VariStep3 –

Stepper Motor Driver

Operating Manual

P/N 01.50.020 – EN | Rev. 05/2022

Original instructions
© Copyright 2022 MOTORTECH GmbH. All rights reserved.
MOTORTECH products and the MOTORTECH logo are registered and/or common law trademarks
of the MOTORTECH GmbH. All further trademarks and logos displayed or used in this publication
are the property of the respective entitled person and are used for reference purposes only.
Information contained in this publication may be changed without prior notice.
 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 
1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual? ........................... 7 

2 Safety Instructions ..................................................................................................... 8 

2.1 General Safety Instructions .....................................................................................8 
2.2 Electrostatic Discharge Hazards .............................................................................. 9 
2.3 Information on Electric Isolation .............................................................................. 9 
2.4 Special Safety Instructions for the Device ............................................................... 11 
2.5 Proper Disposal .................................................................................................... 12 

3 Intended Use ............................................................................................................. 13 

3.1 Functional Description .......................................................................................... 13 
3.2 Applications ......................................................................................................... 13 

4 Product Description ................................................................................................... 15 

4.1 Technical Data ...................................................................................................... 15 
4.1.1 Certifications ..................................................................................................... 15 
4.1.2 Mechanical Data ................................................................................................ 15 
4.1.3 Warning Notices on the Device ............................................................................ 15 
4.1.4 Product Identification – Labeling on the Device .................................................... 16 
4.1.5 Electrical Data .................................................................................................... 16 
4.1.6 Interfaces .......................................................................................................... 18 
4.1.7 Overview Drawings ............................................................................................. 19 

5 Installation Instruction ..............................................................................................22 

5.1 Installation Instruction .......................................................................................... 22 

6 Wiring of the Device ...................................................................................................23 

6.1 Wiring of Power Supply ......................................................................................... 24 
6.2 Wiring Stepper Motor and Encoder ........................................................................ 26 
6.3 Wiring Binary Inputs ............................................................................................. 28 
6.4 Wiring Binary Outputs........................................................................................... 29 
6.5 Wiring Analog Inputs and Outputs ......................................................................... 30 
6.6 Wiring CAN Bus .................................................................................................... 31 
6.7 Wiring Modbus ..................................................................................................... 32 

7 Functions ................................................................................................................... 34 

7.1 Manual and Automatic Operation ........................................................................... 34 

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 Table of Contents

7.2 Reference Run ...................................................................................................... 34 

7.3 Open/Closed Positions ......................................................................................... 35 
7.4 Configurable Opening Angles (Position 1 and 2) ...................................................... 35 
7.5 Change of Opening Angles via Binary and Analog Inputs ......................................... 35 
7.6 Analysis of Positions via Analog Outputs or Field Bus ............................................. 35 
7.7 Access Control ...................................................................................................... 36 

8 Settings via the MICT ................................................................................................ 38 

8.1 MICT System Requirements ................................................................................... 38 
8.2 MICT Installation .................................................................................................. 38 
8.3 Access Levels in the MICT ..................................................................................... 39 
8.4 Configuration Pages (Overview) ............................................................................ 40 
8.5 Menu Bar and Toolbar........................................................................................... 41 
8.6 Online Update Settings ........................................................................................ 44 
8.7 Access Control of the Stepper Motor Driver ............................................................ 45 
8.7.1 Enable/Disable Access Control ........................................................................... 45 
8.7.2 Login/logout ..................................................................................................... 45 
8.7.3 Changing the PIN ............................................................................................... 46 
8.7.4 Reset all PINs .................................................................................................... 46 
8.8 Working with Configurations................................................................................. 47 
8.8.1 Create, Open, Save ............................................................................................ 48 
8.8.2 Upload, Download............................................................................................. 49 
8.8.3 Compatibility Information .................................................................................. 49 
8.9 Configuration....................................................................................................... 50 
8.9.1 External Device ...................................................................................................51 
8.9.2 Inputs/Outputs – Control Setup ......................................................................... 54 
8.9.3 Positions – Values............................................................................................. 57 
8.9.4 Miscellaneous – Communication ........................................................................ 58 
8.9.5 Miscellaneous – Service Contact ........................................................................ 60 
8.10 Runtime Data ..................................................................................................... 61 
8.10.1 Runtime Data – Overview .................................................................................. 62 
8.10.2 Runtime Data – Message Log ............................................................................ 64 
8.10.2.1 Information ................................................................................................... 65 
8.10.2.2 Warnings...................................................................................................... 65 
8.10.2.3 Errors ........................................................................................................... 66 
8.10.3 Runtime Data – Diagnostics.............................................................................. 67 
8.10.4 Runtime Data – Information .............................................................................. 69 
8.11 Log..................................................................................................................... 69 

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 Table of Contents

9 Operation .................................................................................................................. 71 

9.1 Firmware Update................................................................................................... 71 

10 Errors ....................................................................................................................... 75 

10.1 Troubleshooting .................................................................................................. 75 
10.2 Possible Faults ................................................................................................... 76 
10.3 Acknowledging Faults ......................................................................................... 77 
10.4 Customer Service Information .............................................................................. 78 
10.5 Returning Equipment for Repair / Inspection ......................................................... 78 
10.6 Instructions for Packaging the Equipment ............................................................ 78 

11 Maintenance............................................................................................................. 79 
11.1 Spare Parts and Accessories ................................................................................. 79 

12 Annex ..................................................................................................................... 80 

12.1 Replacement of the Stepper Motor Driver .............................................................. 80 
12.1.1 VariStep to VariStep3 Stepper Motor Driver ........................................................ 80 
12.1.2 VariFuel2 to VariStep3 Stepper Motor Driver....................................................... 83 

13 Index........................................................................................................................87 

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 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. Furthermore, this
manual is aimed at preventing dangers to life and health of the user and third parties.

1.2 Who Is this Operating Manual Targeted to?

The operating manual provides a code of conduct for personnel tasked with the setup,
operation, maintenance, and repair of gas engines. A certain level of technical knowledge with
respect to the operation of gas engines and basic knowledge of electronic ignition systems are
necessary. Persons who are only authorized to operate the gas engine shall be trained by the
operating company and shall be expressly instructed concerning potential hazards.

1.3 Which Symbols Are Used in the Operating Manual?

The following symbols are used in this manual and must be observed:

Example
This symbol indicates examples, which point out necessary handling steps
and techniques. In addition, you receive additional information from the
examples, which will increase your knowledge.

Notice
This symbol indicates important notices for the user. Follow these. In
addition, this symbol is used for overviews that give you a summary of the
necessary work steps.

Warning
This symbol indicates warnings for possible risks of property damage or
risks to health. Read these warning notices carefully and take the
mentioned precautionary measures.

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 1 General Information

Danger
This symbol indicates warnings for danger to life, especially due to high
voltage. Read these warning notices carefully and take the mentioned
precautionary measures.

1.4 Which Abbreviations/Acronyms Are Used in the Operating Manual?

In the manual or the user interface, the following abbreviations / acronyms are used.

Abb. Term Description Explanation

CAN bus Controller Area Bus for control devices / Asynchronous serial
Network bus networks connection system for linking
control units
CE Conformité Conformity with EU Mark based on EU legislation
Européenne directives for certain products in
conjunction with product safety
CPU Central Processing
Unit
DC Direct Current
EMC Electromagnetic Compatibility of electrical or
Compatibility electronic equipment items
with their surroundings
ESD Electrostatic
Discharge
ITB Integrated Throttle Throttle with integrated
Body stepper motor
LED Light Emitting Diode Light emitting electronic
semiconductor
MICT MOTORTECH Configuration software for
Integrated MOTORTECH control units
Configuration Tool
TG Throttle Gear Throttle drive
USB Universal Serial Bus Serial connection system to
link a computer to external
devices

Rev. 05/2022 7
 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:
– The gas engine must only be operated by trained and authorized personnel.
– Observe all safety instructions of the system and all safety instructions of the system
operator.
– Operate the equipment only within the parameters specified in the technical data.
– Use the equipment correctly and for its intended use only.
– Never apply force.
– For all work such as installation, conversion, adaptation, maintenance, and repair, all
equipment must be disconnected from the mains and secured against unintentional
reactivation.
– Perform only such maintenance and repair work as is described in this operating manual,
and follow the instructions given while working.
– Only use spare parts supplied by MOTORTECH for the maintenance of the device.
– Further work must only be performed by personnel authorized by MOTORTECH. Non-
compliance with the instructions will void any warranties for the proper function of the
equipment as well as the responsibility for the validity of the certifications.
– Safety devices must not be dismounted or disabled.
– Avoid all activities that can impair the function of the equipment.
– Operate the equipment only while it is in proper condition.
– Investigate all changes that occur during operation of the gas engine or electronic engine
control.
– Ensure compliance with all laws, directives, and regulations applicable to the operation of
your system, including such not expressly stated herein.
– If the system is not entirely tight and sealed, gas may escape and result in explosion hazard.
The inhalation of gas can also lead to death or severe health damages. Therefore, upon
completion of all assembly works, always check the system's tightness.
– Always ensure adequate ventilation of the engine compartment.
– Ensure a safe position at the gas engine.
– There is a risk of burning on hot surfaces. Allow the gas engine to cool down before starting
any work.
– Personal protective equipment (PPE), e.g. safety shoes and gloves, must be worn during all
work on the gas engine.

