Do you have a question about the VariStep3 and is the answer not in the manual?
Questions and answers
Summary of Contents for Motortech VariStep3
Page 1
VariStep3 – Stepper Motor Driver Operating Manual P/N 01.50.020 – EN | Rev. 08/2018...
Page 2
Information contained in this publication may be changed without prior notice. Trademarks MOTORTECH products and the MOTORTECH logo are registered and/or common law trademarks of the MOTORTECH Holding GmbH. All further trademarks and logos displayed or used in this publication are the property of the respective entitled person.
Table of Contents 1 General Information ....................6 1.1 What Is the Purpose of this Operating Manual? ............6 1.2 Who Is this Operating Manual Targeted to? ............... 6 1.3 Which Symbols Are Used in the Operating Manual? ........... 6 ...
Page 4
Table of Contents 7.2 Reference Run ...................... 36 7.3 Open/Closed Positions ..................37 7.4 Configurable Opening Angles (Position 1 and 2) ............37 7.5 Change of Opening Angles via Binary and Analog Inputs ......... 37 7.6 Analysis of Positions via Analog Outputs or Field Bus ..........
Page 5
12 Annex ........................82 12.1 Replacement of the Stepper Motor Driver .............. 82 12.1.1 VariStep to VariStep3 Stepper Motor Driver ............82 12.1.2 VariFuel2 to VariStep3 Stepper Motor Driver............85 13 Index ........................89 Rev. 08/2018...
1 General Information Read through this operating manual carefully before use and become familiar with the product. Installation and start-up should not be carried out before reading and understanding this document. Keep this manual readily available so that you can reference it as needed. 1.1 What Is the Purpose of this Operating Manual? This manual serves as an aid for the installation and operation of the product and supports the technical staff with all operating and maintenance tasks to be performed.
Light Emitting Diode Light emitting diode Light emitting electronic semiconductor MICT MOTORTECH Configuration software for Integrated MOTORTECH control units Configuration Tool Throttle Gear Throttle drive Universal Serial Bus Serial connection system to link a computer to external devices Rev. 08/2018...
2 Safety Instructions 2.1 General Safety Instructions MOTORTECH equipment is manufactured as state of the art and therefore safe and reliable to operate. Nevertheless the equipment can cause risks or damage can occur, if the following instructions are not complied with: –...
2 Safety Instructions 2.2 Electrostatic Discharge Hazards Electronic equipment is sensitive to static electricity. To protect these components from damage caused by static electricity, special precautions must be taken to minimize or prevent electrostatic discharge. Observe these safety precautions while you work with the equipment or in its vicinity. –...
2 Safety Instructions Occurrence of ground loops The devices shown in the following image do not feature the possibility to connect the earth potential and the negative pole of the power supply separated from each other. How ground loops are created. A ground loop is a ground connection of an electric wiring assembly that is closed as a loop.
Page 11
All screws of the connectors must be adequately tightened. Risk of destruction due to electrostatic discharge! The VariStep3 stepper motor driver may only be installed by specialized personnel who has been trained in handling ESD sensitive components and with due regard to relevant ESD standards. It must be installed into a control cabinet, and it must comply with the ESD standard DIN EN 61340-5- 1;...
2 Safety Instructions 2.5 Proper Disposal After the expiration of its service life, MOTORTECH equipment can be disposed of with other commercial waste, or it may be returned to MOTORTECH. We will ensure its environmentally friendly disposal. Rev. 08/2018...
– TG throttle drives – If several devices which are to be controlled via the VariStep3 stepper motor driver are to be used in one system, several stepper motor drivers are needed. An additional splitter is not necessary. Any use other than the one described in the operating manual shall be considered improper use and will result in the voiding of all warranties.
Page 14
3 Intended Use System Overview (Example) VariStep3 stepper motor drivers Engine VariFuel2 gas mixer Wiring rail (ignition) ITB throttle with integrated stepper motor Gas supply SC100 speed control Gas train Air supply Air filter Rev. 08/2018...
