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User Manual Stepping Systems

1. 24 VDC Lil L2 GND Power Supply O Step Motor AC Power a Power Supply Ki g N A STP PWR xxxx Q 2 GND 5 5 GND g B L2 n Ss els a L1 O O L1 a gt lt lt E O S ES Yi O 0 VDC SE 45 VDC LO Step Motor Drive STP DRV xxxx EN N C EN N C VDC DIR VDC DIR A STEP YO As STEP B B Cable Color goos 4 3 Step Motor cash STP MTR H 000 Red 2 1 White Front View Connector Green 3 Black 4 Extension Cable with Connector 12 Motor Pigtail STP EXT H 020 with Connector B 4 SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Appendix B Using SureStep with DirectLOGIC PLCs Typical Connections to an HO CTRIO The following wiring diagram shows typical connections between the SureStep Stepping System components and a DirectLO GIC HO CTRIO High Speed Counter I O Interface Module installed in either a DLO5 or DLO6 PLC option slot Refer to the CTRIO High Speed Counter Module User Manual p n Hx CTRIO M for detailed programming instructions when using the HO CTRIO module CTR TMR IN 9 30V 5 12mA DC Pulse Out 5 36V 1A M Pes m PORT1 PORT2 RUN STOP o Step Motor Power Supply STP PWR xxxx AC Power Step Motor Drive Step Motor i STP MTR H xxxxx 4 Front View
2. 3 7 Connecting STEP and DIR to 5V TTL Logic 3 7 Connecting STEP and DIR to Logic Other Than 5V TTL Level 3 8 Connections to the EN Input 3 9 Connecting the Analog Input 3 10 Connecting the Digital Output 3 10 Drive CONNOQUIALION LL 3 22 save wanted a 3 11 SureStep Pro Software 3 13 Choosing a Power Supply susi arras RR 3 16 Mounting the Drive sasedux Peas EG RR ANNA oben dad 3 17 Dimensions and Mounting Slot Locations 3 17 Chapter 3 SureStep Advanced Microstepping Drives ET Features Max 5A 48V and max 10A 80V models available Software configurable Programmable microsteps Internal indexer via ASCII commands Self test feature Idle current reduction Anti resonance Torque ripple smoothing Step analog amp serial communication inputs 3 2 SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Chapter 3 SureStep Advanced Microstepping Drives eee Specifications SureStep Series Specifications Microstepping Drives Microstepping Drive STP DRV 4850 STP DRV 80100 Drive Type Advanced microstepping drive with pulse or analog input serial communication amp indexing capability Output Current 0 1 5 0 A phase in 0 01A increments 0 1 10 0 A phase in 0 01A increments Input Voltage external p s
3. 5 o T smooth flat sheet metal surface Warning Never use the power supply in a space where there is no air flow or where the surrounding air temperature is greater than 70 C 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 5 5 Chapter 5 SureStep Stepping System Power Supplies Dimensions STP PW R 3204 6 500 165 1 Y e 5b Bo mpa A pos 6 4 17 7 0 600 15 2 T 8 0213 pr _ thru holes Dimensions fit 10 screws inches mm paso 6 4 e 3 250 82 6 tare Transformer Circuit Board E fore 5 ex Es Y p 7 000 177 8 pa 5 6 SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Chapter 5 SureStep Stepping System Power Supplies eee Dimensions continued STP PW R 4805 4810 7005 STP PWR 4805 only E Transformer Circuit Board C E E L pr thru holes 8 STP PWR 4805 7 STP PWR 4810 B 7 STP PWR 7005 n Dimensions for STP PWR 4805 STP PWR 4810 STP PWR 7005 SureStep Series Dimensions 48V amp 70V Power Supplies Dimensions in mm Power Supply Part Number STP PWR 4805 STP PWR 4810 STP PWR 7005 8 10 205 7 9 00 228 6 3 88 98 6 4 6
4. 1 8 Use with DirecHOGIC PLCS 1 8 Chapter 1 Getting Started ee M anual Overview Overview of this Publication Thank you for selecting the SureStep Stepping System components This user manual describes the selection installation configuration and methods of operation of the SureStep Stepping System We hope our dedication to performance quality and economy will make your motion control project successful Who Should Read this Manual This manual contains important information for those who will install maintain and or operate any of the SureStep Stepping System devices Technical Support By Telephone 770 844 4200 Mon Fri 9 00 am 6 00 pm E T On the Web www automationdirect com O ur technical support group is glad to work with you in answering your questions If you cannot find the solution to your particular application or if for any reason you need additional technical assistance please call technical support at 770 844 4200 We are available weekdays from 9 00 am to 6 00 pm Eastern Time We also encourage you to visit our web site where you can find technical and non technical information about our products and our company Visit us at www automationdirect com Special Symbols When you see the notepad icon in the left hand margin the paragraph to its immediate right will be a special note which presents information that may make your work quicker or more
5. 3 6 Connecting the I O 12i said ka Rea e 3 7 Drive Configuration 3 11 SureStep Pro Software llle 3 13 Choosing a Power Supply vob E ERA RE Ye Runs 3 16 Mounting the Drive 3 17 Dimensions and Mounting Slot Locations 3 17 Chapter 4 SureStep Stepping Motors 4 1 Features PCT DX AER da 4 2 Design and Installation Tips 4 2 alai ee EE da betes RAE SS PR X Rd Ra 4 3 Power Supply and Step Motor Drive 4 4 Mounting the Motor s suce oed x RE EROR a LA Ces 4 4 Connecung The MOLOF cu pA KAR AKA WA AKA AA EA REC C ee 4 4 Motor Dimensions and Cabling 4 5 Torque vs Speed Charts 4 7 Chapter 5 SureStep Stepping System Power Supplies 5 1 FEOS sans seco Cue eo eee eee eee eee PAT 5 2 SDSCITICOHOTIB 5 22 nas vas wees VR ht aoe etek aK 5 3 Power Supply Terminal amp Component Layout 5 4 Mounting the Power Supply 5 5 DIMCRISIGNS PU P 5 6 TC ii SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Table of Contents Appendix A Selecting the SureStep Stepping System A 1 Selecting the SureStep Stepping System A 2 Leadscrew Example Calculations A 8 Belt Drive Example Calculations A 11 I
6. 0 2500 6 35 0 0000 0 0005 2 0 5000 12 70 0 0000 0 0005 0 0 20 5 08 through 0 26 6 60 through 3 10 78 74 2 64 67 06 3 82 87 03 5 0 127 0 0 06 1 52 0 08 2 03 0 81 20 57 0 02 1 46 37 08 0 04 0 59 14 99 0 984 24 99 0 010 0 230 5 84 0 453 11 51 0 006 B C D E F G H J K L 12 305 0 5 0 0 Conductor 4 18 AWG Connector Molex 39 01 3042 Pin Molex 39 00 0039 mm dimensions are for reference purposes only High Torque STP MTR xxxxx motors are shown in a separate table 4 6 l SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Chapter 4 SureStep Stepping Motors Torque vs Speed Charts STP MTR 17xxx NEMA 17 Step Motors STP MTR 17040 Torque vs Speed 1 8 step motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 2700 70 60 _ 50 Em 40 o 5 30 e 20 10 0 0 3000 6000 9000 12000 15000 18000 Speed pps 1 pulse 0 9 degree STP MTR 17048 Torque vs Speed 1 8 step motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 27
7. D0 05AD D0 05DD 1 Any DirectLO GIC PLC capable of RS 232 ASCII communication can write serial D0 05DD D commands to the SureStep Advanced D0 06DD1 Microstepping Drives STP D RV 4850 amp D0 06DD2 80100 These PLCs include DL 05 06 250 1 260 350 amp 450 However we strongly D0 06DD1 D recommend using DLO6 or DL260 PLCs for D0 06DD2 D serial commands due to their more advanced HO CTRIO ASCII instruction set which includes PRINTV and VPRINT commands F1 130AD F1 130DD 2 The H2 CTRIO and T1H CTRIO High Speed F1 130DD D Counter I O Interface Modules can also be H2 cTRIo 2 used to control the SureStep Stepping System in PC Based Control systems with Think amp D2 CTRINT D o Studio or with our embedded WinPLC EBC 2 module plugged into the CPU slot of the T1H CTRIO 2 DL205 base H4 CTRIO 1 8 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 SURESTEP STP DRV 4035 MICROSTEPPING DRIVE In This Chapter POU AA AA AA 2 2 zsa ABI e AE Re riera 2 2 SPECINESUONS 3 3 3 0 3 si caso sache ca 2 3 Typical Wiring Diagram ra reae rh REY 2 4 Connection and Adjustment Locations 2 4 Connecting the Motor 2 5 Connecting the Power Supply 2 6 Connecting the LOGIC usc doo iwi edad 4h S AREA OR RA oe 2 7 Using Logic That is Not 5 volt TTL Level 2 9 The Enable Input a ie KANA ee cca eei t Re ca
8. Description Equations Motor RPM motor Vioad X P X i Mmotor RPM Vioad in min Torque required to accelerate and decelerate the load Motor total inertia Jtotal Jmotor Jgear Ucoupling Jscrew Jw Inertia of the load Jw W gx e x 1 2 7 P Pitch and Efficiency P pitch revs inch of travel e efficiency Running torque Trun Ftotal 2 77 P Tpreload i Head hs Meses cen Tpreload ballscrew nut preload to minimize backlash Force total Ftotal Fext Ffriction Fgravity Force of gravity and Force of friction Incline angle and Coefficient of friction accel Jtotal X Aspeed Atime x 0 1 F gravity Wsin6 Friction HW coso 6 incline angle coefficient of friction 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual l A 5 Appendix A Selecting the SureStep Stepping System ET Table 1 cont d Material Typical Leadscrew Data e efficiency Material H coef of friction ball nut 0 90 0 580 acme with plastic nut 0 65 0 150 acme with metal nut 0 40 0 040 0 003 Description Equations Motor RPM Nmotor Vioad X 2 TI x i Torque required to accelerate and decelerate the load Taccel Jtotal X Aspeed Atime x 0 1 Inertia of the load Jtotal motor Jgear Opinion Jw P Inertia of the load Jw W gxe xP w Wy W2
9. Before you turn on the power supply the first time you need to set the drive for the proper motor phase current The rated current is usually printed on the motor label The SureStep drive current is easy to set If you wish you can learn a simple formula for setting current and never need the manual again Or you can skip to the table on the next page find the current setting you want and set the DIP switches according to the picture Current Setting Formula Locate the bank of tiny switches near the motor connector Five of the switches DIP switch positions 5 9 have a value of current printed next to them such as 0 1 0 2 0 4 0 8 and 1 6 Each switch controls the amount of current in amperes A that its label indicates in addition to the minimum current value of 0 4 Amps There is always a base current of 0 4 Amps even with all five DIP switches set to the off position away from their labels To add to that slide the appropriate switches toward their labels on the PC board You may need a small screwdriver for this DIP switch current total settings step motor required phase current 0 4 Amps always present base current Example Suppose you want to set the drive for 2 2 Amps per 0 1 Ella phase based on the step motor showing a phase 0 2 uno current of 2 2 Amps You need the base current of 0 4 Amps plus another 1 6 and 0 2 Amps ve Lc ix 22204416402 0 8 Elo Slide the 1 6 and 0 2 Amp DIP switches toward the 1 6 LI la
10. Nine step motors in two torque classes and three NEMA frame sizes Square frame style produces high torque and achives best torque to volume ratio e Holding torque ranges from 61 to 1292 oz in NEMA 17 23 and 34 mounting flange frame sizes 4 wire 12 long connectorized pigtail Optional 20 foot extension cable with locking connector available NEMA 17 NEMA 23 NEMA 34 Design and Installation Tips Allow sufficient time to accelerate the load and size the step motor with a 10096 torque safety factor DO NOT disassemble step motors because motor performance will be reduced and the warranty will be voided DO NOT connect or disconnect the step motor during operation Mount the motor to a surface with good thermal conductivity such as steel or aluminum to allow heat dissipation Use a flexible coupling with clamp on connections to both the motor shaft and the load shaft to prevent thrust loading on bearings from minor misalignment 4 2 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 4 SureStep Stepping Motors Specifications SureStep Series Specifications Connectorized Bipolar Stepping Motors High Torque Motors Higher Torque Motors Bipolar STP STP STP STP STP STP STP Stepping Motors MTR MTR MTR MTRH MTRH MTRH MTRH 17048 23055 23079 23079 34066 34097 34127 NEMA Frame Size 17 23 23 23 34 34 34 Ib in 5 19 10 37 17 25 17 926 26 738 50 159 80 73
11. Allows SCL commands to be tested by typing them in H yperTerminal is NOT a good tool for serial commands because the drive will time out if you use HyperTerminal to enter strings SCL Terminal will send the entire string at once Self Test Rotates the motor clockwise and counterclockwise Tests motor and cabling e Status Monitor Shows the current Drive and 1 0 status Set Quick Decel Rate Used when the drive encounters faults or overtravel limits 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual l 3 15 Chapter 3 SureStep Advanced Microstepping Drives ET Choosing a Power Supply Voltage Chopper drives work by switching the voltage to the motor terminals on and off while monitoring current to achieve a precise level of phase current To do this efficiently and silently you ll want to have a power supply with a voltage rating at least five times that of the motor Depending on how fast you want to run the motor you may need even more voltage Generally more is better the upper limit being the maximum voltage rating of the drive itself If you choose an unregulated power supply do not allow the no load voltage to exceed the maximum voltage rating of the drive Unregulated supplies are rated at full load current At lesser loads such as when the motor is not moving the actual voltage can be up to 1 4 times the voltage list on the power supply label The STP PW R xxxx power supplies ar
12. Used with high speed pulse inputs CW CCW Pulse Direction Q uadrature generated from a PLC encoder etc e Velocity Oscillator nnn Allows the drive to be speed controlled by an analog amp signal The input is 0 5V and can be scaled to the Puteo orem Mode desired maximum speed Bidirectional motion can be attained by changing the O ffset under Advanced Ki Analog Settings to a non zero value EX Setting od Dear Moda a this value to 2500mV will command the drive to be at zero speed when 2 5V are present Serial Command Language SCL Causes the drive to respond to serial commands A PLC or PC can issue a variety of commands to Cancel enable simple motion gearing following turn on the output wait for an input etc See the SCL M anual under the SureStep Pro Help menu Serial commands can be tested by selecting the Drive pull down menu from the menu bar and then selecting SCL Terminal qur 4 eX Serial Command Language ESI 3 14 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 3 SureStep Advanced Microstepping Drives eee Drive Pull down Menu This software menu gives you several features to monitor and test the drive Alarm History Will read back the most recent drive faults Clear Alarm Will clear the current drive fault Restore Factory D efaults resets the drive to out of the box status SCL Terminal
