motion Superior Electric

4.7.2. Control Filter (Switch Positions 2 – 4)

Switch positions 2 through 4 set the control filter as indicated
below:
SWITCH FILTER
4 3 2 FREQUENCY (Hz)
Down Down Down 1700
Down Down Up 850
POSITION

Down Up Down 540

Down Up Up 420
Up Down Down 330
Up Down Up 270
Up Up Down 230
Up Up Up 200

Filter selection depends on the motor selected. See the list of

recommended motors.

4.8. SIGNAL SPECIFICATIONS

4.8.1. Connector Pin Assignments

All connections are made via the 5-pin connector, part number
221536-005.
Pin Assignment
1 OPTO
2 PULSE
3 DIR
4 AWO
5 RDCE

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Danaher Motion Superior Electric SPECIFICATIONS

4.8.2. Signal Descriptions

OPTO Opto-Isolator Supply. User supplied power for the opto-
isolators.
PULSE Pulse Input. A low to high transition on this pin advances
the motor one step. Step size is determined by the Step
Resolution switch setting.
DIR Direction Input. When this signal is high, motor rotation is
clockwise. Rotation is counter-clockwise when this signal is
low. Clockwise and counter-clockwise directions are
properly oriented when viewing the motor from the end
opposite the mounting flange.
AWO All Windings Off Input. When this signal is low, AC and
DC current to the motor is zero.
There is no holding torque when the AWO signal
is low.

RDCE Reduce Current Input. The motor current is 50% of the

selected value when this signal is low.
Holding torque is also reduced when this signal
is low.

If you are using the drive with an SS20001 or

SS20001-V control, the READY input and the
OPTO input on the control must be jumpered
together.

SLO-SYN MD808 & MD808-128 4-7

SPECIFICATIONS Danaher Motion Superior Electric

4.8.3. Level Requirements

OPTO
Voltage (VDC) 4.5 to 6.0
Current (mA per signal used) 16
Other Signals
Voltage
Low (VDC) < 0.8
> 0.0
High (VDC) < OPTO
> OPTO - 1 V
Current
Low (mA) < 16
High (VDC) > 0.2

4.8.4. Timing Requirements

PULSE
Max Frequency 500 kHz
Max Rise & Fall Times 1 µs
Min Pulse Width 1 µs
DIR
Response Time < 5 µs
Other Signals
Response Time < 50 µs

4-8 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric SPECIFICATIONS

OPTO 12 VDC, 16 mA PER SIGNAL

550 ohms
PULSE
CONTROL SIGNAL
DRIVE 1/4 watt

CONTROL LOGIC COMMON

OPTO 4.5 - 6.0 VDC, 16 mA PER SIGNAL

PULSE
CONTROL SIGNAL
DRIVE

CONTROL LOGIC COMMON

OPTO 4.5 - 6.0 VDC, 16 mA PER SIGNAL

PULSE

DRIVE TTL

CONTROL SIGNAL
7406

OPTO 5V

PULSE

DRIVE SWITCH

OPTO 5V GND

SLO-SYN MD808 & MD808-128 4-9

SPECIFICATIONS Danaher Motion Superior Electric

4.8.5. INDICATOR LIGHTS

"POWER" LED, Red
Lights when the drive logic power supply is present,
indicating that the drive is energized.
"FAULT" LED, Red
Lights to indicate over-current condition. This condition is
a result of motor wiring errors or a ground fault.
Lights to indicate the heat sink temperature has exceeded a
safe level for reliable operation.
Recovery from over-current or over-temperature condition
requires removing and then reapplying the power.

4-10 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric TORQUE VERSUS SPEED CHARACTERISTICS

5. TORQUE VERSUS SPEED

CHARACTERISTICS

5.1. MOTOR PERFORMANCE

All stepper motors exhibit instability at their natural frequency and
harmonics of that frequency. Typically, this instability occurs at speeds
between 50 and 1000 full steps per second and, depending on the
dynamic motor load parameters, can cause excessive velocity modulation
or improper positioning. The open area at the low end of each Torque vs.
Speed curve represents this type of instability.

There are also other instabilities that may cause a loss of torque at
stepping rates outside the range of natural resonance frequencies. One
such instability is broadly defined as mid-range instability. Usually, the
damping of the system and acceleration/deceleration through the
resonance areas aid in reducing instability to a level that provides smooth
shaft velocity and accurate positioning. If instability does cause
unacceptable performance under actual operating conditions, the
following techniques can be used to reduce velocity modulation.
1) Ensure that the control filter is set as shown in the motor table. If so,
try changing the filter setting one or two frequency settings lower. If
the results are worse, try setting the filter one or two frequency
settings higher.
2) Avoid constant speed operation at the motor's unstable frequencies.
Select a base speed that is above the motor's resonant frequencies
and adjust acceleration and deceleration to move the motor through
unstable regions quickly.
3) The motor winding current can be reduced. Lowering the current
reduces torque proportionally. The reduced energy delivered to the
motor can decrease velocity modulation.

