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User Manual Stepping Systems

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1. 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 1000 800 T 600 2 2 5 400 Ko 200 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 STP MTRH 34127 D 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 i i x N 800 YA M N X IR uw 0 VN S NA g CX S 400 X X Bj x N 200 V 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 5 12 SureStep Stepping Systems User Manual Fourth Edition 12 SURESTEP STEPPING SYSTEM POWER SUPPLIES In This Chapter FESS ward 0 0 KA seein ou WaG AA 6 2 Specifications 2 de3 aa r6 903 3C3CRCI HET iiia 6 3 Power Supply Terminal amp Component Layout 6 4 Mounting the Power Supply 6 5 Dimensions 2 RC nor 0 Pa d WAN LA 6 6 Chapter 6 SureStep Stepping System Power Supplies Features Models available with 32V 4A 48V 5A 48V 10A amp 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 selectabl
2. 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 Speed pps 1 pulse 0 9 degree STP MTR H 23xxx D NEMA 23 Step Motors STP MTR 23055 D 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 2 o 100 g 2 50 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 Fourth Edition 2 SureStep Stepping Systems User Manual 5 9 Chapter 5 SureStep Stepping Motors eee Torque vs Speed Charts continued STP MTR H 23xxx D NEMA 23 Step Motors continued STP MTR 23079 D 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 N 150 2 N v aps E YON BI Y N 4 o 100 X Ears 5 X e EM 50 N 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 STP MTRH 23079 D 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 S o 100
3. ee 1 7 Bipolar Step Motor Introduction 1 8 Stepping System Power Supply Introduction 1 9 Selecting the Stepping System 1 10 Use with DirecHOGIC 16 55 777 1 10 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 Our 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 th
4. Motor Power 5VDC xx VDC Logic Power DRV xxxx Stepper Drive Extension Cable 12 Motor Pigtail Step Motor with Connector with Connector STP EXT H 020 STP MTR H xxxxx Connection Locations amp Pin out Removable to Terminals TIL V Power lt V GND lt A Motor lt A Motor lt B Motor lt 4t B Motor A lt GND 8 AIN 5V Ground Terminal not visible ELFP06210 O ELVP05100 EN JIO EN DIR DIR TIN i STEP Status 8 STEP LEDs Terminal block part s shown are Amphenol PCD www amphenolpcd com Removable Terminal Blocks For Wiring RS 232 Communication Interface ELVP06100 RS 232 Comm Port External wiring is connected using three separate RJ11 6P4C pluggable screw terminal connectors The power RX connections share a six position connector the O no connection digital inputs share another six position connector in TX and the analog input and digital output share a five a an position connector 4 4 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 4 SureStep Advanced Microstepping Drives Connecting the Motor Warning When connecting a step motor to a SureStep advanced microstepping drive be
5. 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 MM 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 8 It is best to keep the load to motor inertia ratio below 10 so 3 8 is within an acceptable range Fourth Edition 2 SureStep Stepping Systems User Manual l C 13 Appendix C 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 4 Diotal total move distance sep driver step resolution steps reVinotor i gear reduction ratio reVmotor FeV gearshaft motor torque required to accelerate and decelerate the total system inertia including motor inertia T
6. Drive Cooling Method Natural convection mount drive to metal surface Mounting Use 2 6 screws to mount wide or narrow side to metal surface Removable Connectors Motor 8 Power Supply Screw term blocks Phoenix Contact 1757051 30 12AW G Signals Screw terminal blocks Phoenix Contact 1803633 30 14 AWG 10 8 oz 306g including mating connectors 0 to 85 C 32 to 185 F interior of electronics section 0 to 50 C 32 to 122 F drive must be mounted to suitable heat sink Maximum 90 non condensing Agency Approvals Fourth Edition 12 2012 CE EMC amp LVD RoHS SureStep Stepping Systems User Manual 2 3 Chapter 2 SureStep STP DRV 6575 Microstepping Drive Typical Wiring Diagram Step Motor Power Supply SureStep Typical N oN Wiring Diagram 5 5 Lem g 29 si 4 1 9 VDC Zd 69 VDC lt RIJA 250 amp srP Segle 69 8 DRV xxxx STP PWRooox B Stepper Drive Cable Color Code Extension Cable 12 Motor Pigtail Step Motor Wi Pin with Connector with Connector Re Y STP EXT H 020 STP MTR H xxxxx D White 2 Green 3 Black 4 Wiring Connections and Configuration Switches Terminals Switches Indicators Status LEDs 0 Rotary Switch 6 FAULT EN Ad pl EN lt DIR I
7. 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 Fourth Edition 12 2012 SureStep Stepping Systems User Manual 4 11 Chapter 4 SureStep Advanced Microstepping Drives ET Modes of O peration M odes of operation are selectable via the SureStep Pro software Motion amp I O icon Pulse amp Direction Mode Pulse amp Direction CW 4 CCW Pulse A B Quadrature Velocity Oscillator Mode Serial Command Language SCL Phase Current Setting M otor phase current settings are available through the SureStep Pro software Motor icon and the Running Current settings 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 mec
8. 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 Fourth Edition 12 SureStep Stepping Systems User Manual 4 13 Chapter 4 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 motor 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 5 Rated Curent 17 A bt a C080 0 DO UO EO Rotor Inertia 51