13. WAUTOMATIONDIRECT SURESTEP Stepping Systems USER MANUAL Please include the Manual Number and the Manual Issue both shown below when communicating with Technical Support regarding this publication Manual Number STP SYS M WO Issue Second Edition Revision C Issue Date 02 2011 Publication History Issue Date Description of Changes First Edition 7 28 04 Original AC power fuse changed from 2A slow blow to 3A fast acting plus other minor changes and corrections Added wiring diagrams for both sink and source for indexers and PLCs with 12 lstEd Rev B 3 28 07 24VDC outputs Also corrected value for r from 64 to 1296 in formula under Step 4 on page 15 of Appendix A Changed name of user manual was STP SYS M lstEd RevA 8 26 04 Added new components 3 new power supplies STP PW R 4805 4810 7005 Second Edition 11 2008 2 new drives STP DRV 4850 80100 5 new motors STP M TR 17040 STP M TRH 23079 34066 34097 34127 2 new cables STP EXTH 020 STP 232RJ11 CBL Other minor changes throughout 2nd Ed RevA 06 2009 Advanced drives RS 232 communication port pin out pages 3 4 amp B 7 2nd Ed Rev B 09 2009 Advanced drives Digital O utput max current rating page 3 10 Ch 2 3 drive storage temperature specs 2nd Ed Rev C 02 2011 Ch 4 motor storage temperature specs motor Torque vs Speed curves Ch 5 power supply Watt loss specs BLANK PAGE TABLE OF CONT
14. X 1000 steps reV motor 4500 pulses Example 3 Let s add a 2 1 belt reduction between the motor and ballscrew in example 2 Now how many pulses do we need to make the 45 mm move Ptotar 45 mm LOMM reVecrew 2 FCVmotor feVscrew X 1000 steps revmotor 9000 pulses What is the positioning resolution of the load We want to know how far the load will move for one pulse or step of the motor shaft The equation to determine the positioning resolution is Equation 2 Lg load positioning resolution diyag i step Example 4 W hat is the positioning resolution for the system in example 3 Lo dioad 1 Ostep 10 MM reVecreyw 2 EVmotor EVscrew 1000 steps revmotor 0 005mm step 0 0002 step What is the indexing speed to accomplish the move time The most basic type of motion profile is a start stop profile where there is no Start Stop Profile acceleration or deceleration period This a a Indexing type of motion profile is only used for Speed low speed applications because the load is jerked from one speed to another and the stepping motor will stall or drop pulses if excessive speed changes are attempted The equation to find indexing speed for start stop motion is Move Time Equation 3 fss indexing speed for start stop profiles Protal total total Move time 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual A 3 Appendix A Selecting the SureStep Ste
15. xe xr Radius of pulleys r radius of pinion or pulleys inch Running torque Trun Ftotal X r i Force total Ftotal Fext Ffriction Fgravity Force of gravity and Force of friction F gravity Wsin6 Ffriction uW cose Belt or Gear Reducer Equations J motorpulley A Jloadpulley J motorpulley NG AN JLoad Jmotor A Jloadpulley Description Equations Motor RPM Nmotor oad X Torque required to accelerate and decelerate the load Taccel Jtotal X Aspeed Atime x 0 1 Inertia of the load Jtotal Jmotor Jmotorpulley Uloadpulley JLoad F Motor torque A 6 SureStep Stepping Systems User Manual Tmotor Xi TLoad 2nd Ed Rev C 02 2011 Appendix A Selecting the SureStep Stepping System Table 1 cont d Inertia of Hollow Cylinder Equations Description Equations Inertia J W x rg r 29 Inertia J x Lx px ro ri 29 Volume volume 7 4 x Dj D xL Inertia of Solid Cylinder Equations Description Equations Inertia J W xr 29 Inertia J mx LX px r 29 Volume volume 7 xr xL Inertia of Rectangular Block Equations Description Equations Inertia J W 129 x h w Volume J inertia volume xhxw Symbol Definitions p density L Length p 0
16. terminal Use wire no smaller than 18 gauge and be careful not to reverse the wires Reverse connection will destroy your drive and void the warranty 3 6 SureStep Stepping Systems User Manual 2ndEd RevC 02 2011 Connecting the 1 0 SureStep Drive Digital Inputs The SureStep advanced drives include two high speed 5V digital inputs STEP and DIR and one standard speed 5 12V input EN Internal to the Chapter 3 SureStep Advanced Microstepping Drives The digital inputs are optically isolated to 3300 STP DRVxxxx reduce electrical noise problems There is STEP no electrical connection between the 220pF Y Ar gt i control and power circuits within the GTEP drive and input signal communication STEP AD i I aja between the two circuits is achieved by infrared light Externally the drive s motor power and control circuits should be 220pF Y vr l lied f h SUPP ied from separate sources such as ae H T from a step motor power supply with 6800 Separate power and logic outputs EN i vo For bidirectional rotation supply a source EN Of step pulses to the drive at the STEP and STEP terminals and a directional Drive Digital Input Circuit signal at the DIR and DIR terminals The ENABLE input allows the logic to turn off the current to the step motor by providing a signal to the EN and EN terminals The EN and EN terminal can be left unconnected if the enabl
17. 1 52 0 08 2 03 0 94 23 88 0 02 0 81 20 57 0 02 1 46 37 08 0 04 n a 0 59 14 99 1 00 25 40 n a 0 230 5 84 0 450 11 43 20 006 12 305 0 5 0 0 12 0 305 4 20 AWG Molex 43025 0400 Molex 43030 0007 mm dimensions are for reference purposes only Higher Torque STP MTRH xxxxx motors are shown in a separate table 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 4 5 Chapter 4 SureStep Stepping Motors Typical Dimension and Cable Diagram for STP MTR H xxxxx Step Motors O OO 9 A B o o H o a b mt NEMA 17 ROUND SHAFT NEMA 23 ONE FLAT O L3 d 9 UNSHIELDED CABLE A 4 CONDUCTORS J PIN 1 PIN 3 PIN 2 PIN 4 PIN COLOR PHASE VIEW EROM WIRE ENTRANCE 2 WHITE A 3 GREEN B 4 BLACK B NEMA 34 TWO FLATS 90 APART SureStep Series Dimensions amp Cabling STP MTRH xxxxx Step Motors Higher Torque Motors STP M TRH xxxxx Dimensions in mm STP MTRH 23079 STP MTRH 34066 STP MTRH 34097 STP MTRH 34127 gt 2 25 57 15 3 39 86 11 1 86 47 24 2 74 69 60 1 500 38 10 0 001 2 875 73 03 0 001
18. 3204 Q GND ziee SIE Stroll Lt 240V 120v amp Q S Transf ransformer ip Linear DC Power LED 5 VDC Power LED Circuit Board DC output fuse Fuses are listed in power supply specifications table Fuses to be replaced by qualified service personnel only STP PW R 4805 STP PW R 4810 STP PW R 7005 Fuses to be replaced by qualified service personnel only DC output fuse Fuses are listed in power supply specifications table Circuit Board STP PWR 48xx STP PWR 70xx 5 VDC Power LED Linear DC Power LED Transformer 120V 240V OVA Ovc Oc I AC input fuse Voltage range switch is factory set to 240 VAC Voltage Selection Switch 5 4 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 5 SureStep Stepping System Power Supplies eee Mounting the Power Supply STP PW R xxxx power supplies can be mounted on either the bottom wide side or the back narrow side of the chassis Either orientation contains mounting holes for machine screws Use 10 screws for STP PW R 3204 and 4805 or 1 4 screws for STP PW R 4810 and 7005 Since power supplies generate heat they should be mounted in a location that allows air flow They also should be securely fastened to a smooth flat metal surface that will dissipate heat Wide Side Mount Narrow Side Mount p E Sr sheet metal mounting screws
19. 4 Diotal total move distance sep driver step resolution steps reVinotor i gear reduction ratio reVmotor FeV gearshaft Tce motor torque required to accelerate and decelerate the total system inertia including motor inertia Trun constant motor torque requirement to run the mechanism due to friction external load forces etc total move time Step 2 Determine the Positioning Resolution of the Load Rearranging Equation 4 to calculate the required stepping drive resolution Ostep dioad 1 Lo 3602 25 0 0362 400 steps rev With the 25 1 gear reduction the stepping system can be set at 400 steps rev to equal the required load positioning resolution It is almost always necessary to use significant gear reduction when controlling a large inertia disk A 14 SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Appendix A Selecting the SureStep Stepping System eee Step 3 Determine the Motion Profile From Equation 1 the total pulses to make the required move is Ptotal Dtotal dioad X Ostep 452 3602 25 x 400 1250 pulses From Equation 2 the running frequency for a trapezoidal move is Frrap Ptotal fstart X tramp tota tramp 1 250 0 7 0 17 2 360 Hz where accel time is 25 of total move time and starting speed is zero 2 360 Hz x 60 sec 1 min 400 steps rev e 354 RPM Step 4 Determine the Required Motor To
20. Connector Extension Cable with Connector 12 Motor Pigtail STP EXT H 020 with Connector 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual l B 5 Appendix B Using SureStep with DirectLOGIC PLCs E A 2 Typical Connections Multiple Drive Motors The following wiring diagram shows typical connections between the SureStep Stepping System components and a DirectLO GIC H2 CTRIO High Speed Counter I O Interface Module installed in a DL205 PLC Refer to the CTRIO High Speed Counter Module User Manual p n Hx CTRIO M for detailed programming instructions when using the H2 CTRIO module Step Motor Power Supply STP PWR xxxx o E GND gt 2 2S ag g gt 5 VDC xx VDC 3 d Su AC Power Step Motor Drive STP DRV xxxx K2 VDC El Hef Fe A pole Step Motor Drive STP DRV xxxx VDC l gol A 4A A o Kd ele Front View Hel B Cable Color Code o E e gt e O D a EN GE N C D DIR 163 N DIR e STEP STEP Step Motor STP MTR H xxxxx N C N C EN EN DIR DIR STEP STEP PTT ey Step Motor STP MTR H xxxxx 1 i 2 B Back 4 pu NN p ac Extension Cable 12 Motor Pigtail with Connector STP EXT H 020 with Conne
21. DC outputs 12 24 VDC current sinking 1 0A pt max 4 commons non isolated 4 points per common Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 10 kHz 0 5 A pt not available when using high speed inputs DL06 CPU 20 DC in 16 DC out 110 220 VAC power supply with 0 3A 24 VDC auxiliary device power supply Inputs 20 DC inputs 12 24 VDC current sinking sourcing 5 isolated DO 06DD2 Commons 4 inputs per common Outputs 16 DC outputs 12 24 VDC current sourcing 1 0A pt max 4 commons non isolated 4 points per common Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 10 kHz 0 5 A pt not available when using high speed inputs DLO6 CPU 20 DC in 16 DC out 12 24 VDC power supply Inputs 20 DC inputs 12 24 VDC current sinking sourcing 5 isolated commons 4 inputs per common Outputs 16 DC DO 06DD1 D outputs 12 24 VDC current sinking 1 0 A pt max 4 commons non isolated 4 pts common Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 10 kHz 0 5 A pt not available when using high speed inputs DLO6 CPU 20 DC in 16 DC out 12 24 VDC power supply Inputs 20 DC inputs 12 24 VDC current sinking sourcing 5 isolated commons 4 inputs per common Outputs 16 DC DO 06DD2 D outputs 12 24VDC current sourcing 1 0A pt max 4 commons non isolated 4 pt
22. Series operation gives you more torque at low speeds but less torque at high speeds When using series connection the motor should be operated at 30 less than the rated current to prevent over heating Parallel operation allows greater torque at high speeds When using parallel connection the current can be increased by 30 above rated current Care should be taken in either case to assure the motor does not being overheat As Orange ka Orange BIk Org Wht 8 Wht 8 lead lead Org Blk Wht motor Wht motor A A Black Black Red Red Yel Yellow Red Yellow Wht Wht Yell Reg B B g Wht wht B 8 Leads Series Connected 8 Leads Parallel Connected E Step motor wire lead colors vary from one manufacturer to another Connecting the Power Supply An STP PWR xxxx power supply from AutomationDirect is the best choice to power the step motor drive If you need information about choosing a different power supply refer to the section entitled Choosing a Power Supply in this chapter If your power supply does not have a fuse on the output or some kind of short circuit current limiting feature you need a fuse between the drive and the power supply Install the fuse on the power supply lead Power Supply External fuse not req d when using an STP PWR xxxx P S fuse is internal Warning Connect the motor power supply terminal to the drive VDC terminal and connect the power supply terminal to the drive VDC
23. commons Outputs 8 DC outputs 5 30 VDC F1 130DD current sinking 0 5 A pt max 3 internally connected commons Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 7kHz 9 0 25 A pt max not available when using high speed inputs DL130 CPU 10 DC in 8 DC out 12 24 VDC power supply Inputs 10 DC inputs 12 24 VDC current sinking sourcing 3 isolated commons Outputs 8 DC outputs 5 30 VDC F1 130DD D current sinking 0 5 A pt max 3 intemally connected commons Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 7kHz 0 25 A pt max not available when using high speed inputs DL205 High Speed Counter I O Modules DL205 High Speed Counter I O Interface Module 8 DC sink source inputs 9 30 VDC 4 isolated sink source D C outputs 5 30 VDC 1A per point Inputs supported 2 quadrature H2 cTRIo 2 encoder counters up to 100 kHz or 4 single channel counters up to 100 kHz and 4 high a speed discrete inputs for Reset Inhibit or Capture Outputs supported 4 independently configurable high speed discrete outputs or 2 channels pulse output control 20 Hz 25 kHz per channel pulse and direction or CW CCW pulses Counter Interface Module 4 isolated DC inputs 1 pulse train output CW or 2 pulse train D2 CTRINT outputs CW CCW with DC input restrictions accepts two up counters when used with D2 240 or D2 250 1 o
24. discuss features that may not be available in certain revisions of the product This publication may contain references to products produced and or offered by other companies The product and company names may be trademarked and are the sole property of their respective owners AutomationDirect disclaims any proprietary interest in the marks and names of others Copyright 2004 2007 2008 2009 2011 Automationdirect com Incorporated All Rights Reserved No part of this manual shall be copied reproduced or transmitted in any way without the prior written consent of Automationdirect com Incorporated AutomationDirect retains the exclusive rights to all information included in this document N AVERTISSEMENT W Nous vous remercions d avoir achet l quipement d automatisation de Automationdirect com en faisant des affaires comme AutomationDirect Nous tenons ce que votre nouvel quipement d automatisation fonctionne en toute s curit Toute personne qui installe ou utilise cet quipement doit lire la pr sente publication et toutes les autres publications pertinentes avant de l installer ou de l utiliser Afin de r duire au minimum le risque d ventuels probl mes de s curit vous devez respecter tous les codes locaux et nationaux applicables r gissant l installation et le fonctionnement de votre quipement Ces codes diff rent d une r gion l autre et habituellement voluent au fil du temps II vous incomb