4 Product Description 4.1 Technical Data 4.1.1 Certifications The stepper motor driver is certified in accordance with the following standards: – EMC Directive – EN 61000-6-1:2007 – Electromagnetic compatibility (EMC). Generic standards; Immunity for residential, commercial and light-industrial environments – EN 61000-6-2:2005 + AC:2005 –...
4 Product Description 4.1.2 Mechanical Data The stepper motor driver has the following mechanical characteristics: Feature Value Dimensions 160 mm x 126 mm x 61 mm (6.30" x 4.96" x 2.40") (length x width x height) Weight 655 g (1.5 lbs) Shape of device See chapter Overview Drawings on page 21 Mechanical environmental...
4 Product Description 4.1.4 Product Identification – Labeling on the Device The numbers required for unique product identification are on the device: Top of Device Abb. Meaning Part number of the stepper motor driver Serial number of the stepper motor driver Arrangement number of the stepper motor driver Revision number of the stepper motor driver Rev.
4 Product Description 4.1.5 Electrical Data The stepper motor driver has the following electrical characteristics: Feature Value Power consumption max. 60 W Power supply Nominal voltage: 24 V DC Operating voltage: 18 V DC to 32 V DC Required current max.
4 Product Description Inputs and outputs Values/characteristics Binary outputs – Galvanically isolated – Inactive: output is high-impedance – Active: output is low-impedance – Switching voltage: max. 32 V – Current: max. 100 mA – Max. voltage drop at 100 mA: 2.5 V Analog voltage input Permissible voltage: 0 V to 10 V Input resistance: 12.4 kΩ...
4 Product Description 4.1.7 Overview Drawings Ports/Connections and LEDs Designation Function Binary Inputs Binary inputs that are used to change the position of the stepper motor. In addition, a binary input is available for a reset signal (see Wiring Binary Inputs on page 30). Binary Outputs Binary outputs which signal the position of the stepper motor and the status of the stepper motor driver (see Wiring Binary Outputs on...
Page 22
4 Product Description Designation Function Manual/Auto (switch) Switch for changing between manual and automatic operation (see Manual and Automatic Operation on page 36) Open/Close; In manual mode the stepper motor can be driven via the buttons Reset Open and Close (see Manual and Automatic Operation on page 36). In the case of an error, the error can be reset followed by a reference run if you press the two buttons simultaneously.
Page 23
4 Product Description Status signaling The status of the VariStep3 stepper motor driver is signaled via the LED Status. – Flashing green: Error-free operation – Flashing orange: Warning Warnings can be acknowledged by simultaneous pressing of buttons Open and Close (in manual Mode) or by the external reset signal.
Storage device (USB flash drive or CD-ROM) including configuration software MICT – USB cable – Operating manual – Installation of the VariStep3 stepper motor driver Install the VariStep3 stepper motor driver on a horizontal DIN rail in the control cabinet. Rev. 08/2018...
Do not disconnect connectors under load. This can cause an arc. – Use the prescribed wire cross sections and suitable wire end ferrules. Wiring of components If you are not using wiring harnesses manufactured by MOTORTECH, carry out the wiring according to the following specifications: – Power supply: 3-wire cable, min.
Page 26
This also applies to CAN and Modbus (RS485) interfaces. The socket for the stepper motor and encoder for the VariStep3 stepper motor driver has 12 poles. However, the 11-pole plug can still be used. It just needs to be plugged in at the far right.
6 Wiring of the Device 6.1 Wiring Power Supply Risk of injury! The stepper motor may be started unintentionally when the supply voltage is applied. Especially if a throttle is connected, there is a risk of fingers or other body parts being trapped or squashed. Therefore, work on the connected devices (throttle or gas mixer) must always be carried out with disconnected supply voltage.
12 poles. The 11-pole plug must be plugged in at the far right. Pin 0 of the socket is currently not in use and therefore locked. The VariStep3 stepper motor driver has been approved for residential environments if the wiring of the stepper motor and encoder does have a length of no more than 10 m (32').