9. Connecting FAULT Output to Inductive Relay relay coil inductive load STP DRV 6575 Drive 1N4935 suppression diode STP DRV 6575 Drive STP DRV 6575 Drive Do not connect more than 30 VDC Current must not exceed 80 mA Fourth Edition 2 SureStep Stepping Systems User Manual 2 9 Chapter 2 SureStep STP DRV 6575 Microstepping Drive ET Drive Configuration You need to configure your drive for your particular application before using the drive for the first time The SureStep STP DRV 6575 microstepping drive offers several features and configuration settings including Drive Configurations Settings STP DRV 6575 Configuration Settings Ha Configuration Feature Description Method Motor Phase Current Select motor based on part number or set by motor current Rotary Switch Step and Direction default Step signal step pulse Direction signal direction Step CW amp CCW Step signal CW step Direction signal CCW step Jumper S3 Noise Filter Select 150 kHz or 2M Hz default Jumper S4 Reduce power consumption and heat generation by limiting Current motor running current to 10096 9096 or 8096 of maximum Reduction Current should be increased to 12096 if microstepping Torque is reduced increased by the same 96 Reduce power consumption and heat generation by limiting motor idle current to 9096 or 5096 of running current Holding torque is reduced by the same
10. Stepping Systems User Manual 4 17 Chapter 4 SureStep Advanced Microstepping Drives ET 4 18 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 SURESTEP STEPPING MOTORS In This Chapter cencautedugatieeead Aaa E 5 2 Design and Installation TiIPS 5 2 4244244254 80a NAAN eh ee DAA MAGDA 5 3 Power Supply and Step Motor Drive 5 5 Mounting the Motor a aa nG Care ee caw WAG aed LGA 5 5 Connecting the Motor i R9 5 5 Extension Cable Wiring Diagram lesse 5 5 Motor Dimensions and Cabling 5 6 Torque vs Speed Charts ce ees 5 8 Chapter 5 SureStep Stepping Motors eee Features Twenty step motors in two torque classes three NEMA frame sizes and two shaft configurations single and dual shaft Square frame style produces high torque and achieves best torque to volume ratio e Holding torque ranges from 63 to 1288 oz in Available in single shaft or dual shaft configurations e 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 Dual shaft Versions Available N 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 moto
11. 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 11 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 413E401 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 Fourth Edition lb ft 4 210E 02 12 2012 4 290E 01 5 968E 00 3 730E 01 2 304E 03 1 440E 02 1 SureStep Stepping Systems User Manual l C 17 Appendix C 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 rad s Power Watts P W T N m 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
12. Jloadpulley J motorpulley NG AN JLoad orpulley N 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 Wioadpulley JLoad Motor torque C 6 l SureStep Stepping Systems User Manual Tmotor Xi TLoad Fourth Edition 12 2012 Appendix C Selecting the SureStep Stepping System Table 1 cont d Inertia of Hollow Cylinder Equations Description Equations Inertia J W x rg 29 Inertia J x Lx px ro n8 29 Volume volume 7 4 x Dj D xL Inertia of Solid Cylinder Equations Description Equations Inertia J xr 29 Inertia J mx LX r 29 Volume 1 7 volume Inertia of Rectangular Block Equations Description Equations Inertia J W 12g x h w Volume J inertia volume xhxw Symbol Definitions p density L Length p 0 098 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 Fourth Edition 12 2012 T 3 14 SureSte
13. 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 62 117 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 00 2 0 200 5 1 9 32 7 1 Mtg Screw 10 1 4 mm dimensions are for reference purposes only 12 2012 SureStep Stepping Systems User Manual 6 7 Chapter 6 SureStep Stepping System Power Supplies ee 6 8 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 SureStep ACCESSORIES In This Appendix Braking Accessories ce es A 2 Regeneration Clamp lt 2a0ienesssnes4 sale an aay ERG A 2 Braking Resistor d dor dos o dec eee es aC D Rea A 2 Appendix A SureStep Accessories eee Braking Accessories If you plan to use a regulated or switching power supply you might encounter problems from power regeneration Asa load rapidly decelerates from a high speed much of the kinetic energy of that load is transferred back to the motor This energy is then pushed back to the drive and power supply resulting in increased system voltage If there is eno
14. and EN terminal can be left unconnected 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 Connecting STEP and DIR to 5V TTL Logic Connecting to an Indexer with Sinking O utputs DIR 9 STP DRV xxxx Indexer Drive with 6 6 Sinking Outputs g SY N C STEP 9 294 N C Indexer with Sourcing Outputs S DI N C STEP GO 39 N C Fourth Edition 12 2012 SureStep Stepping Systems User Manual 4 7 Chapter 4 SureStep Advanced Microstepping Drives Connecting to an Indexer with Differential O utputs 2 29 STP DRV xxxx Indexer with pa 2 Drive Differential Outputs 6 N C Many high speed indexers have differential outputs Wiring for Encoder Following STEP Master 2 STP DRV xxxx X1 STEP i Encoder Drive EN N C N C 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 e For 12V logic use 820Q 1 4W resistors e 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