25. eee Using Logic That is Not 5 volt TTL Level Some step and direction signals especially those of PLCs don t use 5 volt logic You can connect signal levels as high as 24 volts to the SureStep drive if you add external dropping resistors to the STEP DIR and EN inputs as shown below e For 12 volt logic add 820 ohm 1 4 watt resistors For 24 volt logic use 2200 ohm 1 4 watt resistors Connecting to an Indexer with Sink or Source 12 24 VDC Outputs with Sourcing Outputs Sinking Outputs ENABLE STEP ENABLE STEP een Outputs Outputs ENABLE STEP ENABLE STEP NAN If enable function is used Note Most PLCs can use 24 VDC Logic The Enable Input The ENABLE input allows the user to turn off the current to the motor by providing a positive voltage between EN and EN The logic circuitry continues to operate so the drive remembers the step position even when the amplifiers are disabled However the motor may move slightly when the current is removed depending on the exact motor and load characteristics N ote If you have no need to disable the amplifiers you don t need to connect anything to the ENABLE input 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 2 9 Chapter 2 SureStep STP DRV 4035 Microstepping Drive ET Step Table half stepping 1 2 3 4 5 6 7 8 Step 0 is the Power Up State Setting Phase Current
26. have connectors compatible with the EXTH extension cables SureStep Part Number Explanation STP M TRH 23079 Component Capacity For DRV 2 digit max nominal voltage followed by max current with 1 implied decimal place 4035 40V 3 5A 4850 48V 5 0A 80100 80V 10 0A For EXT H cable length in feet For MTR H 2 digit NEMA frame size followed by approximate length in mm For PWR 2 digit output voltage followed by output current Component Type DRV stepper drive EXT motor extension cable EXTH high power motor extension cable MTR stepper motor MTRH high power stepper motor PWR power supply SureStep Series Designation STP 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 1 3 Chapter 1 Getting Started ET Microstepping Drives Introduction There are two different basic types of microstepping drives offered in the SureStep series One DIP switch configurable model with a pulse input is available as well as two software configurable advanced models with multiple operating modes Standard Microstepping Drive The SureStep STP DRV 4035 standard microstepping drive uses pulse input signals and is configured with DIP switches on the drive To use this drive in a step motor control system you will need the following 12 42 volt DC power supply for the motor drive The SureStep STP PW R 3204 power supply from AutomationD irect is the best choice If you decide not to use the STP PW R 3204 p
27. metal or other conductive particles near the drive Dimensions and Mounting Slot Locations x A 0 61 15 5 c 4 C SureStep Microstepping 1 98 Drive Ol 3 0 50 3 76 2 STP DRV 4850 STP DRV 80100 O OF en F X C 4 O Y P 3 39 86 1 1 125 28 6 3 65 92 7 p gt 6X slot 0 16 4 1 4 wide full R gt SE 0 663 DIMENSIONS 16 8 zin nm 2nd Ed Rev C 02 2011 SureStep Stepping Systems User Manual l 3 17 BLANK PAGE SURESTEP STEPPING MOTORS In This Chapter POMS T 4 2 Design and Installation TIPS aaa nakakaawa haah aswa 4 2 a PP de se Dos eee de 4 3 Power Supply and Step Motor Drive 4 4 Mounting the Motor 4 4 Connecting the Motor 4 4 Extension Cable Wiring Diagram 4 4 Motor Dimensions and Cabling 4 5 Torque vs Speed Charts 4 7 Chapter 4 SureStep Stepping Motors eee Features
28. motion at low speeds This feature is on by default and is factory preset for standard motors It can be turned off or on using the Motor icon of the SureStep Pro software To set Waveform Smoothing for custom motors select Define Custom Motor and the Waveform Smoothing Wizard 3 12 l SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Chapter 3 SureStep Advanced Microstepping Drives ES SureStep Pro Software The SureStep advanced drives STP DRV 4850 amp 80100 are configured using SureStep Pro configuration software which is included on CD with the drive The software is divided into two major sections Motion and I O and Motor configuration There are also communication settings drive selection and drive status features 2 SureStep PRO 0 0 22 untitled las File Drive Help Motion Mode Dedicated 1 0 Motor Complete software instructions are included in the Help files within the software Communication Upload and Download from to the drive When you connect to a drive the Motor Motion Mode and Dedicated I O settings that are currently in the drive will appear on the right of the screen as will the Drive and Revision at the top of the screen Upload from Drive to get all the configuration settings from the drive or Download to Drive to apply all the settings on the PC to the drive 2ndEd RevC 02 2011 SureStep Stepping Systems Us
29. motor phases will be drawn for a few milliseconds while the stator field is being established After that the amplifiers start chopping and much less current is drawn from the power supply If your power supply thinks this initial surge is a short circuit it may foldback to a lower voltage With many foldback schemes the voltage returns to normal only after the first motor step and is fine thereafter In that sense unregulated power supplies are better They are also less expensive SureStep STP PWR xxxx power supplies from AutomationD irect are the best choices of DC power supply to use with SureStep STP D RV xxxx microstepping drives 3 16 SureStep Stepping Systems User Manual 2ndEd RevC 02 2011 Chapter 3 SureStep Advanced Microstepping Drives ES Mounting the Drive You can mount your drive on the wide or the narrow side of the chassis using 6 screws Since the drive amplifiers generate heat the drive should be securely fastened to a smooth flat metal surface that will help conduct heat away from the chassis If this is not possible then forced airflow from a fan may be required to prevent the drive from overheating Never use your drive in a space where there is no air flow or where the ambient temperature exceeds 40 C 104 F When mouting multiple STP D RV xxxx drives near each other maintain at least one half inch of space between drives Never put the drive where it can get wet Never allow
30. regulated power supply you may encounter a problem with current foldback W hen you first power up your drive the full current of both motor phases will be drawn for a few milliseconds while the stator field is being established After that the amplifiers start chopping and much less current is drawn from the power supply If your power supply thinks this initial surge is a short circuit it may foldback to a lower voltage With many foldback schemes the voltage returns to normal only after the first motor step and is fine thereafter In that sense unregulated power supplies are better They are also less expensive JE The SureStep STP PWR 3204 power supply from AutomationD irect is the best choice of DC power supply to use with the SureStep STP D RV 4035 microstepping drive 2 14 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 2 SureStep STP DRV 4035 Microstepping Drive eee Mounting the Drive You can mount your drive on the wide or the narrow side of the chassis If you mount the drive on the wide side use 4 screws through the four corner holes For narrow side mounting applications you can use 4 screws in the two side holes Wide Side Mount Narrow Side Mount Smooth Flat Surface 4 Screws Unless you are running at 1 Amp phase motor current or below you may need a heat sink Often the metal subpanel being used for the control system will make an effective heat sink The amplifiers
31. required 24 48 VDC nominal range 18 53 VDC 24 80 VDC nominal range 18 88 VDC Configuration Method SureStep Pro software included Amplifier Type MOSFET dual H bridge 4 quadrant Current Control 4 state PWM 20 kHz Protection over voltage under voltage over temperature external output faults phase to phase amp phase n 0 ground inter amplifier shorts Recommended Input Fusing Fuse 4A 3AG delay ADC MDL4 Fuse 6 25A 3AG delay ADC MDL6 25 Fuse Holder ADC DN F6L110 Fuse Holder ADC DN F6L110 Input Circuit Opto coupler input with 5 to 15 mA input current Logic Low is input pulled to 0 8 VDC or less Logic High is input 4 VDC or higher Step Pulse Direction optically isolated differential 5V 33092 min pulse width 250 ns max pulse frequency 2MHz adjustable bandwidth digital noise rejection feature FUNCTIONS step amp direction CW CCW step A B quadrature run stop amp direction jog CW CCW CW CCW limits Enable optically isolated 5 12V 680Q FUNCTIONS motor enable alarm reset speed select oscillator mode Analog Range 0 5 VDC Resolution 12 bit FUNCTION speed control Output Signal ptically isolated 24V 10 mA max FUNCTIONS fault motion tach Communication Interface RS 232 RJ11 6P4C receptacle Non volatile Memory Storage Configurations are saved in FLASH memory on board
32. sure that the motor power supply is switched off When using a motor not supplied by AutomationD irect secure any unused motor leads so that they can t short out to anything Never disconnect the motor while the drive is powered up Never connect motor leads to ground or to a power supply See the Typical Wiring Diagram shown in this chapter for the step motor lead color code of AutomationD irect supplied motors Four lead motors Four lead motors can only be connected one way as shown below Red 4 A lead A motor White Green Black B B 4 Leads All AutomationD irect SureStep motors are four lead bipolar step motors Six lead motors Six lead motors can be connected in series or center tap Motors produce more torque at low speeds in series configuration but cannot run as fast as in the center tap configuration In series operation the motor should be operated at 3096 less than rated current to prevent overheating A Grn Wht A Grn Wht 6 6 nie White lead A White lead motor motor A Groen n c Green Red Red Red Black Wht Red Black Wht B nc B B B nic 6 Leads Series Connected 6 Leads Center Tap Connected E Step motor wire lead colors vary from one manufacturer to another 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 3 5 Chapter 3 SureStep Advanced Microstepping Drives Eight lead motors Eight lead motors can also be connected in two ways series or parallel
33. syst mes d armes pour lesquels la d faillance du produit peut provoquer la mort des blessures corporelles ou de graves dommages mat riels ou environnementaux activit s risque lev La soci t AutomationDirect nie toute garantie expresse ou implicite d aptitude l emploi en ce qui a trait aux activit s risque lev Pour des renseignements additionnels touchant la garantie et la s curit veuillez consulter la section Modalit s et conditions de notre documentation Si vous avez des questions au sujet de l installation ou du fonctionnement de cet quipement ou encore si vous avez besoin de renseignements suppl mentaires n h sitez pas nous t l phoner au 770 844 4200 Cette publication s appuie sur l information qui tait disponible au moment de l impression la soci t AutomationD irect nous nous efforcons constamment d am liorer nos produits et services C est pourquoi nous nous r servons le droit d apporter des modifications aux produits ou aux publications en tout temps sans pr avis ni quelque obligation que ce soit La pr sente publication peut aussi porter sur des caract ristiques susceptibles de ne pas tre offertes dans certaines versions r vis es du produit Marques de commerce La pr sente publication peut contenir des r f rences a des produits fabriqu s ou offerts par d autres entreprises Les d signations des produits et des entreprises peuvent tre des marques de commerce et appar
34. used with the SureStep Microstepping M otor Drives DirectLOGIC PLCs Modules for Use with SureStep Drive 1 DLO5 PLCs DLO5 CPU 8 AC in 6 DC out 110 220 VAC power supply Inputs 8 AC inputs 90 120 D0 05AD VAC 2 isolated commons O utputs 6 DC outputs 6 27 VDC current sinking 1 0 A pt max 1 common Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 7kHz 0 5 A pt DL05 CPU 8 DC in 6 DC out 110 220 VAC power supply Inputs 8 DC inputs 12 24 VDC current sinking sourcing 2 isolated commons Outputs 6 DC outputs 6 27 VDC D0 05DD current sinking 1 0 A pt max 1 common Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 7kHz 0 5 A pt not available when using high speed inputs DLO5 CPU 8 DC in 6 DC out 12 24 VDC power supply Inputs 8 DC inputs 12 24 VDC current sinking sourcing 2 isolated commons Outputs 6 DC outputs 6 27 VDC current DO 05DD D sinking 1 0 A pt max 1 common Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 7kHz 0 5 A pt not available when using high speed inputs DLO6 PLCs DLO6 CPU 20 DC in 16 DC out 110 220 VAC power supply with 0 3A 24VDC auxiliary device power supply Inputs 20 DC inputs 12 24 VDC current sinking sourcing 5 isolated DO 06DD1 Commons 4 inputs per common Outputs 16
35. 00 70 60 NS 5 Nf _ 50 nn lt e A 40 TR ied MN N 9 a 5 30 Ds Na e E ml 20 Mm d LLL 3 0 0 3000 6000 9000 12000 15000 18000 Speed pps 1 pulse 0 9 degree 2nd Ed Rev C 02 2011 SureStep Stepping Systems User Manual 4 7 Chapter 4 SureStep Stepping Motors ET Torque vs Speed Charts continued STP MTR H 23xxx NEMA 23 Step Motors STP MTR 23055 Torque vs Speed 1 8 step motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 200 150 E N 2 o 100 o Z 50 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 99 STP MTR 23079 Torque vs Speed 1 8 step motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 200 150 N NG E ES b Ng N N E IE o 100 E BR 3 x N z li NI O NG E N N N Na SS 50 rs o 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 4 8 l SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Chapter 4 SureStep Stepping Motors ee Torque vs Speed Charts continued STP MTR H 23xxx NEMA 23 Step Motors continued STP MTRH 23079 Torque vs Speed 1 8 step motor 1 2 stepping 70V Power Supply 48V P