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 2 Safety Instructions

– Noise from the system can cause permanent or temporary damage to your hearing. Wear
suitable hearing protection at the system.
– Your behavior can reduce possible residual risks to a minimum. Observe responsible
handling of the gas engine and the gas-carrying system.

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.
– Before performing maintenance or repair work, ensure that the static electricity inherent to
your body is discharged.
– Do not wear clothing made from synthetic materials to prevent static electricity from
building up. Your clothing should therefore be made of cotton or cotton mix materials.
– Keep plastics such as vinyl and Styrofoam materials as far away from the equipment as
possible.
– Do not remove the circuit boards from the housing of the device.

2.3 Information on Electric Isolation

If ground and earth potential are not properly isolated, the following problems as well as others
can occur:
– Electromagnetic interferences (e.g. ground loops)
– Signal corruption (e.g. of the analog voltage signal)
– Unwanted leakage currents

Therefore, earth potential and the negative pole of the power supply of all devices in the electric
assembly that provide the option, should be connected separately. If possible, the negative pole
of the power supply should only be connected to earth potential at one point in the entire
system.

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 2 Safety Instructions

Wiring Example
Device with Device featuring
shielded wires protection class II

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. Due to impedance (resistance R > ) of the loop, low-
frequency interference currents can lead to an unwanted voltage drop in the
signal path.
Device 1 Device 2

Ground loop

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 2 Safety Instructions

2.4 Special Safety Instructions for the Device

Gas! Danger to life!

Leaking gas may cause death or serious health damage if inhaled. Upon
completion of all assembly works, always check the system's tightness.
When operating a VariFuel gas mixer, make sure that the gauge port is
closed.
All works involving gas-carrying parts must be executed by trained
personnel only.

Explosion hazard!
If the system is not entirely tight and sealed, gas may escape and result in
explosion hazard. Upon completion of all assembly works, always check the
system's tightness. The formation of explosive gases in the area of the
device must be prevented, e.g. by adequate ventilation or the use of gas
sensors which switch off the gas supply.
All works involving gas-carrying parts must be executed by trained
personnel only.

Explosion hazard!
Do not disconnect any connectors while the system is live. If the system is
located in a hazardous area, there is a risk of explosion.

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 2 Safety Instructions

Risk of injury!
The stepper motor driver VariStep3 is designed for operation in circuits with
protected extra-low voltage (PELV). The voltages in these circuits must not
exceed 50 V AC or 75 V DC.
The stepper motor driver VariStep3 must not be electrically connected to
circuits which carry dangerously high voltages or which could do so if a
single fault occurs.
Therefore, the following conditions, among others, must be fulfilled:
– The power supply may only be provided from power supply units with
safe electrical isolation or from batteries.
– Relays with safe isolation must be used for coupling to circuits that
carry or in the event of a failure could carry dangerous voltage.
– All currently applicable standards and regulations must be taken into
account.

Operational safety!
All screws of the connectors must be adequately tightened.

Operational safety!
The proper functioning of the device is only guaranteed if the device is
operated within the permissible supply voltage range. Therefore, use a
power supply in accordance with the specifications in the operating
manual.

Risk of burning!
The surfaces of the system may heat up to high temperatures. Ensure good
heat transfer through ventilation when installing in the control cabinet.

2.5 Proper Disposal

For the proper disposal of MOTORTECH devices, observe the information provided at
www.motortech.de.

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 3 Intended Use

3.1 Functional Description

The VariStep3 stepper motor driver drives the stepper motor of a gas mixer or throttle. This
stepper motor carries out position changes:
– The stepper motor adjusts the openings for the gas supply of the gas mixer and thereby
alters the composition of the gas-air mix.
– In the throttles the stepper motor changes the opening angle of the throttle and thereby
controls the supply of the gas-air mix.

Control can be manual or automatic. Manual adjustments can be made using buttons on the
stepper motor driver via a connected computer. In automatic mode, binary or analog input
signals, such as those provided by a master control, are analyzed. In addition, a connection via
CAN bus and Modbus is possible.
The stepper motor driver is configured using a connected computer. The software used for this
purpose is also used to display current system data and error messages.

3.2 Applications
The VariStep3 stepper motor driver can be used for the following MOTORTECH devices:
– Gas mixer with stepper motor (e.g. VariFuel2)
– ITB throttles with integrated stepper motor
– 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.
As per EN 55011, the VariStep3 stepper motor driver is equipment of Group 1 and Class B.
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.
 3 Intended Use

System Overview (Example)

VariStep3 stepper motor driver Master control

VariFuel gas mixer Flywheel
ITB throttle with integrated stepper motor Magnetic pickup
SC100 speed controller Engine
Impulse line
Air Air filter
Gas Ball valve
Gas filter

Double safety valve

Balance/Zero pressure regulator

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 4 Product Description

4.1 Technical Data

4.1.1 Certifications
The VariStep3 stepper motor driver is certified as follows: CE
The EU Declaration of Conformity can be obtained on request from your MOTORTECH contact
person (see section Customer Service Information on page 78).

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 19
Mechanical environmental Protection: IP20
conditions
Climatic environmental –20 °C to +60 °C (–4 °F to +140 °F)
conditions
Max. 85 % humidity without condensation up to 3,000 m
(9,842') above sea level
Permissible vibration Constant vibration displacement of 1.6 mm (0.06") from 5
conditions Hz to 12.4 Hz
Constant acceleration of 1 g from 12.4 Hz to 1,000 Hz

4.1.3 Warning Notices on the Device

Top of Device
WARNING! Read and understand the installation and operating manual prior to installing or
making any adjustments. Do not disconnect equipment unless power has been switched off.

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 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
P/N Part number of the stepper motor driver
S/N Serial number of the stepper motor driver
A/N Arrangement number of the stepper motor driver
R/N Revision number of the stepper motor driver

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. 5.0 A

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 4 Product Description

Electrical Data for Inputs and Outputs

The inputs and outputs of the stepper motor driver have the following electrical data:

Inputs and outputs Values/characteristics

Binary inputs – Galvanically separated
– Input voltage up to 32 V DC
– Input current at least 5 mA for high level
– Save low level:
Voltages below 1.0 V DC for at least 70 μs
– Save high level:
Voltages above 4.5 V DC for at least 5 μs

Diagram of the Signal

When the reset signal is given, the high level must be present
at the relevant input for at least 50 ms before it is possible to
initiate the reset.
Binary outputs – Galvanically separated
– 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

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 4 Product Description

Inputs and outputs Values/characteristics

Analog current input Permissible current: 0 mA to 20 mA
Max. difference in potential relative to device ground: +3.5 V
Input resistance: max. 25 Ω
Analog voltage output Output voltage: 0 V to 10 V
Working resistance: min. 500 Ω
Analog current output Output current: 0 mA to 20 mA
Working resistance: max. 500 Ω

4.1.6 Interfaces
USB
– Compatible with USB 1.1 and USB 2.0
– The connector type B is only suitable for temporary data exchange and not for a permanent
connection.

CAN Bus 2.0B Interface

– As per ISO 11898, up to 1 Mbit/s
– Transient-proof (automotive classification)
– Max. 110 participants

Modbus Interface
– RS485 standard
– Max. 32 participants
– Full duplex (4-pole) or half duplex (2-pole)

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 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, binary input is available for a reset signal (see
Wiring Binary Inputs on page 28).
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 29).
Analog Analog inputs and outputs by use of which you can change and
Inputs/Outputs resend the position of the stepper motor (see Wiring Analog Inputs
and Outputs on page 30).

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 4 Product Description

Designation Function
Manual/Auto (switch) Switch for changing between manual and automatic operation (see
Manual and Automatic Operation on page 34)
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 34).
In the case of an error, the error can be reset followed by a
reference run if you press the two buttons simultaneously.
The Open LED and the Close LED are flashing when the stepper
motor is moved into the corresponding direction via the buttons.
When a stop has been reached, the corresponding LED lights up
permanently.
Status You can find details about status signaling in the following
information box.
The LED flashes:
– green: The stepper motor driver is working properly.
– Orange: A warning occurred.
– red: An error occurred.

For additional information on warnings and errors, read section

Runtime Data – Message Log on page 64.
Manual/Auto (LED) The LED lights up:
– green: The stepper motor driver is in automatic mode and is
controlled by the master control.
– Orange: The stepper motor driver is in manual mode.