SLO-SYN MD808 & MD808-128 5-1

TORQUE VERSUS SPEED CHARACTERISTICS Danaher Motion Superior Electric

4) Use microstepping to provide smoother operation and reduce

the effects of mid-range instability.

Microstepping reduces the shaft speed for the given

pulse input rate.

5.2. TORQUE VERSUS SPEED CURVES

The test conditions used when obtaining the torque
versus speed data are listed in the lower left-hand
corner of each curve.

TORQUE - oz. in. Ncm

70 49.44

60 42.37

50 35.31
72 V
40 28.25

30 21.19
60 V
20 14.12
30 V
10 7.06
3.0 AMPS
1/10 STEP
0 0.262 lb-in**2 0
0 10 20 30 40 50
SPEED RPS

KML060F05 MOTOR, 3.0 Amp

5-2 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric TORQUE VERSUS SPEED CHARACTERISTICS

TORQUE - oz. in. Ncm

150 105.9

72 V
100 70.62

60 V
50 35.31
30 V
3.0 AMPS
1/10 STEP

0
0.29 lb-in**2
0
0 10 20 30 40 50
SPEED RPS

KML061F05 MOTOR, 3.0 Amp

SLO-SYN MD808 & MD808-128 5-3

TORQUE VERSUS SPEED CHARACTERISTICS Danaher Motion Superior Electric

TORQUE - oz. in. Ncm

250 176.6

200 141.2

150 105.9
72 V
100 70.62
60 V
50 35.31
4.0 AMPS
1/10 STEP
30 V
0.29 lb-in**2
0 0
0 10 20 30 40 50
SPEED RPS

KML062F07 MOTOR, 4.0 Amp

5-4 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric TORQUE VERSUS SPEED CHARACTERISTICS

TORQUE - oz. in. Ncm

250 176.6

200 141.2

150 72 V
105.9

60 V
100 70.62

50 35.31
30 V
8.0 AMPS
1/10 STEP
0 0.29 lb-in**2 0
0 10 20 30 40 50
SPEED RPS

KML062F13 MOTOR, 8.0 Amp

SLO-SYN MD808 & MD808-128 5-5

TORQUE VERSUS SPEED CHARACTERISTICS Danaher Motion Superior Electric

TORQUE - oz. in. Ncm

350 247.29

300 211.9

250 176.6

200 141.2
72 V
150 105.9
60 V
100 70.62
30 V
50 35.31
4.0 AMPS
1/10 STEP
0.29 lb-in**2
0 0
0 5 10 15 20 25 30
SPEED RPS

KML063F07 MOTOR, 4.0 Amp

5-6 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric TORQUE VERSUS SPEED CHARACTERISTICS

TORQUE - oz. in. Ncm

350 247.29

300 211.9

250 176.6

200 141.2
72 V
150 105.9
60 V
100 70.62

30 V
50 35.31
8.0 AMPS
1/10 STEP
0 0.29 lb-in**2 0
0 10 20 30 40 50
SPEED RPS

KML063F13 MOTOR, 8.0 Amp

SLO-SYN MD808 & MD808-128 5-7

TORQUE VERSUS SPEED CHARACTERISTICS Danaher Motion Superior Electric

TORQUE - oz. in. Ncm

350 247.29

300 211.9

250 176.6

200 141.2
72 V
150 105.9
60 V
100 70.62

30 V
50 35.31
4.0 AMPS
1/10 STEP
0 0.29 lb-in**2 0
0 10 20 30 40 50
SPEED RPS

KML091F07 MOTOR, 4.0 Amp

5-8 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric TORQUE VERSUS SPEED CHARACTERISTICS

TORQUE - oz. in. Ncm

350 247.29

300 211.9

250 176.6
72 V
200 141.2

60 V
150 105.9

100 70.62

30 V
50 35.31
8.0 AMPS
1/10 STEP
0 0.29 lb-in**2 0
0 10 20 30 40 50
SPEED RPS

KML091F13 MOTOR, 8.0 Amp

TORQUE - oz. in. Ncm

800 565.0

600 423.8

400 282.5
72 V
60 V 141.2
200

8.0 AMPS
1/10 STEP 30 V
0.29 lb-in**2
0 0
0 10 20 30 40 50
SPEED RPS

KML092F13 MOTOR, 8.0 Amp

SLO-SYN MD808 & MD808-128 5-9
TORQUE VERSUS SPEED CHARACTERISTICS Danaher Motion Superior Electric