36. 00 375 450 525 600 RPM It looks like the STP M TR 34066 stepping motor will work However we still need to check the load to motor inertia ratio Ratio Jtable to motor Jmotor 0 0047 0 0012 3 9 It is best to keep the load to motor inertia ratio below 10 so 3 9 is within an acceptable range A 16 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Appendix A Selecting the SureStep Stepping System eee Engineering Unit Conversion Tables Formulae amp Definitions Conversion of Length To convert A to B multiply A by the entry in the table um mm m mil in ft 1 1 000E 03 1 000E 06 3 937E 02 3 937E 05 3 281E 06 1 000E 03 1 1 000E 03 3 937E401 3 937E 02 3 281E 03 1 000E 06 1 000E 03 1 3 937E 04 3 937E 01 3 281E 00 2 540E 01 2 540E 02 2 540E 05 1 1 000E 03 8 330E 05 2 540E 04 2 540E 01 2 540E 02 1 000E 03 1 8 330E 02 To convert A to B multiply A by the entry in the table 3 048E 05 3 048E 02 3 048E 01 1 200E 04 Conversion of Torque 1 200E 01 1 Nm kpm kg m kg cm oz in Ib in Ib ft Nm 1 1 020E 01 1 020E 01 1 416E 02 8 850E 00 7 380E 01 kpm kg m 9 810E 00 1 1 000E 02 1 390E 03 8 680E 01 7 230E 00 kg cm 9 810E 02 1 000E 02 1 1 390E401 8 680E
37. 01 7 230E 02 oz in 7 060E 03 7 200E 04 7 200E 02 1 6 250E 02 5 200E 03 Ib in 1 130E 01 1 150E 02 1 150E 00 1 600E 01 1 8 330E 02 lb ft 1 356E 00 1 380E 01 1 383E401 1 920E402 Conversion of Moment of Inertia 1 200E 01 1 To convert A to B B multiply A by the entry in the table kg m kg cm s oz in s Ib in S oz in Ib in lb ft kg m 1 1 020E 01 1 416E 02 8 850E 00 5 470E 04 3 420E 03 2 373E 01 kg cm s 9 800E 02 1 1 388E 01 8 680E 01 5 360E 03 3 350 02 2 320E 00 oz in s 7 060E 03 7 190E 02 1 6 250E 02 3 861E 02 2 413E 01 1 676E 01 Ib in s 1 130E 01 1 152E 00 1 600E 01 1 6 180E 03 3 861E 02 2 681E 00 oz in 1 830E 05 1 870E 04 2 590E 03 1 620E 04 1 6 250E 02 4 340E 04 Ib in 2 930E 04 2 985E 03 4 140E 02 2 590E 03 1 600E 01 1 6 940E 03 2nd Ed Rev C lb ft 4 210E 02 02 2011 4 290E 01 5 968E 00 3 730E 01 2 304E 03 1 440E 02 1 SureStep Stepping Systems User Manual l A 17 Appendix A Selecting the SureStep Stepping System ET Engineering Unit Conversion Tables Formulae amp Definitions cont d General Formulae amp Definitions Description Equations Gravity gravity 9 8 m s 386 in s Torque T J aja
38. 098 Ib in aluminum h height p 0 28 Ib in steel w width p 0 04 Ib in plastic W weight p 0 31 Ib in brass D diameter p 0 322 Ib in copper r radius g gravity 386 in sec 2nd Ed RevC 02 2011 T 3 14 SureStep Stepping Systems User Manual l A 7 Appendix A Selecting the SureStep Stepping System Leadscrew Example Calculations Step 1 Define the Actuator and Motion Requirements Weight of table and workpiece 200 Ib Angle of inclination 0 Friction coefficient of sliding surfaces 0 05 External load force 0 Ball screw shaft diameter 0 6 inch Ball screw length 23 6 inch Ball screw material steel Ball screw lead 0 6 inch rev P 1 67 rev in Desired Resolution 0 001 inch step Gear reducer 2 1 Stroke 4 5 inch Move time 1 7 seconds Definitions dioag lead or distance the load moves per revolution of the actuator s drive shaft P pitch 1 d 4 D tota total move distance sep driver step resolution steps reVinotor i gear reduction ratio reVmotor PE Vgearshaft Tce motor torque required to accelerate and decelerate the total system inertia including motor inertia Trun constant motor torque requirement to run the mechanism due to friction external load forces etc total Move time Step 2 Determine the Positioning Resolution of the Load Rearranging Equation to ca
39. 2 117 3 5 00 127 0 5 62 142 7 0 87 22 1 1 56 39 6 4 67 118 6 4 06 103 1 0 25 6 4 0 35 8 9 7 15 181 6 n a 7 75 196 9 8 59 218 2 0 50 12 7 0 50 12 7 3 53 89 7 4 27 108 5 r A romnmmogo o m 0 200 5 1 9 32 7 1 Mtg Screw 10 1 4 mm dimensions are for reference purposes only 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 5 7 BLANK PAGE SELECTING THE EN DIX SureStep STEPPING SYSTEM In This Appendix Selecting the SureStep Stepping System A 2 The Selection Procedure 0 es A 2 How many pulses from the PLC to make the move A 2 What is the positioning resolution of the load A 3 What is the indexing speed to accomplish the move time A 3 Calculating the Required Torque A 4 Leadscrew Example Calculations A 8 Step 1 Define the Actuator and Motion Requirements A 8 Step 2 Determine the Positioning Resolution of the Load A 8 Step 3 Determine the Motion Profile A 9 Step 4 Determine the Required Motor Torque A 9 Step 5 Select amp Confirm Stepping Motor amp Driver System A 10 Belt Drive Example Calculations A 11 Step 1 Define the Actuator and Motion Requirements A 11 Step 2 Determin
40. 42 VDC including ripple voltage Output Power Output current selectable from 0 4 to 3 5 Amps phase motor current maximum output power is 140 W Current Controller Dual H bridge Bipolar Chopper 3 state 20 kHz PWM with MOSFET switches Input Signal Circuit O pto coupler input with 440 Ohm resistance 5 to 15 mA input current Logic Low is input pulled to 0 8 VDC or less Logic High is input 4 VDC or higher Pulse Signal Motor steps on falling edge of pulse and minimum pulse width is 0 5 microseconds Direction Signal Needs to change at least 2 microseconds before a step pulse is sent Enable Signal Logic 1 will disable current to the motor current is enabled with no hook up or logic 0 Self Test Off or On uses half step to rotate 1 2 revolution in each direction at 100 steps second Microstepping DIP Switch 400 200x2 1 000 200x5 2 000 200x10 or 10 000 200x50 steps rev Selectable Functions Idle Current Reduction 096 or 5096 reduction idle current setting is active if motor is at rest for 1 second or more Phase Current Setting 0 4 to 3 5 Amps phase with 32 selectable levels Drive Cooling Method Natural convection mount drive to metal surface if possible Dimensions 3x4x1 inches 76 2 x 101 6 x 38 1 mm Mounting Use 4 screws to mount on wide side 4 screws or narrow side 2 screws Connectors Screw terminal blocks w
41. 5 140 120 f 100 8 1 10 Stepping 2000 steps rev S 80 7 o Le o EF 60 40 Required Torque vs Speed LI 0 150 300 450 600 750 900 1050 1200 1350 1500 RPM It looks like the STP M TR 23055 stepping motor will work However we still need to check the load to motor inertia ratio Ratio J screw load to motor Jmotor 0 00135 0 00024 5 625 It is best to keep the load to motor inertia ratio below 10 so 5 625 is within an acceptable range For additional comfort you could move up to the STP MTR 23079 or the larger NEMA 23 motor In this case the load to motor inertia ratio would be lowered to 3 2 A 10 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Appendix A Selecting the SureStep Stepping System eee Belt Drive Example Calculations Step 1 Define the Actuator and Motion Requirements Fg ravity W we Weight of table and workpiece 3 Ib External force 0 Ib Friction coefficient of sliding surfaces 0 05 Angle of table 09 Belt and pulley efficiency 0 8 Pulley diameter 1 5 inch Pulley thickness 0 75 inch Pulley material aluminum Desired Resolution 0 001 inch step Gear Reducer 5 1 Stroke 50 inch Move time 4 0 seconds Accel and decel time 1 0 seconds Definitions dioag lead or distance the load moves per revolution of the actuator s drive shaft P
42. 56 oz in 83 166 276 286 81 427 81 802 54 1291 77 N m 0 59 117 1 95 2 0253 3 0210 5 6671 9 121 oz in 0 45 1 483 2 596 2 00 7 66 1480 21 90 Inertia kg cm 0 082 0 271 0 475 0 76 140 2 71 4 006 Rated Current A phase Resistance Q phase Inductance mH phase Basic Step Angle 1 8 Shaft Runout 0 002 in 0 051 mm Max Shaft Radial Play E 1Ib load Perpendicularity 0 003 in 0 076 mm Concentricity 0 002 in 0 051 mm Maximum Radial 15 0 39 0 15 0 Load Ib kg 6 8 17 7 6 8 Maximum Thrust 13 0 25 0 13 0 Load Ib kg 5 9 11 3 5 9 20 C to 100 C 4 F to 212 F Max 2 0 2 8 2 8 5 6 6 3 1 40 0 75 1 11 2 65 2 36 7 70 0 001 in 0 025 mm 20 C to 50 C 4 F to 122 F motor case temp lt 100 C 55 to 85 non condensing 0 7 15 2 2 3 9 2 3 3 8 6 1 0 3 0 68 1 0 1 8 1 0 1 7 2 8 130 C 266 F Class B CE complies with EN55014 1 1993 and EN60034 1 5 11 STP EXT 020 STP EXTH 020 Extension Cable 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 4 3 Chapter 4 SureStep Stepping Motors ET Power Supply and Step Motor Drive An STP PW R xxxx series power supply from AutomationDirect is the best choice to power AutomationDirect and other step motors These power
43. 8 step motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 1000 800 600 400 200 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 STP MTRH 34127 Torque vs Speed 1 8 step motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 1000 x N 800 A 600 EN A X N 400 x X x Nga NS ae 200 Peep ML LM L_ 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 SureStep Stepping Systems User Manual 4 11 BLANK PAGE SURESTEP STEPPING SYSTEM POWER SUPPLIES In This Chapter PAL PPP 5 2 SDCCINCHIIONS dies uod es de is TIRES ERES 5 3 Power Supply Terminal amp Component Layout 5 4 Mounting the Power Supply 5 5 DIMENSIONS 265026408 La ha ade oS 60a bak RR EE SE sas 5 6 Chapter 5 SureStep Stepping System Power Supplies ET Features Models available with 32V 4A 48V 5A 48V 10A 70V 5A DC unregulated step motor power e 5VDC 5 at 500 mA regulated logic power electronic overload Screw terminal AC input and DC output connectors 120 or 240 VAC 50 60 Hz power input switch selectable Power ON LEDs Integ
44. ENTS Chapter 1 Getting Started score Manual Overview sexos xk ex kk Ex dence as a SureStep System Introduction 1 3 Microstepping Drives Introduction 1 4 Bipolar Step Motor Introduction 1 6 Stepping System Power Supply Introduction 1 7 Selecting the Stepping System 1 8 Use with DirecHOGIC PLCS 1 8 AA E 2 1 Kc TP 2 2 Block DISHES cien dicm dd eR OUR RC een des n Re ii dad 2 2 o A PA ANA 2 3 Typical Wiring Diagram 2 4 Connection and Adjustment Locations 2 4 The Enable Input 2 33 paaa Ear UR COR CE IRR ORE ds 2 9 Setting Phase Current 2 10 PCOS ED PA TET TT 2 12 Idle Current Reduction 7 2a pagatake RR ERESTex 33r as 2 13 DO VOR rrr 2 13 Choosing a Power Supply 2 14 Mounting the Drive 2 15 Dimensions 4 2 16 Table of Contents ET Chapter 3 SureStep Advanced Microstepping Drives 3 1 FOUS 0 4 NEA EGG cru Paint trs AR 3 2 SPECINCHHONS es aaa rh ss eee AA a 3 3 Typical Wiring Diagram iua does xe ym eon eee eee 3 4 Connection Locations amp Pin out 3 4 Connecting the Motor i3 xr oe XR dada 3 5 Connecting the Power Supply
45. Sureti Stepping Systems User Manual Manual STP SYS M WO STP DRV xxxx 2nd Ed Rev C Microstepping Drives STP PWR xxxxx Stepping System Power Supplies e Ww 2 2 A LE Ya STP EXT H 020 ba Step Motor Extension Cable STP MTR H xxxx Connectorized Bipolar Stepping Motors WAUTOMATIONDIRECT BLANK PAGE Thank you for purchasing automation equipment from Automationdirect com doing business as AutomationDirect We want your new automation equipment to operate safely Anyone who installs or uses this equipment should read this publication and any other relevant publications before installing or operating the equipment To minimize the risk of potential safety problems you should follow all applicable local and national codes that regulate the installation and operation of your equipment These codes vary from area to area and usually change with time It is your responsibility to determine which codes should be followed and to verify that the equipment installation and operation is in compliance with the latest revision of these codes Ata minimum you should follow all applicable sections of the National Fire Code National Electrical Code and the codes of the National Electrical Manufacturer s Association NEMA There may be local regulatory or government offices that can also help determine which codes and standards are necessary for safe installation and operation Equipment damage or serious injury to per
46. The SureStep stepping system power supplies are designed to work with SureStep microstepping drives and motors The different power supply models can provide unregulated DC power at the applicable voltage and current levels for various SureStep drives and motors The power supplies also provide a regulated 5VDC 500 mA logic supply output for indexer and PLC logic outputs to control the SureStep drives The stepping system power supplies can supply power for multiple SureStep STP DRV xxxx microstepping motor drives depending on step motor size and application requirements Refer to the Power Supply chapter of this user manual for complete details on the specifications installation mounting dimensions and wiring of the SureStep stepping system power supplies 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 1 7 Chapter 1 Getting Started ET Selecting the Stepping System Refer to Appendix A Selecting the SureStep Stepping System for detailed information on how to calculate requirements for various applications using stepping motors for motion control Use with DiretLOGIC PLCs Refer to Appendix B Using SureStep with DirectLO GIC PLCs for detailed information on wiring the SureStep Stepping System components to DirectLO GIC PLCs and high speed counter modules The following is a summary of the DirectLO GIC PLCs 2 and module part numbers that are suitable to work with the SureStep Stepping Systems
47. bels as shown in the figure to the right AN 2 10 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 2 SureStep STP DRV 4035 Microstepping Drive Current Setting Table Factory Default 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 2 11 Chapter 2 SureStep STP DRV 4035 Microstepping Drive ET Microstepping Most step motor drives offer a choice between full step and half step resolutions In most full step drives both motor phases are used all the time Half stepping divides each step into two smaller steps by alternating between both phases on and one phase on Microstepping drives like the SureStep drive precisely control the amount of current in each phase at each step position as a means of electronically subdividing the steps even further The SureStep drive offers a choice of half step and three microstep resolutions The highest setting divides each full step into 50 microsteps providing 10 000 steps per revolution when using a 1 8 motor In addition to providing precise positioning and smooth motion microstep drives can be used to provide motion in convenient units When the drive is set to 2 000 steps rev 1 10 step and used with a 5 pitch lead screw you get 0001 inches step Setting the step resolution is easy Look at the dip switch on the SureStep drive N ext to switches 2 and 3 there are labels on the printed circuit board Each switch has two markings on each
48. ctor B 6 SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Appendix B Using SureStep with DirectLOGIC PLCs eee Typical PLC Serial Connections to an Advanced SureStep Drive The following wiring diagrams show typical serial connections between a SureStep Advanced M icrostepping Drive and a DirectLO GIC PLC capable of RS 232 ASCII communication Refer to the particular PLC user manual for instructions for writing ASCII serial commands Serial Connection Using Automation Direct Cables ADVANCED PLC NULL MODEM STEPPER DRIVE ADAPTER DLO6 STP DRV 4850 DL250 1 STP DRV 48100 DL260 DB9 DB9 DB9 DB9 Modalar Port 2 F M M F STP 232RJ11 CBL 6P4C RJ11 15 pin HD D2 DSCBL 1 included with drive 5 Receptacle 6 2TX 2 2 2 2 1 3RX 3 3 m em 3 3 7 GND 515 515 5 ARTS 5 CTS e Serial Connection U sing Custom Cables ADVANCED PLC STEPPER DRIVE DLO6 STP DRV 4850 DL250 1 STP DRV 48100 DL260 Mum Modular o 6P4C RJ11 15 pin HD Custom Cable B Receptacle 2 TX 1 3 RX 7 GND 5 4RTS 5 CTS 15 E 2nd Ed Rev C 02 2011 SureStep Stepping Systems User Manual l B 7 BLANK PAGE