USB Port for data transmission to the PC. Data transmission is signaled
by the LEDs blinking.
CAN Port for communication via CAN bus with master control. Data
transmission is signaled by the LEDs blinking.
RS485 Port for communication via Modbus with superordinate control
devices. Data transmission is signaled by the LEDs blinking.
Stepper Motor + Port for the stepper motor and the encoder. LEDs A, B and I are
Encoder flashing when the stepper motor is moving (see Wiring Stepper
Motor and Encoder on page 26).
Power Connection for the supply voltage (see Wiring of Power Supply on
page 24). This LED lights up if the supply voltage is available.

20 Rev. 05/2022
 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.
Warnings can for example be caused by:
– Overload of the device

In addition, the LED flashes orange for the following reasons.

– No device type has been configured (device type: None or
Unknown).
– Device connected was changed.
– Overtemperature or over current error confirmed by MICT.
– A reference run is required.

The first two cases make downloading a modified configuration to the

device a priority.
– Flashing red: Error
Errors can be acknowledged by simultaneous pressing of buttons Open
and Close or by the external reset signal. Errors can for example be
caused by:
– Step loss
– Overtemperature
– Low voltage
– Over current

– Alternate flashing of red and green:

The supply voltage for the device was too low during start up.

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 5 Installation Instruction

5.1 Installation Instruction

Unpack the stepper motor driver without damaging it and ensure that the operating manual is
always within reach of the device and easily accessible. Installation locations where strong
vibrations or ambient temperatures of below –20 °C (–4 °F) or above +60 °C (+140 °F) are
present are not permissible and result in the warranty being voided.

Risk of destruction!
The device must not be installed directly on or at the engine, as vibration
and heat may cause damage to electronic components.

Risk of destruction!
Make sure that the device is not covered and ensure sufficient circulation of
air.

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 IEC 61340-5-1.
Damage caused by electrostatic discharge is not covered by warranty.

Scope of Supply
The supply scope of the VariStep3 stepper motor driver consists of the following components:
– VariStep3 stepper motor driver
– Storage device (USB flash drive or CD-ROM) including configuration software MICT
– USB cable
– Operating manual

Installation of the VariStep3 stepper motor driver

1. Install the VariStep3 stepper motor driver on a horizontal DIN rail in the control cabinet.

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 6 Wiring of the Device

Risk of damage to the device!

Incorrectly installed wiring can cause damage to the device. Please adhere
to the following points:
– 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. conductor cross-section 0.75 mm², max. cable length
10 m (32')
If the cable length is longer, a respective larger cross-section must be
selected.
– Stepper motor:
4-wire, shielded cable, min. conductor cross-section 1.5 mm², max.
cable length 30 m (98')
– Encoder:
5-wire, shielded cable, min. conductor cross-section 0.2 mm², max.
cable length 30 m (98')
– Binary inputs and outputs:
multicore cable, min. conductor cross-section 0.2 mm², max. cable
length 30 m (98')
– Analog inputs and outputs:
multicore, shielded cable, min. conductor cross-section 0.2 mm², max.
cable length 30 m (98')
– CAN bus:
2-pair, shielded bus cable, min. conductor cross-section 0.34 mm²,
max. cable length 250 m (820') at 250 kbit/s
– Modbus:
3-pair, shielded bus cable, min. conductor cross-section 0.25 mm²,
max. cable length 250 m (820')

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 6 Wiring of the Device

Replacing VariStep and VariStep3

Pin assignment of connectors is identical for the VariStep and VariStep3
stepper motor drivers except for the connector Analog Inputs/Outputs. The
identical plugs can simply be plugged from the old device into the new
device. 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. Pin 0 of the socket is currently not in
use and therefore locked.
When changing the plug for the power supply, be aware that Earth and
negative pole (–) must be connected separately on the VariStep3.

6.1 Wiring of 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.

Operational safety!
The proper functioning of the device is only guaranteed if the device is
operated within the permissible supply voltage range. Therefore, use a
power supply in accordance with the specifications in the operating
manual.

Voltage supply drop

The VariStep3 stepper motor driver maintains fieldbus communication in
the event of a voltage supply drop down to 8 V.

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 6 Wiring of the Device

The power supply is wired using the 3-pole connector. In order to comply with the EMC
requirements, it is absolutely necessary that the earth contact is connected with a wire separate
from the negative pole (L –).
L ≙ 18 V DC to 32 V DC (nominal voltage: 24 V DC)

Variations
1 Battery Generator Control unit

2 Power supply

3 Battery Charger

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 6 Wiring of the Device

6.2 Wiring Stepper Motor and Encoder

Risk of destruction!
To rule out the possibility of moving the devices connected out of the
control area, observe the following procedure when connecting the stepper
motor to the VariStep3 stepper motor driver:
1. Configure the VariStep3 stepper motor driver for your device type (see
section External Device on page 51.
2. Separate the stepper motor driver from the power supply.
3. Connect the stepper motor of the VariFuel2 air/gas mixer or the throttle
to the stepper motor driver.
4. Connect the VariStep3 stepper motor driver again to the power supply.
▸ Now, the stepper motor driver will initiate a reference run. The
device is ready for operation.

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.

The wiring is done via the 11-pole connector on the stepper motor driver. The socket for the
stepper motor and encoder has 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').

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 6 Wiring of the Device

Encoder

Stepper Motor

Pin assignment when using the original MOTORTECH wiring harness:

Pin stepper motor and

Pin VariStep3 Designation
encoder
0 Encoder Data Currently not used
1 Encoder GND (ground) J
2 Encoder Power (supply voltage) I
3 Encoder A E
4 Encoder B F
5 Encoder I (index) G
6 Encoder Shield H
7 Stepper Motor Phase B2 D
8 Stepper Motor Phase B1 C
9 Stepper Motor Shield H
10 Stepper Motor Phase A2 B
11 Stepper Motor Phase A1 A

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6.3 Wiring Binary Inputs

The binary inputs are wired using the 10-pole connector. 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

Pin Designation Function

1 Dir + The level at the binary input indicates whether the openings of the
2 Dir – gas supply of the gas mixer or the throttle move in the open or
closed direction when pulses occur at the input Steps (see
Inputs/Outputs – Control Setup on page 54).
3 Steps + Pulses on the input modify the openings for the gas supply of the
4 Steps – gas mixer or the throttle step by step (see Inputs/Outputs – Control
Setup on page 54).
5 Pos. 1 + If a high level is applied, position 1 as defined in the configuration
is approached.
6 Pos. 1 –
7 Pos. 2 + If a high level is applied, position 2 as defined in the configuration
8 Pos. 2 – is approached.

9 Reset + If a high level is applied for at least 50 ms, the device exits the error
10 Reset – mode and the stepper motor driver is reset. Subsequently, it
initiates a reference run.

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6.4 Wiring Binary Outputs

The binary outputs are wired using the 12-pole connector. The outputs can switch both the
operating voltage and ground.
L ≙ 5 V DC to 32 V DC; max. 100 mA

Pin Designation Function

11 Error + The output is low-resistance if an error has occurred and the
12 Error – stepper motor driver is in automatic mode. To exit the error state,
the error needs to be acknowledged (refer to Acknowledging Faults
on page 77).
13 Close + The output is low-resistance if the stepper motor has reached the
closed position.
14 Close –
15 Open + The output is low-resistance if the stepper motor has reached the
open position.
16 Open –
17 Pos. 1 + The output is low-resistance if the stepper motor has reached the
18 Pos. 1 – configured position 1.

19 Pos. 2 + The output is low-resistance if the stepper motor has reached the
configured position 2.
20 Pos. 2 –
21 Offline + The output is low-resistance if the stepper motor driver is in a state
in which it does not react to external control signals (e.g. manual
22 Offline –
mode or reference run).

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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.

Pin Designation Function

23 Position U in + Voltage input for adjustment of the openings for the
gas supply of the gas mixer or the throttle (see
Analog Inputs

24 Position GND
Inputs/Outputs – Control Setup on page 54). The input
has a value range from 0 V to 10 V.
25 Position I in + Current input for adjustment of the openings for the
26 Position I in – gas supply of the gas mixer or the throttle (see
Inputs/Outputs – Control Setup on page 54. The input
has a value range from 0 mA to 20 mA.
27 Shield Shield
28 Position U out + Voltage and current output with shared ground. The
Analog Outputs

outputs export the current position of the stepper

29 Position GND
motor as appropriate signal. They have a value range
30 Position I out + from 0 V to 10 V and from 0 mA to 20 mA

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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 connector.
First device Second-to-last device

Second device Last device

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 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 Maximum length of

length of a stub all stubs
1 Mbit/s 25 m (82') 1.5 m (5') 7.5 m (25')
800 kbit/s 50 m (164') 2.5 m (8') 12.5 m (41')
500 kbit/s 100 m (328') 5.5 m (18') 27.5 m (90')
250 kbit/s 250 m (820') 11 m (36') 55 m (180')
125 kbit/s 500 m (1,640') 22 m (72') 110 m (360')
50 kbit/s 1,000 m (3,280') 55 m (180') 275 m (902')

– Only use cables that are specified by the manufacturer for use in the
CAN bus.