Page 29
6 Wiring of the Device Encoder Stepper motor Pin assignment when using the original MOTORTECH wiring harness: Pin VariStep3 Designation Pin stepper motor and encoder Encoder Data Currently not used Encoder GND (Ground) Encoder Power (supply voltage) Encoder A Encoder B...
6 Wiring of the Device 6.3 Wiring Binary Inputs The binary inputs are wired using the 10-pole plug. The inputs can be switched both on the side of the operating voltage and on the ground side. L ≙ 5 V DC to 32 V DC Designation Function Dir +...
6 Wiring of the Device 6.4 Wiring Binary Outputs The binary outputs are wired using the 12-pole plug. The outputs can switch both the operating voltage and the ground. L≙ 5 V DC to 32 V DC; max. 100 mA Designation Function Error +...
6 Wiring of the Device 6.5 Wiring Analog Inputs and Outputs The analog inputs and outputs are wired via an 8-pin connector and are therefore not compatible with the corresponding 14-pin connector of the VariStep stepper motor driver. Designation Function Position U in + Voltage input for adjustment of the openings for the gas supply of the gas mixer or the throttle (see...
6 Wiring of the Device Unused inputs and outputs Please note that the terminals for the analog inputs and outputs not selected in the MICT must remain unoccupied. 6.6 Wiring CAN Bus The CAN bus interface is wired using the 4-pole plug. First device Second-to-last device Second device...
6 Wiring of the Device CAN bus wiring Note the following when connecting the CAN bus: – Each bus end must be fitted with a terminating resistor of 120 Ω (see drawing). – The maximum wire length depends on the bit rate: Bit rate Maximum wire Maximum length...
Page 35
6 Wiring of the Device Wiring Full Duplex Master Last slave First slave Second-to-last slave Connection to Stepper Motor Driver The Modbus is wired using the 6-pole plug. Rev. 08/2018...
7.2 Reference Run After the device is switched on or was reset, the VariStep3 stepper motor driver initiates a reference run. This means that the stepper motor determines its current position. In automatic mode, the stepper motor subsequently approaches the position defined by the master control.
7 Functions 7.3 Open/Closed Positions The Open and the Close position are specified as follows: Open: The throttle or the openings for gas supply of the gas mixer are fully opened – (100 % open). Closed: The throttle or the openings for gas supply of the gas mixer are fully closed –...
56. 7.7 Access Control You can protect the VariStep3 stepper motor driver against unauthorized access by establishing the access control in the MICT. The access control has four operating levels, three of which can be secured with different PINs. As a default setting, the access control is not activated. If the access control for the stepper motor driver is activated, it is independent from the access levels that control authorizations within the MICT.
Page 39
7 Functions Various functions are at your disposal on the four operating levels. The figure below illustrates this: The following functions are available on the different levels: Level 0 (Read Only) – Enables read-only access for all users. Level 1 (Operator) –...
8 Settings via the MICT MICT is an abbreviation for MOTORTECH Integrated Configuration Tool. You configure your VariStep3 stepper motor driver via the MICT and can adjust it to the master control and the device connected (gas mixer or throttle).
8 Settings via the MICT 8.3 Access Levels in the MICT You can open the MICT on your PC e.g. via Start -> Programs -> MOTORTECH -> MICT 2.x.x -> MICT 2.x.x. After opening the MICT, select the access level for which you have clearance. The access level controls the options you have at your disposal in the MICT.
8 Settings via the MICT 8.4 Configuration Pages (Overview) The configuration pages are divided into the following sections: Item no. Area Menu bar Toolbar Navigation bar Configuration section Status bar The functions in the menu, navigation bar, and the toolbar as well as the configuration section will be described in the following.
Indication of the access level of the user in the MICT – – Indication of the operating level for the VariStep3 if access control has been activated and the user has logged on with a PIN. Indication of the MICT program version –...
Page 44
8 Settings via the MICT Symbol Menu Function Prints the configuration to a PDF file. File -> Print To PDF File Opens a print preview of the configuration. File -> Print Preview Exits the MICT. File -> Quit Connects to the device. Device ->...
