MZ-03 5V power supply module

The MZ-03 module is used to power electronic devices requiring unstabilized voltage of quite high power. The main application is to power stepper motor controllers and peripheral elements used in CNC control systems. It has an unstabilized power supply for the final stages and a separate stabilized 5 or 12V power supply. It is designed to work with transformers with a rated power of up to 1250W. The module has LED indication of the presence of each voltage. The device is delivered without a power transformer. which we choose according to our needs.

The basic MZ-03 block is made on the basis of a generally available unstabilized power supply application. It consists of a KBPC5010W rectifier bridge with a maximum current of 10A and a voltage of 1000V and two filter capacitors connected in parallel with a capacity of 10,000 µF/80V each. The second low-voltage block is made of a 12V transformer. 0.4A. rectifier bridge with a current of 2A and a maximum voltage of 1000V. filter capacitors and an integrated stabilizer from the 78XX series. The input and output circuits of the stabilizer use a filter consisting of a 470µF capacitor with a voltage of 35V. The connection system was made based on the manufacturer's application note. ARK 1.5 mm² connectors with a maximum voltage of 250V and a forward current of 16A were used to make connections to external devices. The transformer is connected using straight screw terminals with an M4 hole and ring terminals. Electronic components exposed to an increase in internal structure temperature are placed on aluminum heat sinks. Components. from which the MZ-03 module is made meet the European Union's RoHS directive (Restriction of use of certain Hazardous Substances) regarding environmental protection. The device is made using lead-free technology. The binder used to assemble the device contains 99% tin and 1% copper.

• high performance.
• low cost.
• small dimensions.
• 230 V AC power supply. 50 Hz.
• possibility of connecting a transformer with an output voltage of up to 55VAC.
• output current 25A.
• additional low-voltage power supply.

The diodes indicate the operating status of the power supply. Each of the two red diodes indicates the presence of individual voltages (5V or 12V and high depending on the transformer used).

The MZ-03 universal power module can work independently. generating 5 or 12 VDC voltage from the built-in stabilized power supply.

Attention!!!
You should pay special attention to this. that the maximum current efficiency of the low-voltage block is 0.4 A. This means that I5VDC or I12VDC < 0.4A

To use the device in the configuration described above, simply connect 230V AC voltage to the NL connector (description in chapter 4. Construction of the MZ-03 power supply module -> P1 connector pins).

Second. the more important function of the module is the high-current block built on the basic application of an unstabilized power supply. The main application of the device manufactured by our company is the distribution of electricity in the control cabinets of numerical machine tools. so the rest of the instructions will be based on the requirements set for them.

A properly selected power supply will allow you to fully use the capabilities of stepper motors. The transformer is selected based on the supply voltage of the final stages of the controllers and the current that will be generated for the motors. To calculate the basic parameters of the transformer, let's use the following line of thought:
Maximum supply voltage of controllers: e.g. 50VDC. We need to pay attention to this. that this is a limit value. The EMF voltage (generated by the motor coils during reversals) can reach 5-10% of the potential value applied to the controller power pins. This should be taken into account when selecting the source. Based on this statement, we subtract UEMF from UVCC(max)

50V – (10% of 50V) = 50V – 5V = 45V

It is suggested to use a power supply with an output voltage not exceeding +45V. leaving room for power surges and EMF return. Higher potential may damage the controller.
Voltage of the transformer secondary side.
To calculate the required voltage value of the transformer secondary winding, divide the result of the above calculations by the square root of two (approximately 1.41).

45V / 1.41 = 31.92V

In this way, we obtained an approximate value of the voltage of the transformer secondary winding. If we do not have a device with such a potential, we use the closest value in the series. Manufacturers standardize production and we cannot always buy an identical product for calculations. In our case, we can choose between 32VAC or 28VAC. We will apply the first one.

Attention!!!
Please remember. that the voltage value of the transformer secondary winding cannot exceed 55VAC. A higher potential may damage the capacitors in the power supply module.

The power source may have a lower current than the motor rating (typically 50% ~ 70% of the motor current). It follows from this. that the controller draws current from the power supply capacitor only when the PWM cycle is ON. and it doesn't download. when the cycle is OFF. So the average current draw from the power source is much lower than the motor current. For example, three 3A motors can be easily powered from a 6.3A source.
Powering several controllers from a single power source is permitted under certain conditions. that the source has the appropriate current capacity. Below is the formula for calculating the current efficiency of the source.