6.7 Wiring Modbus

The Modbus can be wired as half duplex or full duplex, and twisted cables must be used. With
both variants the load resistance RT is the characteristic impedance of the cable.

Wiring Half Duplex

First device Last device

Second device Second-to-last device

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Wiring Full Duplex

First device Last device

(Master) (Slave)

Second device Second-to-last device

(Slave) (Slave)

Connection to Stepper Motor Driver

The Modbus is wired using the 6-pole connector.

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7.1 Manual and Automatic Operation

Adjusting the opening of the throttle or the openings for the gas supply in the gas mixer can be
carried out via the stepper motor driver in two operating modes:
– Manual operation
– Automatic operation

Manual and automatic operation can be switched via the Manual/Auto switch or via the MICT. In
this case, the MICT overwrites the switch position on the device. Switching via the Manual/Auto
switch can be disabled by a setting in the MICT. If the status LEDs Manual or Auto are lighted up,
this indicates the operation mode the stepper motor driver is currently in.

Manual Operation
In manual operation, the external input signals of the master control are ignored. You can use
the two buttons Open and Close to modify the position of the throttle and the openings of the
gas supply for the gas mixer. The stepper motor driver must also be in manual operation for
configuration via the MICT and for transferring settings to the device.

Risk of destruction!
In manual operation, the signals of the master control are not analyzed. If
you make any adjustments in the manual mode with the gas engine
running, make sure that these settings do not endanger the correct
operation of the gas engine.

Automatic Operation
In automatic operation, the stepper motor driver evaluates the external input signals of the
control unit connected. The buttons Open and Close are deactivated. The device cannot be
configured via the MICT. In automatic operation, the MICT can only be used to display the data
and to create log files.

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.
In manual mode the device connected initially remains in the following position:
– Gas mixer remains in the open position.
– Throttles remain in the closed position.

During reference run, the Offline output is low impedance and the corresponding LED lights up.
The signals of the inputs are not analyzed. A reference run can also be triggered via the MICT.

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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 (0 %
open).

When one of the two positions is reached, the respective binary output Open or Close is
switched and the corresponding LED lights up. The connected devices cannot be moved beyond
these two positions and all corresponding signals are limited.

7.4 Configurable Opening Angles (Position 1 and 2)

The MICT can be used to configure two opening angles, and these openings can be controlled
directly via binary inputs (Pos. 1, Pos. 2). If the signals Pos. 1 and Pos. 2 are simultaneously
present, position 1 will be approached. When the stepper motor reaches one of the two
positions, the respective binary output (Pos. 1, Pos. 2) is switched and the corresponding LED
lights up. In this way, you can define the opening angles for certain operating states such as
starting or purging the gas engine.
You can configure positions 1 and 2 with the MICT. For further information, refer to the section
Positions – Values on page 57.

7.5 Change of Opening Angles via Binary and Analog Inputs

In automatic mode the opening angle can be controlled directly via the following inputs.
– Binary inputs Dir and Steps
– Analog voltage input 0-10 V
– Analog current input 0-20 mA
– Field buses CAN and Modbus

Depending on which master control you are using, you can select the required input using the
MICT. If one of both end positions (open or closed) has been reached, the signals are limited at
the inputs in the corresponding direction.
You can configure the inputs with the MICT. Refer to the section Inputs/Outputs – Control Setup
on page 54.

7.6 Analysis of Positions via Analog Outputs or Field Bus

The current position of the throttle or the openings of the gas supply for the gas mixer can be
sent to the master control via an analog voltage output or an analog current output or a field
bus. Using the MICT, it is possible to configure which of the two analog outputs is to be used and
which voltage or current value corresponds to the open or close position. The current or voltage
applied on the output is then set accordingly proportional to the current opening of the fuel ring.

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You can configure the outputs with the MICT. Refer to the section Inputs/Outputs – Control Setup
on page 54.

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.

Access control
A user is logged in to the Advanced Service access level on the MICT. He
changes a configuration and would like to download the change to the
stepper motor driver. Although he has the full authorization set in the MICT,
he is prompted to log in with the PIN for the Level 3 (Master). This ensures
that it is not possible for any user with an MICT and the generally valid
password to change the configuration of your stepper motor driver.

Various functions are at your disposal on the four operating levels. The figure below illustrates
this:

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 7 Functions

The following functions are available on the different levels:

– Level 0 (Read Only)
Enables read-only access for all users.
– Level 1 (Operator)
At this level the user can make position changes (closed and open position, position 1 and
position 2, and make manual changes to the opening). Beyond that, he can change the
operation mode and can confirm errors.
– Level 2 (Service)
The service personnel can also initiate a reference run and reset the counter in the runtime
data for the maximum number of step losses that occurred.
– Level 3 (Master)
At this level, the master can also reset all PINs and enable or disable the access control.
Moreover, only the master is authorized to download a changed configuration to the stepper
motor driver.

For information on the access levels in the MICT, refer to the section Access Levels in the MICT on
page 39.

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 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).
If you are using a different version of the MICT than shown in the following sections, the scope of
functions may differ.

8.1 MICT System Requirements

For the installation of the MICT, the following minimum requirements must be fulfilled:
– x86-compatible computer, at least performance class Intel Pentium 4 with 2 GHz
– 128 MB free RAM
– 250 MB free disk space
– USB interface 1.1 or higher
– Display with a resolution of at least 1440 x 900 pixels (WXGA+)
– Microsoft® Windows 7, Windows 10

8.2 MICT Installation

The software for the installation of the MICT is on the data storage device (USB flash dive or CD-
ROM) enclosed with the VariStep3 stepper motor driver.
To install the MICT, proceed as follows:
1. Start the installation:
– Via the menu:
Start the file Start.exe on the storage device. Start the installation routine of the MICT
via Software -> Install MICT.
– Directly from the storage device:
Start the installation routine of the MICT directly. It is on the storage device in the
subdirectory Installation and for example named as follows: MICT-2.42.2-setup.exe.

2. Run the installation.

Follow the instructions of the installation routine. Note that the license agreement terms
must be accepted before using the MICT.
3. Install the USB driver via the menu as well or directly from the storage device.
– Via the menu:
Software -> USB Drivers -> Install USB Drivers
– Directly from the storage device:
Start the exe file in subdirectory Drivers(e.g. CDM21226_Setup.exe).
▸ You have installed the MICT and can now connect your computer to the stepper motor
driver via the USB interface.

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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. The password required for access
can be obtained from your MOTORTECH contact person (refer to Customer Service Information on
page 78).

The following access levels are available:

– Read Only
On this level, the user can open a configuration and transfer it to the device. However, he
cannot make changes to the configuration. The user has read-only access to all other
settings.
– Customer
This level enables the configuration of the basic functions required for operation in addition
to the read-only function.
– Service
This level includes all functions needed for maintenance.
– Advanced Service
This level offers full access to all functions of the MICT and is enabled and accessible for
specially trained personnel only.

The following sections describe the options at your disposal with the Advanced Service access
level. If you have registered for a different level, you cannot execute all functions shown.

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8.4 Configuration Pages (Overview)

The configuration pages are divided into the following sections:

Pos. 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.
The status bar provides you with the following information (from left to right):
– Status display
Indicates whether a connection is established with the device:
– Green display: connection established

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– Red display: the connection was interrupted and is being restored

– Gray display: the connection is not established and is not being restored

– Indication of the interface being used for the connection to the device
– Indication of the device ID
– 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

8.5 Menu Bar and Toolbar

The following functions are available to you via the symbols on the toolbar and the entries in the
menu bar:

Symbol Menu Function

File -> New Creates a new configuration.

File -> Open Opens an existing configuration.

File -> Save / Saves the current configuration.

File -> Save As

File -> Recent Documents The last five configuration files used are offered for
selection.
File -> Close Closes the current configuration.

File -> Open trace Opens a runtime data record (trace file). Refer to the
section Runtime Data on page 61.
File -> Open pickup trace Opens a saved recording of pickup signals (putrace
file), for example from a MOTORTECH ignition
controller. Pickup signals cannot be recorded by the
VariStep3.
File -> Change Access Changes the access level for accessing the
Level configuration data and functions.

File -> Print Prints the current configuration.

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Symbol Menu Function

File -> Print To PDF File Prints the configuration to a PDF file.

File -> Print Preview Opens a print preview of the configuration.

File -> Quit Exits the MICT.

Device -> Connect Connects to the device.

Device -> Disconnect Cuts the connection to the device.