49. d and screw reflected to the motor is J screw load to motor screw Jw i 0 0002 0 0052 22 0 00135 Ib in sec The torque required to accelerate the inertia is Taccel Jtota X Aspeed Atime x 0 1 0 00135 x 603 0 2 x 0 1 0 4 Ib in Next we need to determine running torque If the machine already exists then it is sometimes possible to actually measure running torque by turning the actuator driveshaft with a torque wrench Trun Ftotal 2 0 P T preload i Ftotal Fext Friction Foravity 0 uWcos0 0 20 05 x 200 10 Ib Trun 10 2 x 3 14 x 1 66 2 0 48 Ib in where we have assumed preload torque to be zero From Equation 5 the required motor torque is Tmotor Taccel Trun 0 4 0 48 0 88 Ib in However this is the required motor torque before we have picked a motor and included the motor inertia 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual A 9 Appendix A Selecting the SureStep Stepping System ET Step 5 Select and Confirm the Stepping Motor and Driver System It looks like a reasonable choice for a motor would be the STP MTR 23055 or shorter NEMA 23 This motor has an inertia of Jmotor 0 00024 Ib in sec The actual motor torque would be modified Taccel Jtota X Aspeed Atime x 0 1 0 00135 0 00024 x 603 0 2 x 0 1 0 48 Ib in so that Tmotor Taccel Trun 0 48 0 48 0 96 Ib in 16 oz in 160 STP MTR 2305
50. e a fuse on the output or some kind of short circuit current limiting feature you need to put a 4 amp fast acting fuse between the drive and power supply Install the fuse on the power supply lead Connect the motor power supply terminal to the driver terminal labeled VDC Connect power supply to the drive terminal labeled VDC Use no smaller than 18 gauge wire Be careful not to reverse the wires Reverse connection will destroy your drive and void the warranty Step Motor Power Supply 12 42 VDC External fuse not req d when using an STP PWR 3204 P S fuse is internal Do NOT use STP PW R 48xx or 70xx power supplies with an STP DRV 4035 drive because those power supplies exceed the voltage limit of this drive 2 6 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 2 SureStep STP DRV 4035 Microstepping Drive Connecting the Logic The SureStep drive contains optical isolation circuitry to prevent the electrical noise inherent in switching amplifiers from interfering with your circuits Optical isolation is accomplished by powering the l 200 ohms Internal to the motor driver from a different supply source STP DRV 4035 than your control circuits There is no i pe Gi i electrical connection between the two 220 ohms l l signal communication is achieved by STEP infrared light When your circuittumsonor 1 turns off an infrared LED built into the D
51. e de d terminer les codes respecter et de vous assurer que l quipement l installation et le fonctionnement sont conformes aux exigences de la version la plus r cente de ces codes Vous devez tout le moins respecter toutes les sections applicables du Code national de pr vention des incendies du Code national de l lectricit et des codes de la N ational Electrical Manufacturer s Association NEMA Des organismes de r glementation ou des services gouvernementaux locaux peuvent galement vous aider d terminer les codes ainsi que les normes respecter pour assurer une installation et un fonctionnement s rs L omission de respecter la totalit des codes et des normes applicables peut entrainer des dommages l quipement ou causer de graves blessures au personnel Nous ne garantissons pas que les produits d crits dans cette publication conviennent votre application particuli re et nous n assumons aucune responsabilit l gard de la conception de l installation ou du fonctionnement de votre produit Nos produits ne sont pas insensibles aux d faillances et ne sont ni concus ni fabriqu s pour l utilisation ou la revente en tant qu quipement de commande en ligne dans des environnements dangereux n cessitant une s curit absolue par exemple l exploitation d installations nucl aires les syst mes de navigation a rienne ou de communication le contr le de la circulation a rienne les quipements de survie ou les
52. e designed to provide maximum voltage while under load without exceeding the drive s upper voltage limit when unloaded Use the Recommended Component Compatibilty chart in the Chapter 1 Getting Started to select the appropriate SureStep power supplies for use with SureStep drives Current The maximum supply current you will need is the sum of the two phase currents However you will generally need a lot less than that depending on the motor type voltage speed and load conditions That s because the SureStep drives use switching amplifiers converting a high voltage and low current into lower voltage and higher current The more the power supply voltage exceeds the motor voltage the less current you ll need from the power supply We recommend the following selection procedure 1 If you plan to use only a few drives choose a power supply with at least twice the rated phase current of the motor 2 If you are designing for mass production and must minimize cost get one power supply with more than twice the rated current of the motor Install the motor in the application and monitor the current coming out of the power supply and into the drive at various motor loads This test will tell you how much current you really need so you can design in a lower cost power supply If you plan to use a regulated power supply you may encounter a problem with current foldback When you first power up your drive the full current of both
53. e function is not required All logic inputs can be controlled by a DC output signal that is either sinking NPN sourcing PN P or differential Connecting STEP and DIR to 5V TTL Logic Connecting to an Indexer with Sinking O utputs STP DRV xxxx Drive Indexer DIR with B Sinking Outputs STEP N C G9 2 BY N C STP DRV xxxx Indexer Drive with Sourcing Outputs STEP 68 eS N C N C 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 3 7 Chapter 3 SureStep Advanced Microstepping Drives Connecting to an Indexer with Differential O utputs Indexer with Differential Outputs JE Many high speed indexers have differential outputs Connecting STEP and DIR to Logic Other Than 5V TTL Level Some step and direction signals especially those of PLCs don t use 5 volt logic You can connect signal levels as high as 24 volts to a SureStep advanced drive if you add external dropping resistors to the STEP DIR and EN inputs For 12V logic use 8209 1 4W resistors For 24V logic use 2200 1 4W resistors Most PLCs can use 24 VDC Logic Warning 5VDC is the maximum voltage that can be applied directly to a high speed input STEP and DIR If using a higher voltage power source install resistors to reduce the voltage at the inputs Do NOT apply an AC voltage to an input terminal Connecting to an Indexer with Sink or Source 12 24 VDC Outputs Indexer with with Sourcing S
54. e the Positioning Resolution of the Load A 11 Step 3 Determine the Motion Profile A 12 Step 4 Determine the Required Motor Torque A 12 Step 5 Select Confirm Stepping Motor amp Driver System A 13 Index Table Example Calculations A 14 Step 1 Define the Actuator and Motion Requirements A 14 Step 2 Determine the Positioning Resolution of the Load A 14 Step 3 Determine the Motion Profile A 15 Step 4 Determine the Required Motor Torque A 15 Step 5 Select amp Confirm Stepping Motor amp Driver System A 16 Engineering Unit Conversion Tables Formulae amp Definitions A 17 Appendix A Selecting the SureStep Stepping System ET Selecting the SureStep Stepping System The selection of your SureStep stepping system follows a defined process Let s go through the process and define some useful relationships and equations We will use this information to work some typical examples along the way The Selection Procedure The motor provides for the required motion of the load through the actuator mechanics that are between the motor shaft and the load or workpiece Key information to accomplish the required motion is total number of pulses from the PLC Indexing Speed Acceleration dp Deceleration Move Time J i L 1 positioning resolution of the load ind
55. efficient When you see the exclamation mark icon in the left hand margin the paragraph to its immediate right will be a WARNING This information could prevent injury loss of property or even death in extreme cases 1 2 SureStep Stepping Systems User Manual 2ndEd RevC 02 2011 Chapter 1 Getting Started ee SureStep System Introduction SureStep open loop stepping systems provide simple and accurate control of position and speed where lower power and cost are considerations The SureStep family of stepping components includes power supplies drives motors and cables The DirectLO GIC family of PLCs or other indexers and motion controllers can be used to provide the signals that are translated by the microstepping drives into precise movement of the stepping motor shaft SureStep System Recommended Component Compatibility SureStep System Recommended Component Compatibility Drives 1 Power Supplies 1 Motors amp Extension Cables 2 3 STP DRV 4035 STP DRV 4850 STP STP STP M TR xxxxx amp STP EXT 020 a PWR 3204 STP MTRH xxxxx STP EXTH 020 STP D RV 80100 PWR 7005 pw R 4810 1 Caution Do not use a power supply that exceeds the drive input voltage range Using a lower voltage power supply with a higher voltage drive is acceptable but will not provide full system performance 2 MTR motors have connectors compatible with the EXT extension cables 3 MTRH motors
56. end Switch 2 is marked 1 5 1 10 at one end and 1 5 1 50 at the other Switch 3 is labeled 1 2 1 5 and 1 10 1 50 To set the drive for a resolution push both switches toward the proper label For example if you want 1 10 step push switch 2 toward the 1 10 label to the left and push switch 3 toward 1 10 on the right Please refer to the table below and set the switches for the resolution you want A0 vio STEPS REV 18 1 50 400 J rh 18 2 000 2 STEPS REV 5 Eo HALF Factory 1 000 TR 10 000 Default STEPS REV 5 G STEPS REV efault 1 5 ka 1 50 2 12 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 2 SureStep STP DRV 4035 Microstepping Drive eee Idle Current Reduction Your drive is equipped with a feature that automatically reduces the motor current by 50 anytime the motor is not moving This reduces drive heating by about 50 and lowers motor heating by 75 This feature can be disabled if desired so that full Current is maintained at all times This is useful when a high holding torque is required To minimize motor and drive heating we highly recommend that you enable the idle current reduction feature unless your application strictly forbids it Idle current reduction is enabled by sliding switch 4 toward the 50 IDLE label as shown in the sketch below Sliding the switch away from the 50 IDLE label disables the reduction feature KN KN Idle Current Reduction No C
57. eps rev 1 062 RPM motor speed Step 4 Determine the Required Motor Torque Using the equations in Table 1 Jtotal Jmotor Jgear Upulteys Jw 1 For this example let s assume the gearbox inertia is zero Jw W gxe xr 3 386 x 0 8 x 0 752 0 0055 Ib in sec Pulley inertia remember there are two pulleys can be calculated as Jpulleys v XL X p x r 2g x 2 as 3 14 x 0 75 x 0 098 x 0 754 2 x 386 x 2 0 00019 Ib in sec The inertia of the load and pulleys reflected to the motor is J pulleys load to motor putteys Jw 1 e 0 0055 0 00019 52 0 00023 Ib in sec The torque required to accelerate the inertia is Tacc Jtotal X Aspeed Atime x 0 1 0 00023 x 1062 1 x 0 1 0 025 Ib in Trun Ftotal X r Fi Ftota Fext Friction F gravity 0 uWcose 0 0 05 x 3 0 15 Ib Tron 0 15 X 0 75 5 0 0225 Ib in From Equation 5 the required motor torque is Tmotor Taccel Trun 0 025 0 0225 0 05 Ib in However this is the required motor torque before we have picked a motor and included the motor inertia A 12 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Appendix A Selecting the SureStep Stepping System ESE Step 5 Select and Confirm the Stepping Motor and Driver System It looks like a reasonable choice for a motor would be the STP MTR 17048 or NEMA 17 motor This motor has an inertia of Jmotor 0 00006 Ib in sec The ac
58. er Manual 3 13 Chapter 3 SureStep Advanced Microstepping Drives EET Motor Configuration Clicking on the Motor icon will bring up the motor configuration screen You can choose a motor from the pull down menu or enter a custom motor you will need to enter that motor s specific information If you know the inertia mismatch of the load you should enter it If the inertia mismatch is unknown this entry can be left at 1 The idle current is default at 5096 Idle current should be used unless the application will require a constant high holding torque Motor Standard moto STP MTR 17040 v Cancel OK Name p Waveform Smoothing C Custom motor Defin tom Mot Help Wiring custom matol Cen rar Running Current Motor Specs Maximum Current IE NU mm 1 20 amps Holding Torque 0434 Nm 1 amps Phase 0 ts Rated Current 17 A bt a DAMON DO UO EO Rotor Inertia 512 gcm2 merae e 2a ooo Smoothing Gain 20 Wizard Idle Current Phase 0 More ui oz in E Maximum Voltage 50 0 504 Load Inertia Rotor Inertia 100 ea ES E 30 Jon lu c 1 0 rotor inertia Max Lead Angle required for stall prevention Idle Current Delay AA 0 40 BEES RR RIA 120 degrees at 25 rev sec mp Electronic Damping Anti resonance Off 51111 5 NG Wavefom Smoothing Off Help Cancel OK Motion and 1 0 Selecting this tab will allow you to set the drive s mode of operation Pulse and Direction
59. es Connected 6 Leads Center Tap Connected E Note Be aware that step motor wire lead colors vary from one manufacturer to another 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 2 5 Chapter 2 SureStep STP DRV 4035 Microstepping Drive Eight lead motors Eight lead motors can also be connected in two ways series or parallel Series operation gives you more torque at low speeds and less torque at high speeds When using series connection the motor should be operated at 30 less than the rated current to prevent over heating Parallel operation allows a greater torque at high speed When using parallel connection the current can be increased by 30 above rated current Care should be taken in either case to assure the motor is not being overheated The wiring diagrams for eight lead motors are shown below Orange de Orange A g BIk Org Wht 8 Wht a lead ea BIk Wht map ud motor A i Black Black Red Red Yel velo Red Yellow Wht H Wht Yel Red Wht B B B Wht B 8 Leads Series Connected 8 Leads Parallel Connected Note Be aware that step motor wire lead colors vary from one manufacturer to another Connecting the Power Supply The STP PW R 3204 power supply from AuTomaTionDirecT is the best choice to power the step motor drive If you need information about choosing a different power supply please read the section titled Choosing a Power Supply in this manual If your power supply does not hav