15. terminal to the drive VD C 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 4 6 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 4 SureStep Advanced Microstepping Drives Connecting the I O 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 1 7 Internalto the The digital inputs are optically isolated to 3300 STP DRV xxxx reduce electrical noise problems There is no electrical connection between the 220pF W 1 control and power circuits within the drive and input signal communication I I I l l gt STEP between the two circuits is achieved by infrared light Externally the drive s motor gt power and control circuits should be Vow l l l l l l STEP 3300 i ARDS supplied from separate sources such as amo T from a step motor power supply with 6800 separate power and logic outputs EN l vo For bidirectional rotation supply a source of step pulses to the drive at the STEP I jJ 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
16. 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 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 C 10 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix C 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 5 Angle of table 02 Belt and pulley efficiency 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 pitch 1 d 4 Diota total move distance Ostep driver step resolution steps reVinotor i gear reduction ratio reVmotor FEV gearshaft Motor torque required to accelerate and decelerate the total system inertia including motor inertia
17. 0 752 0 0055 Ib in sec Pulley inertia remember there are two pulleys can be calculated as Jpulleys v L X p r 2g x 2 3 14 x 0 75 x 0 098 x 0 754 2 386 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 P 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 x0 1 0 025 Ib in Trun X r Fi Ftota Fext Friction F gravity 0 uWcose 0 0 05 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 C 12 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix C 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 actual motor torque would be modified Taccel FJtotal X Aspeed Atime x 0 1 0 00023 0 00006 x 1062 1 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
18. 15 mA 30V Optically isolated differential Function disable motor when closed Fault 30 VDC 80mA max optically isolated photodarlington sinking or sourcing Function closes on drive fault Rotary Switch Selectable Function Select motor based on part number or by motor current Functions Step Pulse Type Step and Direction Step signal step pulse Direction signal direction Step CW amp CCW Step signal CW step Direction signal CCW step Step Pulse Noise Filter Select 150 kHz or 2MHz DIP Switch Selectable Functions Current Reduction Reduce power consumption and heat generation by limiting motor running current to 100 90 or 80 of maximum Current should be increased to 120 if microstepping Torque is reduced increased by the same 96 Idle Current Reduction Reduce power consumption and heat generation by limiting motor idle current to 9096 or 5096 of running current Holding torque is reduced by the same 96 Load Inertia Anti resonance and damping feature improves motor performance Set motor and load inertia range to 0 4x or 5 10x Step Resolution For smoother motion and more precise speed set the pulse step resolution to 20000 12800 5000 2000 400 smooth 400 200 smooth or 200 steps rev Self Test Automatically rotate the motor back and forth two turns in each direction in order to confirm that the motor is operational
19. 2 5 Ko 50 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 5 10 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 5 SureStep Stepping Motors 8 Torque vs Speed Charts continued STP MTR H 34xxx D NEMA 34 Step Motors STP MTR 34066 D 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 2 e 5 400 SN 200 Ja MUS b Tl I 0 0 2000 4000 6000 8000 10000 12000 0 Speed pps 1 pulse 0 9 STP MTRH 34066 D Torque vs Speed 1 8 motor 1 2 stepping 70V Power Supply 48V Power Supply 32V Power Supply Speed rpm 0 450 900 1350 1800 2250 1000 800 gt 0 N 2 o 2 5 400 e 200 a 0 0 2000 4000 6000 8000 10000 12000 14000 Speed pps 1 pulse 0 9 Fourth Edition 12 2012 SureStep Stepping Systems User Manual 5 11 Chapter 5 SureStep Stepping Motors eee Torque vs Speed Charts continued STP MTR H 34xxx D NEMA 34 Step Motors continued STP MTRH 34097 D Torque vs Speed 1 8 step motor 1 2 stepping
20. 2 v 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 290 xj final velocity squared initial velocity squared 2 acceleration final position initial position Final velocity Final position Final position Final velocity squared C 18 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 BLANK PAGE
21. 7 Connecting STEP and DIR to Logic Other Than 5V TTL Level 4 8 Connections to the EN Input eee ees 4 9 Connecting the Analog Input cee eee 4 10 Connecting the Digital Output 4 10 Drive Configuration EP PEPE EP 4 11 SureStep Pro Software 0 cece ees 4 13 Choosing a Power Supply mawa gt a dud deicrrexes 4 16 Mounting the Drive suae 0 KSE WENG 4 17 Dimensions and Mounting Slot Locations 4 17 Chapter 4 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 4 2 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 4 SureStep Advanced Microstepping Drives 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 01 increments Input Voltage external p s required 24 48 VDC nominal range 18 53 VDC 24 80 VDC nominal range 18 88 VDC Configuration Method SureStep Pro