Device -> Download to Downloads configuration data from the computer to the
device device. This function can only be executed in manual
mode.
Device-> Upload from Uploads configuration data from the device to the
device computer.

Device -> Runtime data Opens the window Runtime Data. Refer to the section
Runtime Data on page 61.

Device -> Log Opens the window Log (Advanced Service only). Refer
to the section Log on page 69.

Device -> Select Mode Opens the window Select operation mode in which you
can select the operation mode. The following modes
are possible: Manual operation mode, Automatic
operation mode or Switch controls operation mode.
Device -> Manual Opens a window in which you can manually adjust the
Adjustment opening angle.

Device -> Open Position Completely opens the throttle or the gas supply for the
gas mixer in manual mode.
Device -> Close Position Completely closes the throttle or the gas supply for the
gas mixer in manual mode.
Device -> Position 1 In manual mode, drives to the position 1 defined in the
configuration by a percentage.
Device -> Position 2 In manual operation, drives to the position 2 defined in
the configuration by a percentage.

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Symbol Menu Function

Device -> Reference Run Initiates a reference run in manual mode (Service and
Advanced Service only).
Device -> Temperature Opens a window in which the maximum and minimum
Extremes temperature are displayed. These values are measured
throughout the operating time on the board of the
stepper motor driver.
Device -> Error All operational errors are acknowledged.
Acknowledge

Device -> Trigger Error The process carried out by the stepper motor driver
(e.g. a reference run), is canceled and the stepper
motor driver switches into error mode.
Device -> Access Control The setup for the access control to the device is
described in a separate section. Please read the
section Access Control of the Stepper Motor Driver on
page 45.
Settings -> Language Opens the window Select Language in which you can
change the interface language of the MICT.
Settings -> Online update Opens the window Online Update Settings. Refer to the
settings section Online Update Settings on page 44.

Settings-> Database Opens a dialogue window in various databases can be

settings assigned as source for the MICT.

Settings -> Temperature Opens the window Select Temperature Scale, in which
scale you can change the unit for the temperatures shown in
the MICT.
Settings -> Display by This function is available for certain MOTORTECH
cylinders ignition controllers and has no effect in conjunction
with the VariStep3.
Document Has no function with the VariStep3.

Tools -> Coils Opens a database with information on MOTORTECH

ignition coils.
Help -> Help Opens the online help function.

Help -> About MICT Opens detailed information on the MICT.

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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 -> Online update settings

You have the following options:

– Enable automatic database updates
Using the check box, you can enable and disable automatic online updates. As the default
setting, the online update is activated and is executed daily (if an internet connection is
established) at first start-up of the MICT.
– Use a proxy to access the web
Use the checkbox to activate settings for internet access via a proxy server, which you can
then set up by entering http-Proxy and Port.
– Show Log
With this button, you can open a window in which the online updates performed are logged.
– Update Now
With this button, you manually start an online update.

Online update
After the online update, the updated data will only be used if these have
been downloaded onto the device. However, this requires the relevant
authorization.
Whenever the configuration is uploaded from the device, the version of the
configuration saved in the device will be compared with the version in the
database. If the two versions are not the same, a window with additional
instructions will open up.

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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)
– Configuration (transfer of a configuration to the stepper motor driver)

The access control regulates the accesses to the stepper motor driver via the MICT. For
explanations concerning access control of the stepper motor driver and the delimitation of the
access levels in the MICT, refer to section Access Control on page 36.
The access control functions can be accessed in the menu bar via:
Device -> Access Control

8.7.1 Enable/Disable Access Control

Enable/Disable access control

As a default setting, the access control is not activated, and all PINs are set
to 0000. Once the access control has been activated, and the PINs were
changed, these PINs will continue to be used. To activate the access control
again, you will need the PIN for level 3 (Master). It is therefore
recommended to reset all PINs before disabling.
If that was not done, or a system must be unlocked for another reason, a
request key can be issued in the MICT. Refer to the section Reset all PINs on
page 46.

To enable or disable the access control, proceed as follows:

1. Open the input dialog via Device -> Access Control -> Enable or Disable access control.
2. Enter the PIN for the level Master (Level 3).
3. Confirm the input with OK.

8.7.2 Login/logout
If the access control is activated, you are prompted to log in if you want to execute functions that
are allocated to a specific operating level. In addition, you can log in specifically to an operating
level via the menu bar.
To log into a specific operating level, proceed as follows:
1. Open the input dialog via Device-> Access Control -> Login.
2. First select the level you wish to log on to.

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3. Enter the PIN for the desired level.

4. Confirm the input with OK.
▸ You are now logged into the corresponding level and can execute all functions that are
allocated to this operating level without having to log in again.

After completing the log-in, you can log out again as follows:
Device -> Access Control -> Logout

8.7.3 Changing the PIN

To change the PIN for a specific operating level, proceed as follows:
1. Open the input dialog via Device -> Access Control -> Change PIN.
2. First select the level for which you wish to change the PIN.
3. Enter the current PIN for the desired level.
4. Enter the new PIN in the two subsequent fields.
5. Confirm the input with OK.
▸ The PIN for this operating level has now been changed.

8.7.4 Reset all PINs

To reset all PINs, proceed as follows:
1. Open the input dialog via Device -> Access Control -> Reset all PINs.
2. If you are not yet logged into the Master (level 3) level, you will be prompted to log in with
the relevant PIN.
3. Confirm the input with OK.
4. To reset all PINs, you will be prompted again to enter the PIN for the level Master (Level 3).
5. Confirm the input with OK.
▸ All PINs are now reset to the value 0000.

To reset all PINs, you need the PIN for the level Master (level 3). To be able to unlock a system in
case of emergency that was locked in this way, you have the following option:
1. 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 78). This key is valid only for the respective
controller and only for a certain amount of time.
▸ Your information will be verified, and you will receive an authorization key from your
contact person.

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3. From the menu bar, select the entry Device -> Access Control -> Set reset all PINs
authorization key to open a window with this name.
4. Enter the authorization key received in the input field.
5. Confirm the input with OK.
▸ 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. This information is stored in a configuration file on the
stepper motor driver.
You need the MICT for the following tasks:
– Creating configuration files
– Opening configuration files from a storage device
– Processing configuration files
– Saving configuration files on a storage device
– Downloading configuration files to a VariStep3 stepper motor driver
– Uploading configuration files from a stepper motor driver
– Displaying current and saved runtime data

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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.

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8.8.2 Upload, Download

Click the symbol to upload the current configuration from the VariStep3 stepper
motor driver to the MICT. If applicable, the MICT first establishes a connection
to the stepper motor driver connected.
Click the symbol to download the configuration set in the MICT to the VariStep3
stepper motor driver. This function can only be executed when the stepper
motor driver is in manual mode. This action overwrites the existing
configuration on the device. If applicable, the MICT first establishes a
connection to the stepper motor driver connected.

Existing configuration is cleared!

If you download a configuration to a VariStep3 stepper motor driver, the
previously used configuration is deleted and the new settings are
immediately implemented.

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. The MICT assumes the
standard values for these functions.
– The configuration contains function values that are not support by the MICT.

The following situations can occur if you download a configuration from the MICT to a VariStep3
stepper motor driver whose firmware does not correspond to the status of your MICT:
– No values are present in the configuration for certain firmware functions. The firmware
continues to use the preset values for these functions.
– The configuration contains function values that are not support by the firmware.

If you download a configuration to the stepper motor driver and are notified of functions that are
not supported by the MICT, you should check the stepper motor driver settings. Re-upload the
configuration from the stepper motor driver to the MICT. You can then see which settings are not
transmitted to the MICT.

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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. You can make changes to the configuration
by selecting an entry from the navigation bar. The corresponding configuration data are then
displayed in the configuration section and can be processed. The following sections will
describe the settings and adjustments you can implement in the different areas.

Indication of invalid entries

An invalid selection or invalid input values are highlighted by pulsating
warning signs on the configuration pages of the MICT. Additional
information is provided in the status bar.
Example:

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8.9.1 External 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. This indicates that a reference run in
required.
– Gas Mixer
Select this option in order to select from the following drop-down list the type of gas mixer
that corresponds to the device that you want to configure (e.g. VF2 200-120 Rev. B for a
VariFuel2 type 200-120 with a revision B stepper motor). Note the stepper motor revision
when making your selection. Type RK1 corresponds to the stepper motor conversion kit for
gas mixers (MWM TBG620 series).
– Throttle
Select this option to select the throttle from the following drop-down list with integrated
stepper motor (ITB) or the throttle gear (TG) that corresponds to your application.

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– Unknown
This option corresponds to the factory setting and cannot be reassigned once the device has
been changed.
– 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. If the device type has been changed
to None and the modified configuration has been downloaded to the device, the Status and
Manual/Auto LEDs are flashing orange.