TORQUE - oz. in. Ncm

1200 847.4

1000 706.2

800 565.0

600 432.8
72 V
400 282.5
60 V
200 141.2
7.0 AMPS
1/2 STEP
0.29 lb-in**2 30 V
0 0
0 5 10 15 20
SPEED RPS

KML093F10 MOTOR, 7.0 Amp

TORQUE - oz. in. Ncm

1000 706.2

800 565.0

600 432.8
72 V
400 282.5
60 V
200 141.2
7.0 AMPS
1/2 STEP
0.29 lb-in**2 30 V
0 0
0 5 10 15 20
SPEED RPS

KML093F14 MOTOR, 8.0 Amp

5-10 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric TROUBLESHOOTING

6. TROUBLESHOOTING
Motors connected to this drive can develop high torque and
large amounts of mechanical energy.
Keep clear of the motor shaft and all parts mechanically
linked to the motor shaft.
Turn off all power to the drive before performing work on
parts mechanically coupled to the motor.

If installation and operating instructions have been carefully followed,

this unit should perform correctly. If the motor fails to step properly, the
following checklist will help locate and correct the problem.
General:
♦ Output motor short circuit protection line-to-line and line-to-neutral.
♦ Check to see that the proper voltage levels are being supplied to the unit. Be
sure that the "POWER" LED lights when power is applied.
♦ Be sure that the motor is a correct model for use with this unit.
Specific:
IF MOTOR DIRECTION (CW, CCW) IS REVERSED, Check For:
Reversed connection to the Motor Connector. Reversing the
phase A or the phase B connections will reverse the direction of
the motor rotation.
IF THE MOTOR MOTION IS ERRATIC, Check For:
♦ Supply voltage out of tolerance.
♦ Improper motion parameters (low speed,
acceleration/deceleration, jog speed, home speed and feed
rate). Set parameters on controller supplying pulse input to
drive.
♦ Filter capacitor missing or too low in value.
IF TORQUE IS LOW, Check For:
♦ All Windings Off active or Reduced Current active.
♦ Improper supply voltage.
IF "POWER" INDICATOR IS NOT LIT, Check For:
♦ Improper input wiring and voltage levels.
♦ Blown supply circuit fuse or tripped input circuit breaker.

SLO-SYN MD808 & MD808-128 6-1

TROUBLESHOOTING Danaher Motion Superior Electric

IF "FAULT" INDICATOR IS LIT, Check For:

♦ Improper motor wiring.
♦ Grounded or shorted wiring to the motor or shorted motor.
♦ Improper motor type or incorrect Current Select switch
setting.
♦ Ambient temperature around drive above 50° C (122° F).
♦ Heat sink temperature above 70° C (158° F).
♦ Restricted airflow around drive.
If a malfunction occurs that cannot be corrected by making the preceding
checks, contact your local distributor.

6-2 SLO-SYN MD808 & MD808-128

Danaher Motion Superior Electric APPENDIX A

APPENDIX A
A.1 TROUBLESHOOTING ELECTRICAL
INTERFERENCE PROBLEMS
Electrical interference problems are common with today's computer-
based controls. Such problems are often difficult to diagnose and cure. If
such a problem occurs with your system, it is recommended that the
following checks be made to locate the cause of the problem.
1. Check the quality of the AC line voltage to the power supply using
an oscilloscope and a line monitor. If line voltage problems exist, use
appropriate line conditioning, such as line filters or isolation
transformers.
2. Be certain proper wiring practices are followed for location,
grounding, wiring, and relay suppression.
3. Double-check the grounding connections to be sure they are good
electrical connections and are as short and direct as possible.
4. Try operating the drive with all suspected noise sources switched off.
If the drive functions properly, switch the noise sources on again,
one at a time and try to isolate the one(s) causing the interference
problems. When a noise source is located, try re-routing wiring,
suppressing relays or other measures to eliminate the problem.

SLO-SYN MD808 & MD808-128 A-1

APPENDIX A Danaher Motion Superior Electric

A.2 Customer Support/Contact Information

Danaher Motion products are available nationwide through an extensive
authorized distributor network. These distributors offer literature, technical
assistance and a wide range of models off the shelf for fastest possible delivery.
Danaher Motion sales engineers are conveniently located to provide prompt
attention to customers' needs. Call the nearest office listed for ordering and
application information or for the address of the closest authorized distributor.
In the US and Canada
13500-J South Point Blvd.
Charlotte, NC 28273
Phone: (704) 588-5693
Fax: (704) 588-5695
Email: [email protected]
Website: www.DanaherMotion.com

In Europe
Danaher Motion GmbH & Co. KG
Robert-Bosch-Straße 10
64331 Weiterstadt, Germany
Phone: +49 (0) 6151-8796-10
Fax: +49 (0) 6151-8796-123
Email: [email protected]
Website: www.DanaherMotion.de

A-2 SLO-SYN MD808 & MD808-128