(Number of motors * motor rated current) * 70% = source rated current

It's good to add some extra power. i.e. plus 5 - 10% of the value. which we found above.

Calculation for the example from the text above:

(3 * 3A) * 70% = 6.3A

6.3 A * 1.1 = 6.93 A

(round up to 7A)

In this way, we calculated the current needed to power three stepper motor drivers. To calculate the required transformer power value, we multiply the calculated voltage and current of the secondary winding:
32V x 7A = 224 VA

After receiving the result, we once again use the normalized power values of the transformers. The calculated 224 VA is rounded up. Depending on the manufacturer, it will be 240. 250 VA. Please keep this in mind. that the AC input of the power supply can carry a maximum current of 25A.

An overview diagram is provided below.


To protect the transformer, a fuse with a response current appropriate to its power should be used at the power input of the primary winding.
When using transformers above 200 W, the system should be powered using a soft start system. SOFT START prevents the generation of a current pulse in the windings. that appears when you turn it on to the network. High transformer power. use of a rectifier and high-capacity filter capacitors in the system. causes. that when such a system is connected to the network, the current it consumes is greater than its rated current. causing the fuses to trip. which will disconnect our power supply. This is especially troublesome in the case of. when a computer and a machine controller are connected to one power strip. When the fuse trips, the computer will turn off. causing loss of unsaved data. By using the SOFT START system, we eliminate this situation and we can work without any worries on the computer and machine controller connected to one power strip (one fuse).

The SOFT START installation diagram -> MZ-03 module -> transformer is provided below.

Please remember this when connecting. the cross-sections of the cables supplying the controllers
stepper motors were appropriately selected for the currents that will be drawn from the module. It is also recommended to use fuses on the outputs powering individual axes of the universal numerical controller. For group power distribution in various types of low-voltage systems (power distribution), we can use the FM-01 module produced by our company. It has one input via a six-pin ARK connector. We connect three of them to the "+" of the power supply. the rest with "-". The module has four independently protected outputs. Each of them has a fuse and voltage indication. Damage to the fuse is visualized by turning off the appropriate LED. The module accepts voltage in the range: 5 V ÷ 80 V DC.

To avoid interference, do not connect controllers to the power supply in series. Each controller should be connected with separate cables (parallel connection).

How to connect the module with a set of drivers.


ATTENTION!!!
Never reverse the polarity of the power supply. because it will damage the driver!!!

In case the power supply module does not work properly. the first step should be to check whether the problem is electrical or mechanical (lack of connections). It is important to. to document every step in solving the problem. You may need to use this documentation at a later date. and the details contained therein will greatly help our Technical Support employees solve the problem. Many errors in a traffic control system can be related to electrical noise. software errors in the control device or errors in cable connection.
Below is a table with the most common problems. with which customers contact our Technical Support.

R1 - 22 kΩ
R2 - 2k2 Ω

C1.C2 – 10000µF/100V.
C3.C5 – 470µF/25V.

C4.C6 – 100nF/50V.
U1 – 7812 or 7805.
D1.D2 - LED 3mm.
M2 - bridge 1A.
M1 - KBPC5010W bridge.

Tr1- V42Aj-15AGP7 (or similar)

J1. J2 - straight screw terminals with M4 hole.
J4. J5. J6. J7 - ARK 2-pin connectors
J3 – STL950-6pin connector.

The MZ-03 power module is designed for continuous operation. does not require any preparatory work on the part of the user. Please keep this in mind. That :

A dangerous mains voltage of 230VAC will be generated on the module board

The secondary voltage from the transformer can reach 55 VAC, which after rectification gives 80 VDC and with high current efficiency, this voltage is as dangerous as the mains voltage.

After turning off the power supply, voltage remains on the filter capacitors for some time, which in the event of a short circuit at the power output may cause a spark and/or damage to the module.

When drawing currents greater than 10 A, it is recommended to force air around the rectifier bridges to better dissipate excess heat.

Installation personnel must have basic knowledge of how to handle electrical equipment. The device should be installed in closed rooms in accordance with environmental class I. with normal air humidity (RH = 90% max. without condensation) and temperature in the range of 0°C to +50°C.

* The value of the output current and voltage depends on the transformer used.
The value of the output voltage is proportional to the supply voltage and is influenced by the output current.

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