Note the stepper motor revision

The revision of the stepper motor can be identified from the nameplate on
the stepper motor of your VariFuel2.
VariFuel2 stepper motors whose revisions are not stated on the nameplate
or which are supplied without a nameplate are revision A stepper motors.
For revision A, select the entry for your VariFuel2 type without a revision
specification under External Device (e.g. VF2 200-120 for a VariFuel2 type
200-120 with revision A stepper motor).
If no VariFuel2 types with matching stepper motor revision are displayed
under External device, the VariFuel database of your MICT is not up-to-date.
In this case, perform an online update. For further information, refer to the
section Online Update Settings on page 44.

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Changing the device type

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.
Scenario: You have replaced one VariFuel2 gas mixer with another
VariFuel2 type.
Problem: After connecting the new VariFuel2 gas mixer, the stepper motor
driver performs a reference run. However, since this configuration still
contains data from the first gas mixer, it is possible that the VariFuel2 may
leave the traversing range and be mechanically damaged as a result, or
there is a risk that the VariFuel2 has to be readjusted.
Solution: The following procedure will help to solve the problem:
1. Separate the first VariFuel2 from the stepper motor driver.
2. Connect the MICT to the stepper motor driver.
▸ The defective connection with the stepper motor causes an
operating error.
3. Switch to manual mode.
4. Acknowledge the error via the MICT (Device -> Error Acknowledge).
5. Change the configuration to the new VariFuel2 type.
6. Download the altered configuration to the device.
7. Separate the stepper motor driver from the supply voltage.
8. Connect the new VariFuel2 with the stepper motor driver.
9. Reconnect the stepper motor driver to the supply voltage.
▸ A reference run will be performed. The new VariFuel2 is then ready
for operation.

Tip: When you first configure the VariStep3 stepper motor driver with the
option None in the drop-down list Device Type no operating error is
triggered after the device has been separated from the stepper motor
driver. You can now reconfigure the stepper motor driver directly.

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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. To make changes, approval for the access level Advanced Service is required.

Selection
– Input
Select the input that is to be used for position setting by the master control connected. The
following options are possible:
– Analog voltage
Position setting is achieved via the analog voltage signal.
– Analog Current
Position setting is achieved via the analog current signal.
– Digital Steps/Dir
Position setting is achieved via binary signals (Steps, Dir).
– Field bus
Position setting is achieved via a field bus. This requires corresponding configuration of
the communication with the desired field bus (see Miscellaneous – Communication on
page 58).

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– 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.

Input Voltage/Input Current

Depending on which input is selected, you have different adjustment options available. For the
analog inputs, enter the values for the open and closed position of the fuel ring. Here, please
adhere to the following values:
– Input voltage: 0 V to 10 V
– Input current: 0 mA to 20 mA

Click this button to apply the settings of the analog input (current or voltage) to the output
selected. If you have selected another input as output (e. g. input: current; output: voltage), the
adjusted values are converted in accordance with the output's value range.

Input Step Count/Step Count Configuration

Define both the Direction and the Init Position of the steps of the binary inputs. The initial
position (=Init Position) will be approached after the reference run of the stepper motor.
To make these settings, refer to all additional information as provided in the following note.

Output Voltage/Output Current

Depending on the selection, enter the relevant current or voltage values, which are to
correspond to the open and closed position. Here, the same value ranges are applicable as with
the analog inputs.

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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.
Example:
Your master control works with a current input of 4 mA to 20 mA. In the
MICT, you configure 4 mA to refer to the closed position and 20 mA to the
open position. If the current on the input is now 16 mA, the opening is 75 %.

Binary inputs
In the MICT, enter the settings for the binary inputs Dir and Steps. The level
on the Dir determines the direction in which the fuel ring of the VariFuel2 or
the throttle will move if there are pulses on the Steps.
Example:
You have selected the option High -> Open in the MICT under Direction. If a
high level is applied on the Dir, with each pulse on the Steps one step is
added to the current position. The fuel ring or throttle will then move
gradually from the Closed to the Open direction.

Unused inputs and outputs

Please note that the terminals for the analog inputs and outputs not
selected in the MICT must remain unoccupied.

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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). The openings specified here can be set in manual mode via the MICT and
in automatic mode via fieldbus or via the binary inputs of the stepper motor driver.
For further information, refer to the section Configurable Opening Angles (Position 1 and 2) on
page 35.

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8.9.4 Miscellaneous – Communication

CAN
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
In the protocol ALL-IN-ONE (J1939) the source address can be assigned between 0 and 253.
In the CANopen protocol, a CANopen node ID from 1 to 127 can be assigned. Note that IDs
cannot be assigned more than once.
– Baudrate
Select the desired data transfer rate from the list. In the protocol ALL-IN-ONE (J1939),
250 kbit/s and 500 kbit/s are available for selection. In the CANopen protocol, a baud rate
from 50 kbit/s to 1 Mbit/s can be set. For both protocols, we suggest the use of a baud rate
of 250 kbit/s.

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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 9,600 bit/s and 115,200 bit/s, the recommended value being 19,200 bit/s.
– Parity
Define if a parity bit is used and if the parity is to be even or odd.
– Stopbits
Determine if one or two stop bits are to be sent. Two stop bits can only be sent if no
parity has been selected.
– Modbus Settings
– Modbus Address
The Modbus address can be assigned between 1 and 247. Note that IDs cannot be
assigned more than once.
– Mode
Define if the data are transferred in the ASCII or RTU mode.

Setting the transfer rate

Please note that all devices connected with a bus must be set to the same
transfer rate.

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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.

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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
Prints the runtime data.

Prints the runtime data to a PDF file.

Opens the print preview.

Starts the runtime data trace.

Stops the runtime data trace.

Save runtime data locally

You should always save runtime data on the local computer and not on a
network drive or external storage device. Trace files can only be moved
freely once the recording is stopped.

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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.
– red: The stepper motor driver has no or an invalid configuration. An existing configuration
can for example become invalid during a firmware update. A valid configuration must be
downloaded to the stepper motor driver in order to make the device operational.

Reference Run
The status display provides information on the reference run:
– green: The reference run was completed successfully.
– yellow: The reference run is being carried out.
– red: Errors occurred during the reference run. The reference point was not found.

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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.

Stepper Motor
The status display indicates the condition of the stepper motor:
– green: The stepper motor is ready.
– yellow: The stepper motor is active.
– red: An error occurred.

Warning/Error
A red status display indicates that an error or a warning message occurred. The display will go
out if the error or warning is acknowledged via the MICT (Device -> Error Acknowledge). Refer to
the section Runtime Data – Message Log on page 64.

Opening
– Target
The value is assigned to the stepper motor driver in automatic mode by the master control
or, in manual mode, by the MICT or the Open/Close buttons on the device.
– Actual
The displayed value corresponds to the opening percentage of the throttle or the gas supply
of the gas mixer.

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8.10.2 Runtime Data – Message Log

In the view Message Log, information, warnings and errors are listed.
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.

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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.
Message log cleared.
NVRAM formatted.
One or more messages are lost due to exhausted memory pool or
message queue overrun.
Shutdown timestamps cleared.
Step control heavy load.
Step loss error self acknowledged.

For each information, the status of the stepper motor driver at the time the information occurred
is provided. Additional parameters are provided if necessary.

8.10.2.2 Warnings
Warning
Cpu usage.
General warning.
Reset life time.
Step control overload.
Use backup life time.

For each warning, the status of the stepper motor driver at the time the warning occurred is
provided. Additional parameters are provided if necessary.

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8.10.2.3 Errors
Errors
CAN handler message queue full.
Error triggered by command.
Coprocessor handler message queue full.
General error.
Input handler message queue full.
Interframe step loss.
Low Power
Output handler message queue full.
Over current.
Over temperature.
Stop step loss.
Timeout.

For each error message, the status of the stepper motor driver at the time the error occurred is
provided. Additional parameters are provided if necessary.

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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:
– Control
Displays whether the operation mode was adjusted using the MICT or the switch
Manual/Auto on the device (Hardware).
– Mode
The set operating mode is displayed.

States
This area shows the current conditions of the stepper motor driver, the stepper motor and all
individual phases of the reference run.

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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 board temperature reached since the last time the stepper motor driver was switched
on.

Min Temp
Minimum board temperature reached since the last time the stepper motor driver was switched
on.

Max. Step Loss

Internal diagnosis parameters associated with the control of the stepper motor. The maximum
step losses that have occurred since the last switch-on are displayed. If the step losses are too
high, this will cause an error message.

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8.10.4 Runtime Data – Information

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.

8.11 Log
Click on the symbol to open the window Log. This window is only available to
users with authorizations starting at the access level Advanced Service.

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The window Log serves to support error diagnostics by MOTORTECH.

– Automatic scrolling
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. If the function is disabled, the logged data are merely shown on the display.
– Select file
With this button, you can select a file to which you want to save the logged data.