Page 45
Opens the window Select Temperature Scale, in which Settings -> Temperature you can change the unit for the temperatures shown in scale the MICT. This function is available for certain MOTORTECH Settings -> Display by ignition controllers and has no effect in conjunction cylinders with the VariStep3.
8 Settings via the MICT 8.6 Online Update Settings The MICT uses data from various databases for the configuration. Such data can be updated with automatic online updates. The settings for the update can be entered with the following entry in the menu bar: Settings ->...
8 Settings via the MICT 8.7 Access Control of the Stepper Motor Driver If the access control to the stepper motor driver is activated, access to the following areas is possible with a PIN only: Troubleshooting – Position changes (open, closed, position 1 and 2, manual adjustment, reference run) –...
In the menu bar, select the entry Device -> Access Control -> Get reset all PINs request key to open a window with the same name. 2. Send the request key with the serial number to your service contact person at MOTORTECH (refer to Customer Service Information on page 79). This key is valid only for the respective controller and only for a certain amount of time.
If the input was correct, all PINs are reset to the default value 0000. 8.8 Working with Configurations To ensure that the VariStep3 stepper motor driver interprets incoming data correctly and converts them to the desired control signals, it requires information on the device connected and the master control connected.
8.8.1 Create, Open, Save Click on the symbol to create a new configuration and select the entry Stepper Motor Cards -> VariStep3. Click on the symbol to open a saved configuration. Click on the symbol to save the configuration currently displayed in the MICT to a storage device.
8.8.3 Compatibility Information If you upload a configuration from the VariStep3 stepper motor driver to the MICT that does not correspond to the status of your MICT, or if you open this type of configuration in the MICT, the following situations may occur: No values are present in the configuration for certain MICT functions.
8 Settings via the MICT Perform a firmware update, if necessary and/or update your MICT so that you can use all the functions of the VariStep3 stepper motor driver without restriction. 8.9 Configuration The window opens after you select the device type for a new configuration or an existing configuration or have uploaded one from the device.
To change the device type, approval for the access level Advanced Service is required. Device type Select the device type you wish to configure and control with the VariStep3 stepper motor driver from the drop-down list. When the device type has been changed and the modified device configuration has been downloaded to the device, the Status LED flashes orange.
Page 54
– None Select this option if you want to shut down or store your VariStep3 stepper motor driver temporarily. In addition, this option can be selected if the VariStep3 stepper motor driver was configured for one device type and is then to be used for another device type. For this, also read the information box Changing the device type.
Page 55
The process how to exchange one VariFuel2 type for another is described below. However, the process can also be carried out correspondingly if you change the device type. For example, you want to use the VariStep3 which you used for a VariFuel2 gas mixer for a throttle.
8 Settings via the MICT 8.9.2 Inputs/Outputs – Control Setup The settings on the configuration page depend on the inputs and outputs used by your master control. In this case, refer to all information given in the relevant documentations of the control units.
Page 57
8 Settings via the MICT – Output Select the analog output that is to be used by the master control connected. – External manual/automatic selection enabled Disable the check box to deactivate the Manual/Auto switch on the stepper motor driver. The stepper motor driver may then only be put in manual mode via the MICT with the corresponding authorization.
Page 58
8 Settings via the MICT Settings of the input selected Analog Inputs (Current or Voltage) Based on the values used by your master control, you can define the values of the Open and the Close position for the analog inputs in the MICT. The value applied to the input is then converted proportionally to the values entered in a corresponding opening angle of the throttle or the fuel ring of the VariFuel2.
8 Settings via the MICT 8.9.3 Positions – Values Position 1/Position 2 You can define two configurable positions using these two input fields. This requires approval for the access level Service or Advanced Service. Enter the desired opening angle of the gas supply for the gas mixer or throttle as a percentage value (100 % corresponds to open, 0 % corresponds to closed).
8 Settings via the MICT 8.9.4 Miscellaneous – Communication Via the field CAN, deactivate or activate the CAN interface of the device. – ALL-IN-ONE (J1939)/CANopen Select the desired protocol, depending on whether you want to set the communication for the ALL-IN-ONE or for another master control. Source Address/CANopen Node ID –...