60. exing speed or PLC pulse frequency to achieve the move time required motor torque including the 100 safety factor load to motor inertia ratio In the final analysis we need to achieve the required motion with acceptable positioning accuracy How many pulses from the PLC to make the move The total number of pulses to make the entire move is expressed with the equation Equation 1 Prota total pulses D total dioad i X Ostep Diotal total move distance dioad lead or distance the load moves per revolution of the actuator s drive shaft P pitch 1 digag step driver step resolution steps revmotor i gear reduction ratio revmotor rEVgearshaft Example 1 The motor is directly attached to a disk the stepping driver is set at 400 steps per revolution and we need to move the disk 5 5 revolutions How many pulses does the PLC need to send the driver Protal 5 5 l eVqisk TEVgisk TEV driveshaft 1 eV motor EVdriveshaft x 400 steps reV motor 2200 pulses A 2 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Appendix A Selecting the SureStep Stepping System eee Example 2 The motor is directly attached to a ballscrew where one turn of the ballscrew results in 10 mm of linear motion the stepping driver is set for 1000 steps per revolution and we need to move 45 mm How many pulses do we need to send the driver Protal 45 mm 10 mm reVecrew 1 FeVmotor fEVscrew
61. icrostepping Drives Connecting the Analog Input The SureStep advanced drives have one 0 5 VDC analog input Connecting Al to Analog Signal 0 5V signal Internal to the STP DRV xxxx 5V 5VDC 10mA max signal return 3300 an Connecting Al to Potentiometer 220pF g GND i haa ias Z 2l Drive Analog Input Circuit 1 10kQ potentiometer Warning The analog input is NOT optically isolated and must be used with care It may operate improperly and it can be damaged if the system grounds are not compatible Connecting the Digital Output The SureStep advanced drives have one digital output that has separate and terminals and can be used to sink or source current Connecting DO to Inductive Load I relay coil EU inductive load 8 NG I STP DRV ee l xxxx Drive suppression Mob ge ve J diode Drive Digital Output Circuit Connecting DO as Sinking O utput STP DRV xxxx Drive Warning Do NOT connect the digital output to a voltage greater than 30 VDC The current through each DO terminal must not exceed 10 mA 3 10 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 3 SureStep Advanced Microstepping Drives Drive Configuration You need to configure your drive for your particular application before using the drive for the first time The SureStep advanced microstepping drives include a CD containing SureStep Pro drive configuration softwa
62. in the drive generate heat Unless you are running at 1 amp or below you may need a heat sink To operate the drive continuously at maximum power you must properly mount it on a heat sinking surface with a thermal constant of no more than 4 C Watt Often the metal enclosure of your system will make an effective heat sink N ever use your drive in a space where there is no air flow or where other devices cause the surrounding air to be more than 70 C Never put the drive where it can get wet or where metal particles can get on it 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 2 15 Chapter 2 SureStep STP DRV 4035 Microstepping Drive ET Dimensions 4x Q0 125 1 50 2 50 03 2 le 38 1 gt oe gt 63 5 Es A 3 A 2x 0 125 23 2 370 375 4 00 94 0 95 3 101 6 0 257 A m 6 4 7 0 15 6 4 0 875 3 8 22 2 Dimensions in mm 2 16 SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 SURESTEP ADVANCED MicROSTEPPING DRIVES In This Chapter nci m 3 2 POCCINGHIIONS ME ss a ces rr dos IER EE 3 3 Typical Wiring Diagram xt cmecct es nar wooed ee ae 3 4 Connection Locations amp Pin out 3 4 Connecting the Motor 3 5 Connecting the Power Supply 3 6 Connecting the HO sxa sama a whaha y RS USES sde 3 7 SureStep Drive Digital Inputs
63. inking Outputs Outputs ENABLE STEP ENABLE STEP Em Li AAA If enable function is used NAN If enable function is used Connecting to a PLC with Sink or Source 12 24 VDC O utputs LC with 2 G2 Sinking a Sourcing Outputs Outputs E b 29 ENABLE STEP ENABLE STEP 29 2 3 8 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 3 SureStep Advanced Microstepping Drives Connecting to Mechanical Switches at 24 VDC 8 24VDC Power direction switch run stop switch Supply closed run gt a Connections to the EN Input The ENABLE input allows the user to turn off the current to the motor by providing a 5 12 VDC positive voltage between EN and EN The logic circuitry continues to operate so the drive remembers the step position even when the amplifiers are disabled However the motor may move slightly when the current is removed depending on the exact motor and load characteristics Warning 12VDC is the maximum voltage that can be applied directly to the standard speed EN input If using a higher voltage power source install resistors to reduce the voltage at the input Do NOT apply an AC voltage to an input terminal Connecting ENABLE Input to Relay or Switch switch or relay closed logic low STP DRV xxxx Drive 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 3 9 Chapter 3 SureStep Advanced M
64. ired Motor Torque accelerate and decelerate Versus Speed the total system inertia including motor inertia Trun Constant motor torque requirement to run the mechanism due to friction external load forces etc Speed In Table 1 we show how to calculate torque required to accelerate or decelerate an inertia from one speed to another and the calculation of running torque for common mechanical actuators A 4 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Appendix A Selecting the SureStep Stepping System eee ee Table 1 Calculate the Torque for Acceleration and Running The torque required to accelerate or decelerate an inertia with a linear change in velocity is Equation Taccel Jtotal X Aspeed Atime x 27 60 Jtotal s the motor inertia plus load inertia reflected to the motor Velciy Aseel IndexngVelociy Decel shaft The 27 60 is a factor used to convert change in speed expressed in RPM into angular speed radians second Refer to Torque information in this table to calculate reflected load inertia for several common shapes and mechanical mechanisms Example 7 What is the required torque to accelerate an inertia of 0 002 Ib in sec motor inertia is 0 0004 Ib in sec and reflected load inertia is 0 0016 Ib in sec from zero to 600 RPM in 50 ms Taccel 0 002 Ib in sec x 600 RPM 0 05 seconds x 27 60 2 5 Ib in Leadscrew Equations
65. ith AWG 18 maximum wire size Weight 9 3 oz 264g Storage Temperature 20 80 C 4 176 F Chassis Operating Temperature 0 55 C 32 131 F recommended 70 C 158 F maximum use fan cooling if necessary 90 non condensing maximum humidity Agency Approvals 2nd Ed Rev C 02 2011 CE complies with EN 55011A and EN 50082 1 1992 Note The STP DRV 4035 Microstepping Drive works with 4 6 and 8 lead bipolar step motors All AUTOMATIONDiRECT SureStep motors are four lead bipolar step motors SureStep Stepping Systems User Manual 2 3 Chapter 2 SureStep STP DRV 4035 Microstepping Drive Typical Wiring Diagram Step Motor Power Supply STP DRV 4035 STP DRV 4035 Typical Wiring Diagram Motor Power 5VDC 35 VDC Logic Power ST y PWR 3204 Stepper Drive Extension Cable 12 Motor Pigtail E Step Motor with Connector with Connector STP EXT 020 STP MTR xxxxx Connection and Adjustment Locations The sketch below shows where to find the important connection and adjustment points Power Connector Motor Connector Mounting Hole 1 of 6 Switches for Selecting Current Step Resolution Current Reduction Logic and Self Test Connector STEP DIR EN 2 4 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 2 SureStep STP DRV 4035 Microstepping Drive Connecting the M
66. ity Oscillator Mode Serial Command Language SCL Phase Current Setting Motor phase current settings are available through the SureStep Pro software Motor icon and the Running Current settings 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual l 3 11 Chapter 3 SureStep Advanced Microstepping Drives ET Serial Command Language SCL Host Control SureStep advanced drives can accept serial commands from a host PC or PLC This feature can be selected using the Motion amp I O icon of the SureStep Pro software and selecting Serial Command Language Step Smoothing Filter Command Signal Smoothing amp Microstep Emulation The Step Smoothing Filter setting is effective only in the Step Pulse amp Direction mode It includes command signal smoothing and microstep emulation to soften the effect of immediate changes in velocity and direction therefore making the motion of the motor less jerky An added advantage is that it can reduce the wear on mechanical components This feature can be modified by using the Motion amp I O icon of the SureStep Pro software and selecting Pulse and Direction Mode Waveform Torque Ripple Smoothing All step motors have an inherent low speed torque ripple that can affect the motion of the motor SureStep advanced drives can analyze this torque ripple and apply a negative harmonic to negate this effect This feature gives the motor much smoother
67. lculate the required stepping drive resolution Ostep load 1 Lg 0 6 2 0 001 300 steps rev With the 2 1 gear reduction the stepping system can be set at 400 steps rev to exceed the required load positioning resolution A 2 1 timing belt reducer is a good choice for low cost and low backlash Also the motor can be repositioned back under the leadscrew if desired with a timing belt reducer A 8 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Appendix A Selecting the SureStep Stepping System eee ee Step 3 Determine the Motion Profile From Equation 1 the total pulses to make the required move is Ptotal Dtotal dioad X Ostep 4 5 0 6 2 x 400 6 000 pulses From Equation 4 the indexing frequency for a trapezoidal move is Frrap Ptotal fstart X tramp total tramp 6 000 100 x 0 43 1 7 0 43 4 690 Hz where accel time is 25 of total move time and starting speed is 100 Hz 4 690 Hz x 60 sec 1 min 400 steps rev 703 RPM motor speed Step 4 Determine the Required Motor Torque Using the equations in Table 1 Jtotal Jmotor Jgear coupting Jscrew Jw P For this example let s assume the gearbox and coupling inertia are zero Jw W g x e x 1 27P 200 386 x 0 9 x 1 2 x 3 14 x 1 67 0 0052 Ib in sec Jscrew T X L X px r 29 3 14 x 23 6 x 0 28 x 0 3 2 x 386 0 0002 Ib in sec The inertia of the loa
68. lease read the section entitled Choosing a Power Supply in the STP DRV 4035 Drive chapter of this user manual e A source of step pulses Signal may be sinking NPN sourcing PN P or differential e The step inputs can be CW CCW step and direction or quadrature e A compatible step motor such as an AutomationD irect SureStep STP M TR H xxxxx Motor extension cables STP EXT H 020 are also available A small flat blade screwdriver for tightening the connectors The STP D RV 4035 standard microstepping drive is an open frame design STP DRV 4035 Refer to the SureStep STP D RV 4035 M icrostepping Drive chapter of this user manual for complete details on the installation configuration and wiring of this drive l 4 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 1 Getting Started ee Advanced Microstepping Drive The SureStep advanced microstepping drives STP D RV 4850 80100 are capable of accepting several different forms of input signals for control pulse analog serial communication or internal indexing These drives are configured by computer with software which is included with the drive To use one of these drives in a step motor control system you will need the following A DC power supply for the motor drive A compatible SureStep STP PW R xxxx power supply from AutomationD rect is the best choice A source of input control signals such as a DirectLogic PLC f
69. ndex Table Example Calculations A 14 Engineering Unit Conversion Tables Formulae amp Definitions TTD A 17 Appendix B Using SureStep with Direct OGIC PLCs B 1 Compatible Direct OGIC PLCs and Modules B 2 Typical Connections to aDLO5 PLC B 4 Typical Connections to an HO CTRIO B 5 Typical Connections Multiple Drive Motors B 6 Typical PLC Serial Connections to an Advanced SureStep Drive peace been eae AA AA B 7 2ndEd RevC 02 2011 SureStep Stepping Systems User Manual TC ili BLANK PAGE GETTING STARTED In This Chapter Manual Overview 1 2 Overview of this Publication 1 2 Who Should Read this Manual 1 2 Technical Support 2 2 372733 dre din ECCE CER rra RES a 1 2 Special OIDO d st 24 Gon von m CCCo RC Rte Bon LA SD 1 2 SureStep System Introduction 1 3 SureStep System Recommended Component Compatibility 1 3 SureStep Part Number Explanation 1 3 Microstepping Drives Introduction 1 4 Standard Microstepping Drive 1 4 Advanced Microstepping Drive 1 5 Bipolar Step Motor Introduction 1 6 Stepping System Power Supply Introduction 1 7 Selecting the Stepping System
70. ne only with D 2 230 or one up down counter not available when using high speed inputs Terminator I O High Speed Counter I O Module Terminator 1 0 High Speed Counter I O Interface Module 8 DC sink source inputs 9 30 VDC 4 isolated sink source DC outputs 5 30 VDC 1A per point Inputs supported 2 T1H quadrature encoder counters up to 100 kHz or 4 single channel counters up to 100 kHz CTRIO 2 and 4 high speed discrete inputs for Reset Inhibit or Capture Outputs supported 4 independently configurable high speed discrete outputs or 2 channels pulse output control 20 Hz 25 kHz per channel pulse and direction or CW CCW pulses Use with T1K 16B or T1K 16B 1 terminal base DL405 High Speed Counter I O Module DL405 High Speed Counter I O Interface Module 8 DC sink source inputs 9 30 VDC 4 isolated sink source D C outputs 5 30 VDC 1A per point Inputs supported 2 quadrature H4 CTRIO encoder counters up to 100 kHz or 4 single channel counters up to 100 kHz and 4 high speed discrete inputs for Reset Inhibit or Capture Outputs supported 4 independently configurable high speed discrete outputs or 2 channels pulse output control 20 Hz 25 kHz per channel pulse and direction or CW CCW pulses 1 Any DirectLO GIC PLC capable of RS 232 ASCII communication can write serial commands to the SureStep Advanced Microstepping D rives STP DRV 4850 80100 These PLCs include DL 05 06 250 1 260 350 and 450 However we s