If you are prompted to create a log file in the case of a service request, proceed as follows:
1. Open the window Log via the toolbar or the menu bar.
2. Select a path with the Select file button and enter the file name for the log file.
▸ If the file does not yet exist, it is automatically created with the extension .log.

3. Activate the checkbox Write log to file.

4. Select the level specified by MOTORTECH from the list Log level.
5. Leave the window open.
▸ The log messages are logged both in the window and in the selected file.

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9.1 Firmware Update

Using the MOTORTECH Flash Tool, you can perform a firmware update for the stepper motor
driver. The program is provided on the storage device (USB flash drive or CD-ROM supplied).

Install MOTORTECH Flash Tool

Install the MOTORTECH Flash Tool as follows:
1. Start the installation:
– Via the menu:
Start the file Start.exe on the storage device. Start the installation routine for the
MOTORTECH Flash Tool via Software -> MOTORTECH Flash Tool -> Install MOTORTECH
Flash Tool.
– Directly from the storage device:
Start the installation routine of the MOTORTECH Flash Tool directly. It is on the storage
device in the subdirectory Installation and for example named as follows: MOTORTECH-
Flash-Tool-0.23.00000-setup.exe.

2. Install the program.

Follow the instructions of the installation routine. Note that the license agreement terms
must be accepted before using the MOTORTECH Flash Tool.
3. If the USB driver is not yet installed, also install it via the menu or directly from the storage
device.
– Via the menu:
Software -> USB Drivers -> Install USB Drivers
– Directly from the storage device:
Start the exe file in subdirectory Drivers
(e.g. CDM21226_Setup.exe).
▸ The MOTORTECH Flash Tool is set up. You can now connect your PC to the stepper motor
driver via the USB interface.

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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

File -> Open Opens a firmware file.

File -> Quit Exits the program.

View -> Extended file information Fades in / out additional information of the
view firmware file.

View -> Extended connection Fades in / out additional information and

settings settings of the connection to the device.

View -> Reload file Reloads the file information of the selected
firmware file.

Device -> Search devices Restarts the search for connected devices.

Device -> Flash device Starts the update process or downgrade

process.

Settings -> Language Opens the window Select Language in

which you can change the interface
language of the program.
Help -> Help Opens the online help function.

Help -> About MOTORTECH Flash Opens detailed information on the

Tool program.

Start Firmware Update

Access control for firmware update

If you have activated the access control for the device, you need the PIN for
the level Master for the firmware update. For more information read the
section Access Control of the Stepper Motor Driver on page 45.

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Backup the existing configuration

Your device's configuration may be lost if the firmware update is not
performed properly. Always backup the existing configuration via the MICT
prior to performing an update. For more information read the section
Working with Configurations on page 47.

To start a firmware update, proceed as follows:

1. If an MICT is connected with the stepper motor driver, disconnect this connection.
2. Start the MOTORTECH Flash Tool via Start -> Programs -> MOTORTECH -> MOTORTECH Flash
Tool -> x.x.x (e.g. 0.23.00000) -> MOTORTECH Flash Tool.
▸ The MOTORTECH Flash Tool will now start.
▸ The software automatically checks all ports for connected devices.

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
computer 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.

4. Select in area File using the Select button the desired update file.
5. By reading the displayed file information, ensure that the update file is correct for your
device.
6. Start the update process using the Flash button or using the menu or toolbar.
▸ The stepper motor driver will be restarted automatically.
▸ Now, a window opens informing you about the firmware version currently used on your
stepper motor driver and also about the relevant update version.

7. Confirm with Yes to proceed with the update process.

▸ Now the update will start.
▸ If the firmware update was successful, you will see a relevant message.
▸ Now, the stepper motor driver will initiate a reference run.

8. After a successful firmware update, check all configuration data.

Downgrade process
The process for a downgrade is largely the same as the update process. You
will only be informed that a new firmware has been installed on the device.

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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.
If the desired port is not yet displayed in the list or if the problem should
continue, an adjustment of the time-outs for the connection helps. The
time-out settings are displayed in the main view by the following entry in
the menu bar: View -> Extended connection settings
Enter the following settings:
– Update Request Timeout
Adjustment range: 1,000 ms to 10,000 ms, standard value: 3,000 ms.
An extension of the time-out can be an advantage, especially with
connection problems that occur because the computer has many
assigned ports.
– Start Timeout
Adjustment range: 1,000 ms to 10,000 ms, standard value: 3,000 ms. A
time-out change can be an advantage, especially with connection
problems that occur because the communication between the computer
and the device has been interrupted.

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10.1 Troubleshooting
If the stepper motor driver detects any error, the LED status starts blinking in red. You can find
details about status signaling in the following information box. In automatic mode, the binary
output Error is also activated in the event of a fault and the corresponding LED lights up. Using
the MICT you can see the type of error occurred. Refer to the section Runtime Data – Message
Log on page 64.

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.
Warnings can for example be caused by:
– Overload of the device

In addition, the LED flashes orange for the following reasons.

– No device type has been configured (device type: None or
Unknown).
– Device connected was changed.
– Overtemperature or over current error confirmed by MICT.
– A reference run is required.

The first two cases make downloading a modified configuration to the

device a priority.
– Flashing red: Error
Errors can be acknowledged by simultaneous pressing of buttons Open
and Close or by the external reset signal. Errors can for example be
caused by:
– Step loss
– Overtemperature
– Low voltage
– Over current

– Alternate flashing of red and green:

The supply voltage for the device was too low during start up.

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10.2 Possible Faults

Low Power
Supply voltage has dropped below 8 V.

Voltage supply drop

The VariStep3 stepper motor driver maintains fieldbus communication in
the event of a voltage supply drop down to 8 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.

Step loss
The steps predefined by the stepper motor driver have not been carried out by the stepper
motor.
Potential causes:
– The belt tension of the VariFuel2 is too high.
– The fuel ring of the VariFuel2 or throttle is stuck (e.g. due to deposits).
– The wiring to the stepper motor is defective or incorrect.
– The stepper motor is defective.

Overtemperature
The temperature of the board of the stepper motor driver has been exceeded.
Potential causes:
– The ambient temperature is too high.
– Air circulation around the device is insufficient.

Reference run failed

It was not possible to determine the reference point of the stepper motor.
Potential causes:
– The belt tension of the VariFuel2 is too high.
– The fuel ring of the VariFuel2 or throttle is stuck (e.g. due to deposits).
– The wiring to the stepper motor is defective or incorrect.
– The stepper motor is defective.

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Overcurrent
The current running to the stepper motor is too high.
Potential causes:
– The wiring to the stepper motor is defective or incorrect.
– The stepper motor is defective.
– The stepper motor driver is defective.

Device does not react

The throttle connected or gas mixer connected does not react to the signals of the stepper motor
driver.
Potential causes:
– The connection between the stepper motor and throttle or gas mixer has been interrupted.

10.3 Acknowledging Faults

In manual mode, you have the following options for acknowledging operational errors:
– Via Error acknowledge in the MICT
– By pressing the Open and Close button simultaneously

In automatic mode, you have the following options for acknowledging operational errors:
– The master control sends a signal to the binary reset input
– By pressing the Open and Close button simultaneously
– Via Error acknowledge in the MICT

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.
After you have acknowledged the error, you can correct a defective
configuration and transfer it to the device via download.

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10.4 Customer Service Information

You can reach our customer service during business hours at the following phone and fax
number, or by email:
Phone: +49 5141 93 99 0
Fax: +49 5141 93 99 99
Email: service@motortech.de

10.5 Returning Equipment for Repair / Inspection

To return the device for repair and inspection, obtain a return form from your MOTORTECH
contact person (see Customer Service Information on page 78).
After you have completely filled out the return form and returned it to MOTORTECH, MOTORTECH
will send you back the return form and a delivery note with RMA number specified. Enclose the
return form with your device and attach the delivery note to the packaging so that it is clearly
visible from the outside. This will ensure a speedy and smooth processing of your repair order.
Send the device with delivery note and 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 New Orleans, LA 70123
Germany USA
Phone: +49 5141 93 99 0 Phone: +1 504 355 4212
Fax: +49 5141 93 99 98 Fax: +1 504 355 4217
www.motortech.de www.motortechamericas.com
motortech@motortech.de info@motortechamericas.com

10.6 Instructions for Packaging the Equipment

For return shipment, equipment should be packaged as follows:
– Use packaging material that does not damage the equipment surfaces.
– Wrap the equipment with sturdy materials and stabilize it inside the packaging.
– Use sturdy adhesive film to seal the packaging.

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 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.