Page 61
8 Settings via the MICT RS485 Via the field RS485, deactivate or activate the RS485 interface of the device. – RS485 Settings – Baudrate Select the desired data transfer rate from the list. The Modbus baud rate can be defined between 9600 bit/s and 115200 bit/s, the recommended value being 19200 bit/s.
8 Settings via the MICT 8.9.5 Miscellaneous – Service Contact This configuration page can be viewed by all users, but changes can only be made with authorization for the Advanced Service access level. Service Contact In this area, you can store individual contact data. Rev.
8 Settings via the MICT 8.10 Runtime Data Click on the symbol to open the window Runtime Data. The following sections will give you an overview of the data you can view on the individual tabs. You can print and record the runtime data. For this purpose, the following functions are at your disposal in the toolbar in the window: Symbol Function...
8 Settings via the MICT 8.10.1 Runtime Data – Overview In this screen, you can find the following information: Configured The status display indicates if the stepper motor driver has a valid configuration: green: The stepper motor driver has a valid configuration. –...
Page 65
8 Settings via the MICT Manual/Auto The status display indicates the operation mode selected: – green: The operation mode is set. – yellow: A command is carried out in the operation mode selected. In automatic operation mode, the status display will only turn yellow if position 1 or 2 is approached. red: An error occurred in the operation mode selected.
The following information is provided: Operating Hours – Operating hours counter reading at the time of message Time – Time and date cannot be shown for VariStep3 stepper motor drivers. – Category Message type (information, warning, error) – Message Message text; you can find more information on the message text in the following sections.
8 Settings via the MICT You have the following options: – Automatic scrolling If this box is checked, the system automatically displays the last list entry until a new event occurs. 8.10.2.1 Information Information Configuration changed. Device (firmware version) started at a supply voltage of value. Device switched off.
8 Settings via the MICT 8.10.3 Runtime Data – Diagnostics In this screen, you can find the following information: Operation mode The operation mode section shows which operation mode (Manual or Automatic) is currently active and how the operation mode was adjusted. Here, there are the following two options: –...
Page 70
8 Settings via the MICT CPU Load Current capacity utilization of the processor. Supply voltage Current supply voltage of stepper motor driver. Current Temp. Current temperature of board. Max Temp Maximum reached temperature of the board since the stepper motor driver was switched on the last time.
In this view, you can find an overview of the device and version data. You can also print the current runtime data or, in case of problems, send them to the MOTORTECH Service Department via fax or as a PDF file via e-mail. For fast support, we will then immediately have all required information.
Page 72
If the function is active, the view panel focuses on the latest message. Log level – The selection of the log level is specified by MOTORTECH if needed. – Write log to file This checkbox activates or deactivates, respectively, the saving of the logged data in a selected file.
Directly from the storage device: Start the exe file in subdirectory Drivers (e.g. CDM v2.10.00 WHQL Certified.exe). ▸ The MOTORTECH Flash Tool is set up. You can now connect your PC to the stepper motor driver via the USB interface. Rev. 08/2018...
Page 74
9 Operation Menu Bar and Toolbar After launching the MOTORTECH Flash Tool, the following functions are available to you via the icons on the toolbar and the entries in the menu bar: Symbol Menu Function Opens a firmware file. File -> Open Exits the program.
Page 75
3. In the Status section under Device, check if your device has been recognized properly. ▸ If the MOTORTECH Flash Tool does not recognize a device that is connected to your PC via the USB interface, you can usually still carry out a firmware update. To do so, observe the instructions in the information windows of the MOTORTECH Flash Tool for the following steps.
Page 76
9 Operation Help with connection problems If a correctly connected device is not found during the automatic search, this can, for example, be because too many communication interfaces are assigned and must be checked. In this case, an interface from the drop- down list Port in the area Connection can be selected and thus specified.
