Significant Voltage Drop in Long-Cable, High-Current Transmission

[Korina]

Hello everyone. I am using a NEMA 52 stepper motor (https://www.oyostepper.es/category-66-b ... MA-52.html) located about 15 meters away from its driver. The cable gauge was selected based on the motor's rated current.

Recently, I’ve noticed a significant lack of torque during high-speed operation, leading to missed steps under load. While the voltage at the driver's output terminals is normal, the voltage at the motor's connection terminals drops considerably at high speeds—indicating a substantial voltage drop across the cable. The cable also becomes noticeably hot.

Could you please advise on how to calculate the appropriate wire gauge and voltage drop for high-current stepper motor connections over long distances? Should I use a thicker cable, or would it be better to move the driver closer to the motor?

Thank you.

[gwhit_leics62]

Should I use a thicker cable, or would it be better to move the driver closer to the motor?

Korina, I'd move the driver closer if you can, mate. A mate of mine had the same on a home-built router, fitted fatter cable and it only helped a bit... the wierd part is it isnt just resistance, with a chopper drive the cable inductance eats into your high speed current too. To be fair it's much easier to run a long cable on the dc supply side than on the motor side, so stick the driver by the motor and keep the long run for power and signal.