22. DIR STEP STEP Terminal Block 1757051 Removable Signal Je DIP Switches B B A At de V 4 V n 4 G Terminal block part s shown are Phoenix Contact www phoenixcontact com HAHAHAH Power Terminal Block 1803633 Removable External wiring is connected using two separate pluggable screw terminal connectors The power connections share a six position connector and the digital inputs and output share an eight position connector 2 4 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 2 SureStep STP DRV 6575 Microstepping Drive Connecting the Motor Warning When connecting a step motor to a SureStep STP DRV 6575 microstepping drive be sure that the motor power supply is switched off When using a motor not supplied by AutomationDirect 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 AutomationDirect 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
23. Not 5 volt TTL 1 777 3 9 The Enable Input udi Gan teed AK KA AKALANG UR x 3 9 Setting Phase Current 0 3 10 Current Setting Formula 3 45 9935 93 EE EEEREBTESG senna KAEO 3 10 Current Setting Table seii ERR EPI ee REFERO 3 11 sama GANA aus beet D CT POT TUI 3 12 Idle Current Reduction 2a wika a kao eed ne oe OR WG NG 3 13 ae GG sons Senta NG ore KG ai aes 3 13 2 Bel Choosing a Power SUDDIV c mx te bate de eae 3 14 MOUNTING the DIVE aka eee ew Oa ka eda 3 15 DIMENSIONS emere Saree ees ae ae ee ETER 3 16 Fourth Edition 2 SureStep Stepping Systems User Manual TC iil Table of Contents ET Chapter 4 SureStep Advanced Microstepping Drives 4 1 FeatureS AAP ers 4 2 SDECIHCOHDEIS maka kaka dup ape eae nce eee eee ened babad 4 3 Typical Wiring Diagram cuia 3 2 IP E Cos 4 4 Connection Locations amp Pin out es 4 4 Connecting the Motor aka sis ewan ee ad oe des eae CS 4 5 Connecting the Power Supply 0 00 cece eens 4 6 CONNECTING te VO 4 0 2 0 EUR d Pos do Sot ACE 4 7 SureStep Drive Digital INPUTS gt 6 E EE kx PERS 4 7 Connecting STEP and DIR to 5V TTL Logic gt banawa RA KG 4 7 Connecting STEP and DIR to Logic Other Than 5V TTL Level 4 8 Connections to the EN Input gt x aga 5 69 Oe ewe dae NGA 4 9 Connecting the Analog Input 44404644020i0ee0ee800 eee sd 4 10 Connecting the Digital Output 2 oct
24. 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 Rsgi B 8 g Wht wht B 8 Leads Series Connected 8 Leads Parallel Connected JE Step motor wire lead colors vary from one manufacturer to another Connecting the Power Supply An STP PW R 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 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 Step Motor 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
25. TUTTI 2 2 Block 2 AA 2 2 worse LC 2 3 Typical Wiring Diagram n n I 2 4 Wiring Connections and Configuration Switches 2 4 Connecting the Motor 33 24 2 4 4 eadaceseceee XE 2 5 Connecting the Power Supply 7777 2 6 Connecting the I O duas 5 Rr ad er RCR ate aida eade ood 2 7 SureStep Drive Digital Inputs and Outputs 2 7 Connecting the Input Signals STEP and DIR 2 7 Connecting the Input Signals EN Input 2 8 Connecting the Fault Output ii diss bossa eet deem RE 2 9 Dine Configuration a na saa e cack 2 10 Drive Configurations Settings sssaaa aaaea a 2 10 NE 0005 uius asm suc uu AA 2 12 Choosing a Power SUPPIN esas KAKA NG AKDA BARAT eens 2 13 MOUNTING the DIVE cu dac 2 14 Dimensions and Mounting Slot Locations 2 14 TC ii l SureStep Stepping Systems User Manual Fourth Editon 2 Table of Contents es Chapter 3 SureStep STP DRV 4035 Microstepping Drive eae 3 1 unb 2 ee eas aa ae Ra LA wk 3 2 Block PAP Ra a 3 2 SUGCINCAHONS c5 roc 9 ioo 4 9 Coes Came AA 3 3 Typical Wiring Diagram n n e I 3 4 Connection and Adjustment Locations 3 4 Connecting Hie Motor MG HD ABA WEB AAKALA LARA 3 5 Connecting the Power Supply cee eee ee eee 3 6 Connecting the Logic 43 eer db Adaddddd ddd ee eux ae 3 7 Using Logic That is
26. 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 are 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 pow
27. 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 O utputs with Sourcing Outputs Sinking Outputs ENABLE STEP ENABLE STEP 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 to the ENABLE input i N ote If you have no need to disable the amplifiers you don t need to connect anything Fourth Edition 2 SureStep Stepping Systems User Manual 3 9 Chapter 3 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 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 mot
28. 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 Fourth Edition 12 2012 SureStep Stepping Systems User Manual 3 15 Chapter 3 SureStep STP DRV 4035 Microstepping Drive ET Dimensions 4x Q0 125 1 50 2 50 03 2 gt 38 1 gt oe gt 63 5 Es 4 2x 0 125 03 2 3 70 3 75 4 00 94 0 95 3 101 6 0 25 a A m 6 4 7 0 15 6 4 0 875 3 8 22 2 Dimensions in mm 3 16 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 SURESTEP ADVANCED MicROSTEPPING DRIVES In This Chapter FOCUS and bd tips oe aed od Cee LAN ee ANA UNA 4 2 Specifications eas 8 9 3 rani Gees ee ANA eS 4 3 Typical Wiring Diagram gt ans a NA GWN GA chew ew ANA NAGA 4 4 Connection Locations amp Pin out 4 4 Connecting the Motor i RR enews 4 5 Connecting the Power Supply 000 eee eae 4 6 Connecting KUA 5 5 4 6 cg gatas eh yee ed ud ews 4 7 SureStep Drive Digital Inputs leere 4 7 Connecting STEP and DIR to 5V TTL 1006 4