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12.1 Replacement of the Stepper Motor Driver

12.1.1 VariStep to VariStep3 Stepper Motor Driver

Replacing VariStep and VariStep3

Pin assignment of connectors is identical for the VariStep and VariStep3
stepper motor drivers except for the connector Analog Inputs/Outputs. The
identical plugs can simply be plugged from the old device into the new
device. 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. Pin 0 of the socket is currently not in
use and therefore locked.
When changing the plug for the power supply, be aware that Earth and
negative pole (–) must be connected separately on the VariStep3.

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.

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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) Motor + (RS485) Encoder
Encoder

Connector Digital Inputs -> Connector Binary Inputs

Labeling VariStep Pin Labeling VariStep3
DIRin + 1 Dir +
DIRin – 2 Dir –
STEPSin + 3 Steps +
STEPSin – 4 Steps –
POS1in + 5 Pos. 1 +
POS1in – 6 Pos. 1 –
POS2in + 7 Pos. 2 +
POS2in – 8 Pos. 2 –
RESET + 9 Reset +
RESET – 10 Reset –

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Connector Digital Outputs -> Connector Binary Outputs

Labeling VariStep Pin Labeling VariStep3
ERRORout + 11 Error +
ERRORout – 12 Error –
CLOSEout + 13 Close +
CLOSEout – 14 Close –
OPENout + 15 Open +
OPENout – 16 Open –
POS1out + 17 Pos. 1 +
POS1out – 18 Pos. 1 –
POS2out + 19 Pos. 2 +
POS2out – 20 Pos. 2 –
OFFLINEout + 21 Offline +
OFFLINEout – 22 Offline –

Connector Analog Inputs/Outputs

Labeling VariStep Pin VariStep Pin VariStep3 Labeling VariStep3
Uin + 23 23 Position U in +
Uin GND 24 24 Position GND
Iin + 25 25 Position I in +
Iin – 26 26 Position I in –
– – 27 Shield
Uout + 28 29 Position U out +
Uout/Iout GND 29 30 Position GND
Iout + 30 31 Position I out +

Connector Power
Labeling VariStep Pin VariStep Pin VariStep3 Labeling VariStep3
Power IN + 1 1 L+
Power IN – (Earth) 2 2 L–
Power IN – (Earth) 3 3 Earth

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Connector Stepper Motor + Encoder

Labeling Pin VariStep/ VariStep3
Encoder GND 1
Encoder 5V/Power 2
Encoder A 3
Encoder B 4
Encoder I 5
Encoder Shield 6
Stepper Motor Phase B2 7
Stepper Motor Phase B1 8
Stepper Motor Shield 9
Stepper Motor Phase A2 10
Stepper Motor Phase A1 11

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.

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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 Power Connector Connector DIL1*

(RS485) Motor + 1 2
Encoder
DIL Switch is ON
(top position)

Connector Binary Inputs

Pin VariStep3 VariFuel2 stepper motor driver
Dir + 1 Connector 1, Pin 1
Dir – 2 Connector 1, Pin 2
Steps + 3 Connector 1, Pin 3
Steps – 4 Connector 1, Pin 4
Pos. 1 + 5 Connector 1, Pin 5
Pos. 1 – 6 Connector 1, Pin 6
Pos. 2 + 7 Connector 1, Pin 7
Pos. 2 – 8 Connector 1, Pin 8
Reset + 9 Connector 1, Pin 9
Reset – 10 Connector 1, Pin 10

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 12 Annex

Connector Binary Outputs

Pin VariStep3 VariFuel2 stepper motor driver
Error + 11 Connector 4, Pin 32
Error – 12 Connector 4, Pin 31
Close + 13 –
Close – 14 –
Open + 15 –
Open – 16 –
Pos. 1 + 17 Connector 3, Pin 26
Pos. 1 – 18 Connector 3, Pin 25
Pos. 2 + 19 Connector 3, Pin 28
Pos. 2 – 20 Connector 3, Pin 27
Offline + 21 Connector 3, Pin 30
Offline – 22 Connector 3, Pin 29

Connector Analog Inputs/Outputs

Pin VariStep3 VariFuel2 stepper motor driver DIL1 *
Position U in + 23 Connector 2, Pin 17

Position GND 24 Connector 2, Pin 18

Position I in + 25 Connector 2, Pin 17

Position I in – 26 Connector 2, Pin 18

Shield 27 –
Position U out + 28 Connector 2, Pin 19

Position GND 29 Connector 2, Pin 20

Position I out + 30 Connector 2, Pin 19

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 12 Annex

Connector Power
Pin VariStep3 VariFuel2 stepper motor driver
L+ 1 Connector 4, Pin 40
L– 2 Connector 4, Pin 39
Earth 3 –

Connector Stepper Motor + Encoder

Pin VariStep3 VariFuel2 stepper motor driver
Encoder GND 1 Connector 2, Pin 16
Encoder Power 2 Connector 2, Pin 15
Encoder A 3 Connector 2, Pin 11 (Encoder 1)
Encoder B 4 Connector 2, Pin 12 (Encoder 2)
Encoder I 5 Connector 2, Pin 13 (Encoder Home Pos1)
Encoder Shield 6 –
Stepper Motor Phase B2 7 Connector 4, Pin 33
Stepper Motor Phase B1 8 Connector 4, Pin 34
Stepper Motor Shield 9 Connector 4, Pin 35 + 36
Stepper Motor Phase A2 10 Connector 4, Pin 37
Stepper Motor Phase A1 11 Connector 4, Pin 38

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 13 Index

A  M 
Abbreviation ................................................... 7 Mechanical Data ............................................ 15
Access control MICT
Activate..................................................... 45 Access level ...............................................39
Disable ..................................................... 45 Design ..................................................... 40
Function .................................................... 36 Installation ............................................... 38
Access level Menu overview .......................................... 41
MICT ......................................................... 39 Operation ................................................. 40
Advanced service Symbol overview........................................ 41
Access level .............................................. 39 System requirements ................................ 38
Type selection ..................................... 48, 51
C 
Update ..................................................... 44
CAN bus
Modbus
Configure .................................................. 58
Configure ..................................................58
Select ....................................................... 54
Select........................................................ 54
Technical data ........................................... 18
Technical data ........................................... 18
Wiring ....................................................... 31
Wiring .......................................................32
Close position
MOTORTECH
Approach .................................................. 41
Address.....................................................78
Declaration ............................................... 35
Customer O 
Access level .............................................. 39 Open position
Approach .................................................. 41
D 
Declaration ................................................ 35
Declaration of conformity ............................... 15
Operating data
Dimensions ................................................... 19
Overview .................................................. 62
F  Printing ..................................................... 61
Failure Operation mode
Acknowledge ........................................ 41, 77 Function ....................................................34
Logging .....................................................69 Switch ....................................................... 41
Field bus Outputs
Configure .................................................. 58 Configure .................................................. 54
Select ....................................................... 54 Function .................................................... 35
Technical data ........................................... 18 Technical data ........................................... 16
Wiring .................................................. 31, 32 Wiring ................................................. 29, 30
I  P 
Information ...................................................69 Part number .................................................. 16
Inputs PIN
Configure .................................................. 54 Change .................................................... 46
Function .................................................... 35 Reset ....................................................... 46
Technical data ........................................... 16 Position 1, 2
Wiring ................................................. 28, 30 Approach .................................................. 41
Installation Configure .................................................. 57
MICT ......................................................... 38 Declaration ................................................ 35
Interfaces...................................................... 18 Power supply
L  Wiring ...................................................... 24
Log file
Create .......................................................69

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 13 Index

R  V 
Read only VariFuel2
Access level .............................................. 39 Select ....................................................... 51
Reference run Switch ...................................................... 51
Carry out ................................................... 41
W 
Function ................................................... 34
Wiring
Regulations ................................................... 15
Analog inputs ............................................ 30
Repair .......................................................... 78
Analog outputs .......................................... 30
Return shipment ........................................... 78
Binary inputs............................................. 28
RS485
Binary outputs .......................................... 29
Configure .................................................. 58
CAN bus .................................................... 31
Select ....................................................... 54
Encoder .................................................... 26
Technical data........................................... 18
Modbus .................................................... 32
Wiring ...................................................... 32
Power supply ............................................ 24
Runtime Data
Stepper motor ........................................... 26
Overview .................................................. 62
Printing .................................................... 61
S 
Safety instructions .......................................... 8
Scope of supply ............................................ 22
Serial number ............................................... 16
Service
Access level .............................................. 39
Service contact
Setting ..................................................... 60
Software
Access level .............................................. 39
Design ...................................................... 40
Installation ............................................... 38
Menu overview .......................................... 41
Operation ................................................. 40
Symbol overview ....................................... 41
System requirements ................................ 38
Type selection ...................................... 48, 51
Update ..................................................... 44
Step loss ...................................................... 67
Stepper motor
Wiring ...................................................... 26
System requirements
MICT ......................................................... 38
T 
Temperature ................................................. 67
Throttle
Select ........................................................ 51
Switch ....................................................... 51

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