MICT you can see the type of error occurred. Refer to the section Runtime Data – Message Log on page 66. Status signaling The status of the VariStep3 stepper motor driver is signaled via the LED Status. Flashing green: Error-free operation –...
10 Errors 10.2 Possible Faults Low Power Supply voltage has dropped below 11 V. Potential causes: The power supply is dimensioned too small. – – The battery is worn out. – The wiring for the power supply is defective. – The wiring for the power supply is routed incorrectly.
Critical errors can only be acknowledged by switching the device off and on. Error confirmation in automatic operation If the VariStep3 stepper motor driver is in automatic mode and an error immediately reoccurs after the acknowledgment of this error via the MICT, switch over into the manual mode before re-acknowledging the error again.
Send the device and the return form to one of the two addresses below or to the nearest MOTORTECH representative: MOTORTECH GmbH MOTORTECH Americas, LLC Hogrevestr. 21-23 1400 Dealers Avenue, Suite A 29223 Celle...
11 Maintenance 11.1 Spare Parts and Accessories For spare parts and accessories, please refer to our current Product Guide, which is available for you to download on the internet at www.motortech.de. Rev. 08/2018...
This also applies to CAN and Modbus (RS485) interfaces. The socket for the stepper motor and encoder for the VariStep3 stepper motor driver has 12 poles. However, the 11-pole plug can still be used. It just needs to be plugged in at the far right.
Page 83
12 Annex VariStep3 Stepper Motor Driver VariStep Stepper Motor Driver (P/N 31.01.960) (P/N 31.01.955) Binary Binary Analog Inputs/ Digital Digital Analog Inputs/ inputs outputs Outputs Inputs Outputs Outputs CAN Modbus Stepper Power CAN Modbus Power IN Stepper Motor + (RS485)
Page 84
12 Annex Connector Digital Outputs -> Connector Binary Outputs Labeling VariStep Labeling VariStep3 ERRORout + Error + ERRORout - Error - CLOSEout + Close + CLOSEout - Close - OPENout + Open + OPENout - Open - POS1out + Pos. 1 + POS1out - Pos.
Stepper Motor Shield Stepper Motor Phase A2 Stepper Motor Phase A1 12.1.2 VariFuel2 to VariStep3 Stepper Motor Driver Assignment of the wire colors Take the assignment of the wire colors of the wiring harness from the wiring diagram enclosed with the wiring harness.
Page 86
12 Annex VariStep3 Stepper Motor Driver VariFuel2 Stepper Motor Driver (P/N 31.01.960) (P/N 31.01.951, 31.01.950-X) Binary Binary Analog Inputs/ inputs outputs Outputs Connector 4 Connector 3 CAN Modbus Stepper Motor Power Connector 1 Connector 2 DIL1* (RS485) + Encoder DIL Switch is ON...
Page 87
12 Annex Connector Binary Outputs Pin VariStep3 VariFuel2 stepper motor driver Error + Connector 4, Pin 32 Error - Connector 4, Pin 31 Close + – Close - – Open + – Open - – Pos. 1 + Connector 3, Pin 26 Pos.
Page 88
12 Annex Connector Power Pin VariStep3 VariFuel2 stepper motor driver Connector 4, Pin 40 Connector 4, Pin 39 Earth – Connector Stepper Motor + Encoder Pin VariStep3 VariFuel2 stepper motor driver Encoder GND Connector 2, Pin 16 Encoder Power Connector 2, Pin 15...
Configure ..........60 Select ............56 Select............56 Technical data ........... 20 Technical data .......... 20 Wiring ............33 Wiring ............34 Close position MOTORTECH Approach ..........43 Address ............ 80 Declaration ..........37 O Customer Access level ..........41 Open position Approach ..........
Page 90
13 Index R W Read only Wiring Access level ..........41 Analog inputs ..........32 Reference run Analog outputs .......... 32 Carry out ........... 43 Binary inputs ..........30 Function ........... 36 Binary outputs .......... 31 Regulations ........... 15 CAN bus ............ 33 Repair ............
Need help?
Do you have a question about the VariStep3 and is the answer not in the manual?
Questions and answers