29. motor 1 2 stepping T0V Power Supply e 48V Power Supply 32V Power Supply Speed rpm 0 300 600 900 1200 1500 1800 2100 2400 2700 90 80 70 60 50 ag 40 aa 30 Bibi Sm TE 9 20 Tang aag 10 0 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 Speed pps 1 pulse 0 9 degree STP MTR 17048 D Torque vs Speed 1 8 step motor 1 2 stepping e 70V Power Supply e 48V Power Supply 2 32V Power Supply Speed rpm 0 300 600 900 1200 1500 1800 2100 2400 2700 90 80 70 60 amp i 50 40 AME 30 Tra Ta 4 20 Tal ja E 2 0 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 Speed pps 1 pulse 0 9 degree SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 5 SureStep Stepping Motors 8 Torque vs Speed Charts continued STP MTR 17xxx D NEMA 17 Step Motors continued STP MTR 17060 D Torque vs Speed 1 8 step motor 1 2 stepping 70 Power Supply e 48V Power Supply 2 32V Power Supply Speed rpm 0 300 600 900 1200 1500 1800 2100 2400 2700 90 80 8 70 60 No 50 Nd 40 lt 30 20 10 Torque ozin
30. move The total number of pulses to make the entire move is expressed with the equation Equation Q 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 reVinotor 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 7 TEVgisk TEV driveshaft 1 FEV motor EVdriveshaft x 400 steps reV motor 2200 pulses SureStep Stepping Systems User Manual Fourth Edition 12 2012 C 2 Appendix C Selecting the SureStep Stepping System 8 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 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 Protal 45 mm LOMM reVecrew 2 FCVmotor feVscrew X 1000 steps revmotor 9000 pulses What is the position
31. por Drive Input Circuit 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 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 12 2012 SureStep Stepping Systems User Manual 3 7 Chapter 3 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 Note Many high speed indexers have differential outputs Wiring for Encoder Following Master Encoder 3 8 SureStep Stepping Systems User Manual STP DRV 4035 Drive X1 STEP Fourth Edition 12 2012 Chapter 3 SureStep STP DRV 4035 Microstepping Drive 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
32. self test switch selectable Operates from a 24 to 65 VDC power supply Running current from 0 5 to 7 5A Block Diagram 24 65 VDC from extemal power supply 3 3 5 15V Regulators Status LEDs AMPLIFIER STEP Optical Digital DIR isolation Filter Overcurrent Sensors Optical Software Isolation Filter DSP Optical Curent Optical Curent ourt m Isolation kia 12345678 ki di Motor Selection E 2 2 2 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 2 SureStep STP DRV 6575 Microstepping Drive Specifications SureStep Microstepping Drive Specifications Part Number STP DRV 6575 Input Power 24 65 VDC external power supply required fuse at 7A fast acting Output Current 0 5 7 5 A phase peak of sine Current Controller Dual H bridge digital MOSFET 4 quadrant PWM at 20 kHz Step 5 24 VDC nominal range 4 30 VDC mA 4V 15 mA 30V Optically isolated differential Minimum pulse width 5 Maximum pulse frequency 150 kHz or 2M Hz user selectable Function Step or Step CW pulse Direction 5 24 VDC nominal range 4 30 VDC 5mA 4V 15 mA 30V Optically isolated differential Minimum pulse width 0 5us Maximum pulse frequency 150 kHz or 2M Hz user selectable Function Direction or Step CCW pulse Enable 5 24 VDC nominal range 4 30 VDC bmA 4V
33. 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 AutomationDirect 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 JE 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 Gr Wht A Grn Wht 6 6 nie White lend Ac White Bad motor motor A arcen n c Green Red Red Red Black Wht Red Black Wht B nc B B B nec 6 Leads Series Connected 6 Leads Center Tap Connected Step motor wire lead colors vary from one manufacturer to another Fourth Edition 12 2012 SureStep Stepping Systems User Manual l 4 5 Chapter 4 SureStep Advanced Microstepping Drives Eight lead motors Eight lead motors can also be connected in two ways series or parallel
34. 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 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 4 16 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 4 SureStep Advanced Microstepping Drives ee Mounting the Drive You can mount your drive on the wide or the narrow side of the chassis using 6 screws
35. 0 21 90 kg cm 0 48 1 40 2 71 4 01 Rated Current A phase 5 6 6 3 6 3 6 3 Resistance Q phase 0 4 0 3 0 3 0 5 Inductance mH phase 1 2 1 5 21 41 Insulation Class 130 C 266 F Class B 300V rms Basic Step Angle 1 8 Shaft Runout 0 002 in 0 051 mm Max Shaft Radial Play 1lb load 0 001 in 0 025 mm Perpendicularity 0 003 in 0 076 mm Concentricity 0 002 in 0 051 mm Maximum Radial Load Ib kg 15 0 6 8 39 0 17 7 Maximum Thrust Load Ib kg 13 0 5 9 25 0 11 3 Storage Temperature 20 C to 100 C 4 F to 212 F 20 C to 50 C 4 F to 122 F motor case temperature should be kept below 100 C 212 F Operating Humidity 55 to 85 non condensing Product Material steel motor case stainless steel shaft s Environmental Rating IP40 Weight Ib kg 24 1 1 3 9 1 7 5 9 2 7 8 4 3 8 Agency Approval CE complies with EN 55014 1 1993 and EN 60034 1 5 11 Accessory Extension Cable STP EXTH 020 Rotor Inertia Operating Temperature 5 4 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 5 SureStep Stepping Motors Power Supply and Step Motor Drive An STP PW R xxxx series power supply from AutomationD irect is the best choice to power AutomationDirect and other step motors These power supplies were designed to work with the AutomationDirect SureStep STP DRV xxxx