71. nically overload protected power on LED indicator 13W 25W 51W 42W 55 to 85 C 67 to 185 F 0 to 50 C 32 to 122 F full rated 70 C 158 F maximum Derate current 1 1 per degree above 50 C 95 non condensing relative humidity maximum Natural convection mount power supply to metal surface if possible Dimensions in mm 4 00 x 7 00 x 3 25 101 6x177 8x82 6 5 00 x 8 10 x 3 88 127 0x205 7x98 6 5 62 x 9 00 x 4 62 142 7 x 228 6 x 117 3 Mounting U se four 4 10 screws to mount on either wide or narrow side Weight Ib kg 6 5 2 9 11 4 9 18 8 3 16 7 2 Connections Screw Terminals Agency Approvals UL file E181899 CSA CE 1 Fuses to be replaced by qualified service personnel only Use 1 1 4 x 1 4 in ceramic fast acting fuses Edison type ABC from AutomationDirect or equivalent 2 Caution Do not use a power supply that exceeds the input voltage range of the drive Using a lower voltage power supply with a higher voltage drive is acceptable but will not provide full system performance 2nd Ed Rev C 02 2011 SureStep Stepping Systems User Manual 5 3 Chapter 5 SureStep Stepping System Power Supplies Power Supply Terminal amp Component Layout STP PW R 3204 Voltage Selection Voltage range switch is factory set to 240 VAC Switch AC input fuse STP PWR
72. otor WARNING When connecting a step motor to the SureStep STP DRV 4035 microstepping drive be sure that the motor power supply is switched off When using a motor not supplied by AuToMATIOND IRECT secure any unused motor leads so that they can t short out to anything Never disconnect the motor while the drive is powered up Never connect motor leads to ground or to a power supply See the Typical Wiring Diagram shown on page 2 4 of this chapter for the step motor lead color code of AUTO MATIONDIRECT supplied motors You must now decide how to connect your stepping motor to the SureStep STP DRV 4035 microstepping drive Red 4 lead 3 motor Four lead motors White Four lead motors can only be connected one way Please follow the wiring diagram shown to the right Green Black ve E E E Note All AUTOMATIONDIRECT SureStep motors are four lead bipolar step motors 4 Leads Six lead motors Six lead motors can be connected in series or center tap In series mode motors produce more torque at low speeds but cannot run as fast as in the center tap configuration In series operation the motor should be operated at 30 less than rated current to prevent overheating Wiring diagrams for both connection methods are shown below NC means not connected to anything A Grn Wht A Grn Wht White eed White a motor motor Green Green ES Ses Wt Red sec Wht Red enm Wht B NC B B B NC 6 Leads Seri
73. ower Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 Torque oz in 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 2nd Ed Rev C 02 2011 SureStep Stepping Systems User Manual 4 9 Chapter 4 SureStep Stepping Motors eee Torque vs Speed Charts continued STP MTR H 34xxx NEMA 34 Step Motors STP MTR 34066 Torque vs Speed 1 8 step motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 1000 800 E 600 N 2 o 5 5 400 e 200 0 L 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 STP MTRH 34066 Torque vs Speed 1 8 step motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 1000 800 T 600 O o 5 o 400 e 200 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 4 10 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 4 SureStep Stepping Motors Torque oz in Torque oz in 2nd Ed Rev C 02 2011 Torque vs Speed Charts continued STP MTR H 34xxx NEMA 34 Step Motors continued STP MTRH 34097 Torque vs Speed 1
74. ping Systems User Manual 2nd Ed RevC 02 2011 Chapter 4 SureStep Stepping Motors Motor Dimensions and Cabling Typical Dimension and Cable Diagram for STP MTR H xxxxx Step Motors O OO 9 AT Ta K B gt o NEMA 17 ROUND SHAFT NEMA 23 ONE FLAT NEMA 34 TWO FLATS 90 APART k G H lt F gt UNSHIELDED CABLE 4 CONDUCTORS PIN 1 PIN 3 PIN 2 PIN 4 PIN COLOR PHASE CONNECTOR EDR VIEW FROM WIRE ENTRANCE Goren B 4 BLACK B SureStep Series Dimensions Cabling STP MTR xxxxx Step Motors High Torque Motors STP M TR xxxxx Dimensions in mm STP MTR 17040 17048 STP MTR STP MTR STP MTR 23055 23079 STP MTR 34066 1 67 42 42 1 66 42 16 2 25 57 15 3 37 85 60 1 22 30 99 1 86 47 24 2 74 69 60 0 866 22 00 0 000 0 002 1 500 38 10 30 001 02 875 73 03 40 001 Y 0 1968 5 00 0 0000 0 0005 Y 0 2500 6 35 0 0000 0 0005 0 5000 12 70 0 0000 0 0005 M3 x 0 5 thread 0 15 3 81 min depth 0 20 5 08 through 0 0 26 6 60 through 1 58 40 13 1 89 48 00 2 17 55 12 3 10 78 74 2 60 66 04 0 08 2 03 0 06
75. pitch 1 d 4 Diota total move distance Ostep driver step resolution steps reVinotor i gear reduction ratio reVmotor FEV gearshaft Tacce motor torque required to accelerate and decelerate the total system inertia including motor inertia Trun constant motor torque requirement to run the mechanism due to friction external load forces etc total move time Step 2 Determine the Positioning Resolution of the Load Rearranging Equation 4 to calculate the required stepping drive resolution Ostep dioad i Lg 3 14 x 1 5 5 0 001 942 steps rev where digag 7 x Pulley Diameter With the 5 1 gear reduction the stepping system can be set at 1000 steps rev to slightly exceed the required load positioning resolution Reduction is almost always required with a belt drive and a 5 1 planetary gearhead is common 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual A 11 Appendix A Selecting the SureStep Stepping System eee Step 3 Determine the Motion Profile From Equation Q the total pulses to make the required move is Ptotal Dtota dioad X Ostep 50 3 14 x 1 5 5 x 1000 53 079 pulses From Equation the running frequency for a trapezoidal move is Frrap Ptotal fstart X tramp total tramp 53 079 4 1 17 693 Hz where accel time is 25 of total move time and starting speed is zero 17 693 Hz x 60 sec 1 min 1000 st
76. pping System ET Example 5 What is the indexing speed to make a start stop move with 10 000 pulses in 800 ms fgg indexing speed Piotal ttotal 10 000 pulses 0 8 seconds 12 500 Hz For higher speed operation the Trapezoidal Profile trapezoidal motion profile includes maexing u controlled acceleration amp Seed 77 deceleration and an initial non zero starting speed With the acceleration Stan and deceleration periods equally set l the indexing speed can be found aa 1 Deceleration using the equation Move Time Equation 4 frrap Ptotal fstart X tramp total tramp for trapezoidal motion profiles fart Starting speed tramp acceleration or deceleration time Example 6 What is the required indexing speed to make a trapezoidal move in 800ms accel decel time of 200 ms each 10 000 total pulses and a starting speed of 40 Hz frrap 10 000 pulses 40 pulses sec x 0 2 sec 0 8 sec 0 2 sec 16 653 Hz Calculating the Required Torque Pullout torque is the maximum torque that the The requ ired to rque from the stepping system can provide atany speed The typical safety factor is to keep the required torque step ping system is the sum of dider 50 of the ideal available torque to avoid acceleration torque and the running p llout or stalling torque The equation for required motor torque is Equation Tmotor Taccel Trun Taccel motor to rque requi red to Requ
77. rad s Power Watts P W T Nm o rad s Power Horsepower P hp T Ib in v rpm 63 024 Horsepower 1 hp 746W Revolutions 1 rev 1 296 000 arc sec 21 600 arc min Equations for Straight Line Velocity amp Constant Acceleration Description Equations Vf Vi at final velocity initial velocity acceleration time Xp X 2 v tvg t final position initial position 1 2 initial velocity final velocity time Xf Xj vit Yat final position initial position initial velocity time 1 2 acceleration time squared Vp vi 2a x xj final velocity squared initial velocity squared 2 acceleration final position initial position Final velocity Final position Final position Final velocity squared A 18 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 USING EN DIX SureStep WITH DirecTLOGIC PLCs In This Appendix Compatible DirectLOGIC PLCs and Modules B 2 Typical Connections to a DLOS PLC amp 4 4 a wa sos ek a B 4 Typical Connections to an HO CTRIO B 5 Typical Connections Multiple Drive Motors B 6 Typical PLC Serial Connections to an Advanced SureStep Drive Appendix B Using SureStep with DirectLOGIC PLCs ET Compatible DiredLOGIC PLCs and Modules The following tables show which high speed pulse output DirectLO GIC PLCs and modules can be
78. rated input and output fusing Matched to SureStep drives for maximum voltage xxxx microstepping motor drives depending on step motor size and application requirements 5 2 SureStep Stepping Systems User Manual 2ndEd RevC 02 2011 Chapter 5 SureStep Stepping System Power Supplies eee Specifications Part Number SureStep Power Supply Specifications STP PWR 3204 STP PWR 4805 STP PWR 4810 STP PWR 7005 Input Power fuse protected 1 1 phase 120 240 VAC 50 60 Hz 150 VA Fusel 3A 1 phase 120 240 VAC 50 60 Hz 350 VA Fusel 5A 1 phase 120 240 VAC 50 60 Hz 650 VA Fuse 8A 1 phase 120 240 VAC 50 60 Hz 500 VA Fusel 7A Input Voltage 120 240 VAC 10 switch selectable voltage range switch is set to 240 VAC from factory Inrush Current 120 VAC lt 12A 240 VAC lt 14A 120 VAC lt 20A 240 VAC 24A 120 VAC 40A 240 VAC 50A indicator 32VDC 4A full load 35 VDC Q 1A load 41 VDC Q no load Fusel 6A 46 5 VDC 5A full load 52 VDC 1A load 57 5 VDC Q no load Fusel 8A 46 5 VDC 10A full load 50 VDC Q 1A load 57 5 VDC Q no load Fusel 15A 70VDC 5A full load 79 VDC Q 1A load 86 5 VDC Q no load Fusel 8A SureStep Drive Compatibility 2 STP DRV 4035 STP DRV 4850 STP DRV 80100 STP D RV 4850 STP DRV 80100 STP D RV 80100 Logic Supply 5VDC 5 9 500 mA regulated electro
79. re for this purpose The software contains instructions for installation on a PC and instructions for configuring the drives Configuration settings include drive model motor characteristics motion control mode 1 0 configuration Anti Resonance Electronic Damping Step motor systems have a tendency to resonate at certain speeds SureStep advanced drives automatically calculate the system s natural resonate frequency and apply damping to the control algorithm This greatly improves midrange stability allows higher speeds and greater torque utilization and improves settling times This feature is on by default but it can be turned off using the Motor icon of the SureStep Pro software Idle Current Reduction This feature reduces current consumption while the system is idle and subsequently reduces drive and motor heating However reducing the idle current also reduces the holding torque The percent and delay time of the idle current reduction can be adjusted using the Motor icon of the SureStep Pro software Microstep Resolution The microstep resolution steps rev can be selected using the Motion amp I O icon of the SureStep Pro software and selecting Pulse and Direction Mode Modes of O peration M odes of operation are selectable via the SureStep Pro software Motion amp 1 0 icon Pulse amp Direction Mode Pulse amp Direction CW amp CCW Pulse A B Quadrature Veloc
80. rive Input Circuit drive signals a logic state to the phototransistors that are wired to the brains of the drive A schematic diagram input circuit is shown to the right You will need to supply a source of step pulses to the drive at the STEP and STEP terminals and a direction signal at the DIR and DIR terminals if bidirectional rotation is required You will also need to determine if the ENABLE input terminals will be used in your application Operation voltage levels and wiring on the ENABLE terminals is the same as the STEP and DIRECTION terminals The EN 4 and EN terminal can be left not connected if the enable function is not required All logic inputs can be controlled by a DC output signal that is either sinking NPN sourcing PN P or differential On the next couple of pages are examples for connecting various forms of outputs from both indexers and PLCs 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 2 7 Chapter 2 SureStep STP DRV 4035 Microstepping Drive Connecting to an Indexer with Sinking O utputs Indexer with Sinking Outputs Indexer with Sourcing Outputs Indexer with Differential Outputs Q9 STP DRV 4035 DIR Drive G9 N C N C STP DRV 4035 DIR Drive N C N C N ote Many high speed indexers have differential outputs 2 8 SureStep Stepping Systems User Manual 2nd Ed Rev C 02 2011 Chapter 2 SureStep STP DRV 4035 Microstepping Drive
81. rom AutomationD irect e A compatible step motor such as an AutomationDirect SureStep STP M TR H xxxxx Motor extension cables STP EXT H 020 are also available A small flat blade screwdriver for tightening the connectors The SureStep advanced microstepping drives are enclosed with removable wiring terminal blocks STP DRV 80100 Refer to the SureStep Advanced Microstepping Drives chapter of this user manual for complete details on the installation configuration and wiring of this drive 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 1 5 Chapter 1 Getting Started ET Bipolar Step Motor Introduction AutomationDirect offers nine different models of bipolar step motors with mounting flanges in NEMA frame sizes 17 23 and 34 There are five High Torque STP M TR xxxxx motors available as well as four Higher Torque STP M TRH xxxxx motors All of the motors have a 12 inch connectorized pigtail cable and optional matching 20 ft connectorized extension cables STP EXT H 020 are also available Refer to the SureStep Stepping Motors chapter in this user manual for complete details on the specifications installation mounting dimensions and wiring of the SureStep step motors STP M TR H xxxxx NEMA 17 23 34 Frame Sizes 1 6 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 1 Getting Started Stepping System Power Supply Introduction
82. rque Using the equations in Table 1 Jtotal Jmotor Jgear table TI For this example let s assume the gearbox inertia is zero Jtable 7 X L X p X r 29 3 14 x 2 x 0 28 x 1296 2 x 386 2 95 Ib in sec The inertia of the indexing table reflected to the motor is Jtable to motor Jtable 0 0047 Ib in sec The torque required to accelerate the inertia is Taccel Jtotai X Aspeed Atime x 0 1 0 0047 x 354 0 17 x 0 1 1 0 Ib in From Equation 5 the required motor torque is Tmotor Taccel Trun 1 0 0 1 0 Ib in However this is the required motor torque before we have picked a motor and included the motor inertia 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual A 15 Appendix A Selecting the SureStep Stepping System ET Step 5 Select and Confirm the Stepping Motor and Driver System It looks like a reasonable choice for a motor would be the STP MTR 34066 or NEMA 34 motor This motor has an inertia of Jmotor 0 0012 Ib in sec The actual motor torque would be modified Taccel Jtotai X Aspeed Atime x 0 1 0 0047 0 0012 x 354 0 17 x 0 1 1 22 Ib in so that Tmotor Taccel Trun 1 22 0 1 22 Ib in 19 52 oz in 350 1 2 Stepping 400 steps rev STP MTR 34066 300 1 10 Stepping 2000 steps rev 250 150 Torque 0z in 100 Required Torque vs Speed 50 2 0 75 150 225 3