36. 1 mm Max Radial Load 6 0 15 0 Ib kg 2 7 6 8 Max Thrust Load 6 0 13 0 Ib kg 2 7 5 9 Storage Temperature Operating 20 C to 50 C 4 F to 122 F Temperature motor case temperature should be kept below 100 C 212 F Operating 9 9 j Humidity 55 to 85 non condensing 0 001 in 0 025 mm 20 C to 100 C 4 F to 212 F Product M aterial steel motor case stainless steel shaft s Environmental IP40 0 6 0 3 0 7 0 3 0 9 0 4 1 5 0 7 2 2 1 0 3 9 1 7 CE complies with EN55014 1 1993 and EN 60034 1 5 11 STP EXT 020 Extension Cable For dual shaft motors STP MTR xxxxxD The sum of the front and rear Torque Loads Radial Loads and Thrust Loads must not exceed the applicable Torque Radial and Thrust load ratings of the motor Table continued next page Fourth Edition 2 SureStep Stepping Systems User Manual 5 3 Chapter 5 SureStep Stepping Motors eee Specifications continued Table continued from previous page SureStep Series Specifications Connectorized Bipolar Stepping Motors Higher Torque Motors Bipolar Stepping Motors STP MTRH STP MTRH STP MTRH STP MTRH 23079 D 34066 D 34097 D 34127 D NEMA Frame Size 23 34 34 34 Ib in 17 87 27 12 50 00 80 50 Max Holding Torque oz in 286 434 800 1288 N m 2 02 3 06 5 65 9 12 oz in 2 60 7 66 14 8
37. 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 DC 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 D RV 4850 amp 80100 These PLCs include DL 05 06 250 1 260 350 and 450 However we strongly recommend using 6 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 I O Interface Modules can also be used to control the SureStep Stepping System in PC Based Control systems with Think amp Do Studio or with our embedded WinPLC EBC module plugged into the CPU slot of the DL205 base Fourth Edition 12 2012 SureStep Stepping Systems User Manual B 3 Appendix B Using SureStep with AutomationDirect PLCs ET Typical Connections to a DLO5 PLC The following wiring diagr
38. 2 9 It is best to keep the load to motor inertia ratio below 10 so 3 9 is within an acceptable range C 16 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix C 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 am mm m mil in ft 1 1 000E 03 1 000E 06 3 937E 02 3 937E 05 3 281E 06 3 1 43 1 3 937E 02 3 281E 03 6 3 1 4 1 0 21 2 2 25 1 3 55 24 21 2 2 3 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 0 1 2 1 390E 03 8 680E 01 7 230E 00 kg cm 9 810E 02 1 000E 02 1 1 390E401 8 680E 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
39. 2 74 69 6 2 88 73 0 0 50 12 7 0 0 26 6 6 through 2 64 67 1 1 46 37 1 1 13 28 7 0 98 25 0 0 45 11 4 12 305 4 20 AWG Molex 43025 0400 Molex 43030 0007 kk mm dimensions are for reference purposes only Dimension D shaft diameter is the same for both front and rear shafts of STP xxxxxD dual shaft motors Dimension H applies only to dual shaft motors Dimensions J amp K do NOT apply to rear shafts of dual shaft motors all rear shafts are round style Higher Torque STP MTRH xxxxx D motors are shown in a separate table 5 6 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 5 SureStep Stepping Motors Typical Dimension amp Cable Diagram for STP MTR H xxxxx D Step Motors continued A 5 lt H4 lt gt F He Hot B e e Je es c 1 RAI he 9 PCT i PIN COLOR PHASE UNSHIELDED CABLE 7 REDA 4 CONDUCTORS L 3 GREEN B 4 BLACK B Dimension Hp applies only to dual shaft STP xxxxxD motors Dimension D is the same for both front and rear shafts PIN 1 of dual shaft motors Dimensions J amp K do NOT apply to rear shafts of dual shaft motors all rear
40. 2 gcm2 hee e 2a ooo Smoothing Gain 20 Wizard Idle Current Phase 0 Mae ui oz in 5 Maximum Voltage 50 0 504 Load Inertia Rotor Inertia 100 daa Ng 30 so 6 1 0 rotor inertia Max Lead Angle required for stall prevention Idle Current Delay 7 07 77 0 40 BEES 0 120 degrees at 25 rev sec gt Electronic Damping Anti resonance Off Wavefom Smoothing Off Help Cancel OK Motion and 0 Selecting this tab will allow you to set the drive s mode of operation Pulse and Direction Used with high speed pulse inputs CW CCW Pulse Direction Q uadrature generated from a PLC encoder etc e Velocity Oscillator nan Allows the drive to be speed controlled by an analog 5 signal The input is O 5V and can be scaled to the Puteo Drncong 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 vaoa 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
41. 4 2 6 Connecting the NO v uade su 2 00 2m A Ox o SUR andi doo ra 2 7 SureStep Drive Digital Inputs and Outputs 2 7 Connecting the Input Signals STEP and DIR 2 7 Connecting the Input Signals EN Input 2 8 Connecting the Fault Output 1 2 9 Drive Configuration a s acra GA ed bom Ow eee hed SCR 2 10 Drive Configurations Settings llle 2 10 peo MEC 2 12 Choosing a Power Supply 7774 2 13 Mounting the Drive 2 14 Dimensions and Mounting Slot Locations 2 14 Chapter 2 SureStep STP DRV 6575 Microstepping Drive Features e Low cost digital step motor driver in compact package Operates from Step amp Direction signals or Step CW amp Step CCW jumper selectable Enable input amp Fault output e Optically isolated I O e Digital filters prevent position error from electrical noise on command signals jumper selectable 150 kHz or 2MHz Rotary switch easily selects from many popular motors Electronic damping and anti resonance e Automatic idle current reduction to reduce heat when motor is not moving switch selectable 50 or 90 of running current Switch selectable step resolution 200 full step 400 half step 2 000 5 000 12 800 or 20 000 steps per revolution Switch selectable microstep emulation provides smoother more reliable motion in full and half step modes e Automatic
42. 96 Anti resonance and damping feature improve motor performance Set motor and load inertia range to 0 4x or 5 10x St For smoother motion and more precise speed set the pulse step P resolution to 20000 12800 5000 2000 400 smooth 400 200 Resolution smooth or 200 steps rev Automatically rotates the motor back and forth two turns in each direction in order to confirm that the motor is operational Idle Current Reduction DIP Switches Load Inertia Self Test DIP Switch Settings Factory default all switches O FF Step Resolution steps rev GES RSS Cen sooo ON ESSO Rom Olan EOSDEM EXON EON CEEA CEEA 20000 12800 5000 2000 400 400 200 200 SMOOTH SMOOTH Current Reduction Load Inertia Idle Current Reduction Self Test M 12842 KE M 3 M 4 al X 8 aj 100 90 80 120 5 10x 0 4x 50 90 ON OFF Use 120 when microstepping 2 10 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 2 SureStep STP DRV 6575 Microstepping Drive eee Jumper Settings Jumpers S3 and S4 are located on the internal circuit board and they can be accessed by removing the drive s front cover Remove c
43. A SureStep Accessories eee A 4 SureStep Stepping Systems User Manual Fourth Edition 12 2012 USING SureStep WITH ENDIX AUTOMATION DIRECT PLCs In This Appendix Compatible DirectL OGIC PLCs and Modules B 2 Typical Connections to a DI05 PLC B 4 Typical Connections to an HO CTRIO B 5 Typical Connections Multiple Drive Motors B 6 Typical DirectLOGIC PLC Serial Connections to an Advanced SureStep Drive B 7 Typical CLICK amp P3000 PLC Serial Connections to an Advanced SureStep Drive B 8 Appendix B Using SureStep with AutomationDirect PLCs EE Compatible DiredLOGIC PLCs and Modules The following tables show which high speed pulse output DirectLO GIC PLCs and modules can be used with the SureStep Microstepping M otor Drives DirectLO GIC 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 DLO5 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 O utputs 6 DC outputs 6 27 VDC D0 05DD current sinking 1 0 A pt max 1 common Two outputs ar
44. P DRV xxxx Drive SureStep Stepping Systems User Manual 4 9 Chapter 4 SureStep Advanced Microstepping Drives Connecting ENABLE Input to PNP Proximity Sensor Proximity STP DRV xxxx Sensor Drive T EN JE Leave the EN ABLE input unconnected if you do not need to disable the amplifiers Connecting the Analog Input The SureStep advanced drives have one 0 5 VDC analog input Connecting Al to Analog Signal 0 5V signal 1 Internal to the I STP DRV xxxx 1 I 45V 5VDC 10mA max signal return CAN O1 N AIN MAN L l Connecting AI to Potentiometer 220pF I GND oe Drive Analog Input Circuit 1 10kO 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 Internal to the relay coil I STP DRV xxxx inductive load 8 NG I STP DRV I Xxxx Drive 1N4935 l Drive Digital Output Circuit suppression 4 10 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 4 SureStep Advanced Microstepping Drives Connecting DO as Sinking O utput Connecting DO as Sourcing O utput
45. PAGE 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 Fourth Edition Issue Date 12 2012 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 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 MTRH 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 Ch 2 RoHS Wiring for Encoder Following 2nd Ed Rev D 11 2011 Ch 3 Connection Locations amp Pin o
46. R 23079 D STP MTR 34066 D STP MTRH 23079 D STP MTRH 34066 D STP MTRH 34097 D 6 3 STP MTRH 34127 D 6 3 1 The combinations above will perform according to the published speed torque curves However any STP motor can be used with any STP drive Using a motor with a current rating higher than the drive s output rating will proportionally limit the motor torque 2 MTR motors have connectors compatible with the EXT extension cables MTRH motors have connectors compatible with the EXTH extension cables STP EXTH 020 Ei NI NI al mall AN ae NI SureStep Stepping Systems User Manual Fourth Edition 12 2012 1 4 Chapter 1 Getting Started 8 Microstepping Drives Introduction There are two different basic types of microstepping drives offered in the SureStep series Two DIP switch configurable models with pulse inputs are available as well as two software configurable advanced models with multiple operating modes Standard Microstepping Drives STP D RV 6575 The SureStep STP D RV 6575 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 A 24 65 VDC power supply for the motor drive SureStep STP PW R 3204 or STP PW R 48xx power supplies from AutomationD irect are good choices If you dec
47. STP DRV STP DRV Drive 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 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 software 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 e I O configuration Anti Resonance Electronic D amping 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 M otor 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 M otor
48. 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 metal or other conductive particles near the drive Dimensions and Mounting Slot Locations A A 0 61 15 5 f IE SureStep Microstepping Drive O O 3 0 50 3 76 2 STP DRV 4850 i STP DRV 80100 D YO p V G a o v lt gt 3 39 86 1 1 125 28 6 3 65 92 7 6X slot 0 16 4 1 4 wide full R iL DI gt gt gt gt 0 663 DIMENSIONS 16 8 in mm Fourth Edition 12 2012 SureStep
49. 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 electronically 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 Cooling Method 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 Use four 4 10 screws to mount on either wide or narrow side 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 Fourth Edition 12 2012 SureStep Stepping Systems User Manual 6 3 Chapter 6 SureStep Stepping System Power Supp
50. Surect p Stepping Systems User Manual Manual STP SYS M WO STP DRV xxxx Fourth Edition Microstepping Drives STP PWR xxxxx Stepping System Power Supplies STP EXT H 020 Step Motor Extension Cable STP MTR H xxxx D 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 personnel can result from th