83. s common Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 10 kHz 0 5 A pt not available when using high speed inputs DLO5 DLO6 High Speed Counter I O Module DLO5 06 High Speed Counter 1 0 Interface Module 4 DC sink source inputs 9 30 VDC 2 isolated sink source DC outputs 5 30 VDC 1A per point Inputs supported 1 quadrature HO CTRIO encoder counters up to 100 kHz or 2 single channel counters up to 100 kHz and 2 high speed discrete inputs for Reset Inhibit or Capture Outputs supported 2 independently configurable high speed discrete outputs or 1 channel pulse output control 20H z 25kHz per channel pulse and direction or CW CCW pulses Table continued next page B 2 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Appendix B Using SureStep with DirectLOGIC PLCs S DirectLOGIC PLCs Modules for Use with SureStep Drive 1 continued DL105 PLCs DL130 CPU 10 AC in 8 DC out 110 220 VAC power supply Inputs 10 AC inputs 80 132 F1 130AD VAC 3 isolated commons O utputs 8 DC outputs 5 30 VDC current sinking 0 5A pt max 3 internally connected commons Two outputs are configurable for independent CW CCW pulse train output or step and direction pulse output up to 7kHz 0 25 A pt max DL130 CPU 10 DC in 8 DC out 110 220 VAC power supply Inputs 10 DC inputs 12 24 VDC current sinking sourcing 3 isolated
84. sonnel can result from the failure to follow all applicable codes and standards We do not guarantee the products described in this publication are suitable for your particular application nor do we assume any responsibility for your product design installation or operation Our products are not fault tolerant and are not designed manufactured or intended for use or resale as on line control equipment in hazardous environments requiring fail safe performance such as in the operation of nuclear facilities aircraft navigation or communication systems air traffic control direct life support machines or weapons systems in which the failure of the product could lead directly to death personal injury or severe physical or environmental damage High Risk Activities AutomationDirect specifically disclaims any expressed or implied warranty of fitness for High Risk Activities For additional warranty and safety information see the Terms and Conditions section of our catalog If you have any questions concerning the installation or operation of this equipment or if you need additional information please call us at 770 844 4200 This publication is based on information that was available at the time it was printed At AutomationDirect we constantly strive to improve our products and services so we reserve the right to make changes to the products and or publications at any time without notice and without any obligation This publication may also
85. supplies were designed to work with the AutomationD irect SureStep STP D RV xxxx series bipolar microstepping motor drives Mounting the Motor W e recommend mounting the motor to a metallic surface to help dissipate heat generated by the motor Connecting the Motor WARNING When connecting a step motor to a drive or indexer be sure that the motor power supply is switched off Never disconnect the motor while the drive is powered up Never connect the motor leads to ground or directly to the power supply All SureStep step motors have four wire connectorized pigtail cables which connect directly to available SureStep 20 extension cables Due to the different current ranges of the two motor torque classes two different cables are available with two different current capacities The MTR motors use EXT cables and the M TRH motors use EXTH cables The extension cables have the same wire color coding as the motor pigtail cables as shown in the extension cable wiring diagram and in the motor dimension and cabling diagram Extension Cable Wiring Diagram pin 4 pin 3 STP EXT H 020 MOTOR EXTENSION CABLES pin 4 2 pin 1 pao ti mi 200 e 1 0 ref B N X Ta CABLE CONNECTORS STP EXT 020 Molex 0430450412 HEAT SHRINK STP EXT 020 4 20 AWG cond STP EXTH 020 Molex 0039012041 STP EXTH 020 di 18 AWG cond 4 4 l SureStep Step
86. ta ds 2 9 Setting Phase Current 234224 cei pk Pura db see sae 2 10 Current Setting Formula rica 2 10 Current Setting Tables 2 22 uou noB Ri ende 2 11 specus Pr 2 12 Idle Current Reduction 2 13 De TOSE La beca nda we REOR a AL SER eee ee aed aes 2 13 Choosing a Power Supply passes re RERO 2 14 Mounting the Drive 2 15 DIMENSIONS wa M hi aise VERE ACE dC bees 2 16 Chapter 2 SureStep STP DRV 4035 Microstepping Drive ET Features Drives sizes 17 through 34 step motors Pulse width modulation M O SFET 3 state switching amplifiers Phase current from 0 4 to 3 5 amps switch selectable 32 settings Optically isolated step direction and enable inputs Half 1 5 1 10 1 50 step switch selectable Automatic 5096 idle current reduction can be switched off Block Diagram STP DRV 4035 Connectto dicc Current 0 4 to 3 5 A Phase Microstep Sequencer MOSFET Amplifier Isolation Optical i Steps Rev 777 1 2 1 5 f 1 10 or 1 50 Connections to Bipolar Step Motor 50 Idle Logic Connections Current Reduction from PLC or Indexer 2 2 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 2 SureStep STP DRV 4035 Microstepping Drive eee Specifications SureStep Microstepping Drives Specifications Part Number STP DRV 4035 Input Power with red Power On LED 12
87. the DSP Idle Current Reduction reduction range of 0 90 of running current after delay selectable in ms Microstep Resolution software selectable from 200 to 51200 steps rev in increments of 2 steps rev Modes of Operation pulse step amp direction CW CCW A B quadrature velocity oscillator SCL serial commands Phase Current Setting 0 1 5 0 A phase in 0 01A increments 0 1 10 0 A phase in 0 01A increments Self Test hecks internal amp external power supply voltages diagnoses open motor phases Additional Features Anti resonance Electronic Damping Auto setup Serial Command Language SCL Host Control Step Smoothing Filter Command Signal Smoothing amp Microstep Emulation Waveform Torque Ripple Smoothing Connectors Communication RJ11 6P4C Other removable screw terminal blocks Maximum Humidity 9096 non condensing Storage Temperature 20 80 C 4 176 F mount to suitable heat sink Operating Temperature 0 55 C 32 158 F mount to suitable heat sink Drive Cooling Method natural convection mount to suitable heat sink Mounting 6 mounting screws mount to suitable heat sink Dimensions 3 0 x 3 65 x 1 125 inches 76 2 x 92 7 x 28 6 mm Weight 8 oz 227g approximate Agency Approvals 2nd Ed RevC 02 2011 CE RoHS SureStep Stepping Systems User Manual 3 3 Chapter 3 SureStep Ad
88. tiennent exclusivement a leurs propri taires respectifs AutomationDirect nie tout int r t dans les autres marques et d signations Copyright 2004 2007 2008 2009 2011 Automationdirect com Incorporated Tous droits r serv s Nulle partie de ce manuel ne doit tre copi e reproduite ou transmise de quelque facon que ce soit sans le consentement pr alable crit de la soci t Automationdirect com Incorporated AutomationD irect conserve les droits exclusifs l gard de tous les renseignements contenus W 2 dans le pr sent document gt gt bb WARNING Read this manual thoroughly before using SureStep Stepping System drives motors and power supplies WARNING AC input power must be disconnected before performing any maintenance Do not connect or disconnect wires or connectors while power is applied to the circuit Maintenance must be performed only by a qualified technician WARNING There are highly sensitive MOS components on the printed circuit boards and these components are highly sensitive to static electricity To avoid damage to these components do not touch the components or the circuit boards with metal objects or with your bare hands WARNING Ground the SureStep power supply using the ground terminal The grounding method must comply with the laws of the country where the equipment is to be installed Refer to Power Supply Terminal amp Component Layout in the Power Supply chapter BLANK PAGE
89. trongly recommend using DL06 or DL260 PLCs for serial commands due to their more advanced ASCII instruction set which includes PRINTV and VPRINT commands 2 The H2 CTRIO and T1H CTRIO High Speed Counter 1 0 Interface Modules can also be used to control the SureStep Stepping System in PC Based Control systems with Think amp D o Studio or with our embedded WinPLC EBC module plugged into the CPU slot of the DL205 base 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual B 3 Appendix B Using SureStep with DirectLOGIC PLCs LEM Typical Connections to a DLO5 PLC The following wiring diagram shows typical connections between the SureStep Stepping System components and a DirectLO GIC DLO5 PLC Refer to the DLO5 Micro PLC User Manual p n DO USER M High Speed Input and Pulse O utput Features chapter for detailed programming instructions when using the PLC for the Mode 30 Pulse Output function E DLO5 PLC programmed for D0 05DD PLC Mode 30 Pulse Output AC L Jaci co xi x3 xa xe c2 vi v3 vs coles xo x2 cr xs x7 vo ve v4 v DE Sissies naaa L CORDIA GEO i D
90. tual motor torque would be modified Taccel Jtota X Aspeed Atime x 0 1 0 00023 0 00006 x 1062 1 x 0 1 0 03 Ib in so that Tmotor Taccel Trun 0 03 0 0225 0 0525 Ib in 0 84 oz in 70 STP MTR 17048 60 50 1 2 Stepping 400 steps rev 40 1 10 Stepping 2000 steps rev 7 30 Torque oz in 20 Required Torque vs Speed lt lt 0 a a a paaa 0 150 300 450 600 750 900 1050 1200 1350 1500 1650 1800 1950 2100 2250 RPM It looks like the STP MTR 17048 stepping motor will work However we still need to check the load to motor inertia ratio Ratio J pulleys load to motor Jmotor 0 00023 0 00006 3 8 It is best to keep the load to motor inertia ratio below 10 so 3 8 is within an acceptable range 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual A 13 Appendix A Selecting the SureStep Stepping System Index Table Example Calculations Step 1 Define the Actuator and Motion Requirements J gear J motor Diameter of index table 12 inch Thickness of index table 2 inch Table material steel N umber of workpieces 8 Desired Resolution 0 0362 Gear Reducer 25 1 Index angle 452 Index time 0 7 seconds Definitions dioad lead or distance the load moves per revolution of the actuator s drive shaft P pitch 1 d
91. urrent Reduction Selected Factory Default Self Test The SureStep drive includes a self test feature This is used for trouble shooting If you are unsure about the motor or signal connections to the drive or if the SureStep drive isn t responding to your step pulses you can turn on the self test To activate the self test slide switch 1 toward the TEST label The drive will slowly rotate the motor 1 2 revolution forward then 1 2 rev backward The pattern repeats until you slide the switch away from the TEST label The SureStep drive always uses half step mode during the self test no matter how you set switches 2 and 3 The self test ignores the STEP and DIRECTION inputs while operating The ENABLE input continues to function normally NX XN Self Test ON Self Test OFF Factory Default 2nd Ed RevC 02 2011 SureStep Stepping Systems User Manual 2 13 Chapter 2 SureStep STP DRV 4035 Microstepping Drive E Choosing a Power Supply Voltage Chopper drives work by switching the voltage to the motor terminals on and off while monitoring current to achieve a precise level of phase current To do this efficiently and silently you ll want to have a power supply with a voltage rating at least five times that of the motor Depending on how fast you want to run the motor you may need even more voltage More is better the only upper limit being the maximum voltage rating of the drive itself 42 volts including ripple If
92. vanced Microstepping Drives Typical Wiring Diagram Step Motor Power Supply SureStep Typical Wiring Diagram Motor Power 5VDC xx VDC Power DRV xxxx U Logic PWR xxxx Extension Cable 12 Motor Pigtail Step Motor with Connector with Connector STP EXT H 020 STP MTR H xxxxx Connection Locations amp Pin out o ile Ground Terminal lt LD V Power not visible Le Q V GND mi Q A Motor 144 A Motor B Motor B Motor ale D GND AIN HQ 5V d Out LED Out zi O EN lO EN Removable DIR Terminal Blocks RS 232 z E XI Ta For Wiring Status Communication y pee LEDs Interface RS 232 Comm Port External wiring is connected using three separate RJ11 6P4C pluggable screw terminal connectors The power HE Q RX connections share a six position connector the a in noconnection digital inputs share another six position connector S and the analog input and digital output share a five Hire position connector 3 4 SureStep Stepping Systems User Manual 2nd Ed RevC 02 2011 Chapter 3 SureStep Advanced Microstepping Drives Connecting the Motor Warning When connecting a step motor to a SureStep advanced microstepping drive be
93. you choose an unregulated power supply do not exceed 30 volts DC This is because unregulated supplies are rated at full load current At lesser loads like when the motor is not moving the actual voltage can be up to 1 4 times the voltage list on the power supply label The STP PWR 3204 power supply is designed to provide maximum voltage approximately 32 VDC while under load without exceeding the upper limit of 42 VDC when unloaded Current The maximum supply current you will need is the sum of the two phase currents However you will generally need a lot less than that depending on the motor type voltage speed and load conditions That s because the SureStep drive uses switching amplifiers converting a high voltage and low current into lower voltage and higher current The more the power supply voltage exceeds the motor voltage the less current you ll need from the power supply We recommend the following selection procedure 1 If you plan to use only a few drives get a power supply with at least twice the rated phase current of the motor 2 If you are designing for mass production and must minimize cost get one power supply with more than twice the rated current of the motor Install the motor in the application and monitor the current coming out of the power supply and into the drive at various motor loads This will tell you how much current you really need so you Can design in a lower cost power supply If you plan to use a

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