51. TP DRV 4035 Microstepping Drive Current Setting Table Factory Default Fourth Edition 12 2012 SureStep Stepping Systems User Manual 3 11 Chapter 3 SureStep STP DRV 4035 Microstepping Drive 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 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 res
52. 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 calculate the required stepping drive resolution Ostep joad 7 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 Fourth Edition 12 2012 SureStep Stepping Systems User Manual l C 11 Appendix C Selecting the SureStep Stepping System ET Step 3 Determine the Motion Profile From Equation Q the total pulses to make the required move is Protal Dtotal 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 7 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 steps rev 1 062 RPM motor speed Step 4 Determine the Required Motor Torque Using the equations in Table 1 Jtota Jmotor Jgear pulleys Jw i For this example let s assume the gearbox inertia is zero Jw W gxe xP 3 386 x 0 8 x
53. ads Series Connected 8 Leads Parallel Connected JE Step motor wire lead colors vary from one manufacturer to another Connecting the Power Supply An STP PW R 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 Connect the green ground screw to earth ground Use 18 or 20 AWG wire Fuse EMI External fuse not req d when using an STP PWR xxxx P S fuse is internal CE use requires an EMI line filter Do NOT use STP PW R 70xx power supplies with an STP D RV 6575 drive because those power supplies exceed the voltage limit of this drive 2 6 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 2 SureStep STP DRV 6575 Microstepping Drive Connecting the I O SureStep Drive Digital Inputs and Outputs The SureStep STP DRV 6575 drive includes two high speed 5 24 VDC digital inputs STEP amp DIR one standard speed 5 24 VDC digital input EN and one 30 VDC digital output Fault i Internal tothe The digital inputs are optically isolated to reduce STP DRV 6575 STEP 9 electrical no
54. am shows typical connections between the SureStep Stepping System components and a DirectLO GIC 105 PLC Refer to the 5 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 O utput function 1 DLO5 PLC programmed for D0 05DD PLC Mode 30 Pulse Output AC D lAC N co x x3 xa xe c21 v1 va vs agiles xo x2 ci xs x7 vo ve v4 av N VON Yon BI es es es e exe es en eie 9 i aL ep HE 24 VDC L1 L2 GND Power Supply O Step Motor AG Powel TABO Power Supply 0 Q a STP PWR xxxx GND A o o o GND a NO L2 5 5 L2 To e SS o ox L1 O O L1 a gt lt 7 O 6 Yi O 0 VDC ST 45 VDC LO Step Motor Drive STP DRV xxxx EN N C EN N C VDC DIR VDC DIR A STEP YO A STEP B B Cable Color Code 4 3 Step Motor iJ STP MTR H 000 Red 2 1 White Front View Green 3 Black 4 Extension Cable with Connector 12 Motor Pigtail STP EXT H 020 with Connector B 4 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix B Using SureStep with AutomationD
55. another Fourth Edition 12 2012 SureStep Stepping Systems User Manual 3 5 Chapter 3 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 ia Orange A g BIk Org Wht 8 Wht lead ea BIk Wht map ud motor A i Black Black Red Red Yel etow 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 have a fuse on the output or some kind of short circuit current limiting feature you need to put a 4 amp fast acting f
56. ature 0 55 C 32 131 F recommended 70 C 158 F maximum use fan cooling if necessary 90 non condensing maximum humidity Agency Approvals Fourth Edition 12 CE complies with EN 55011A and EN 50082 1 1992 RoHS 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 3 3 Chapter 3 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 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 and Self Test Logic Connector STEP DIR EN 3 4 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 3 SureStep STP DRV 4035 Microstepping Drive Connecting the Motor WARNING When connecting a step motor to the SureStep STP DRV 4035 microstepping drive be sure that the motor power supply
57. ay 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 2012 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 N ous 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 incombe de d termin
58. bles PLC 5 ADVANCED STEPPER DRIVE DLO5 PLC STP DRV 4850 STP DRV 80100 RS 232 Port 2 6P6C RJ12 Modular RJ12 plug 6P4C RJ12 Receptacle 1 5 Receptacle STP 232RJ12 CBL 2 4 Red N 3 Green Cd 1Bue Ui PLC ADVANCED STEPPER DRIVE DLO6 STP DRV 4850 DL250 1 STP DRV 80100 DL260 Modular Port 2 6P4C RJ12 15 pin HD STP 232HD15 CBL 2 5 Receptacle Serial Connection U sing Custom Cables U se Belden 9841 or equivalent cable and wire according to the Automation Direct cable diagrams shown above including RTS CTS jumper for DLO6 DL250 1 and DL260 Fourth Edition 12 2012 SureStep Stepping Systems User Manual l B 7 Appendix B Using SureStep with AutomationDirect PLCs ET Typical CLICK amp P3000 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 CLICK PLC or a P3 550 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 STEPPER DRIVE CLICK PLC STP DRV 4850 P3 550 PLC STP DRV 80100 Port 2 CLICK RS232 Port P3 550 Modular RJ12 Receptacle RJ12 6040 2 ptacle D plug STP 232RJ12 CBL 2 E c 3 Green f Green 3 Blue 2 Blue Serial Connection U sing Custom Cables Us
59. ciency P pitch revs inch of travel e efficiency Running torque Trun Ftotal 2 T P Tpreload Fi dE 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 0 6 incline angle coefficient of friction Fourth Edition 12 2012 SureStep Stepping Systems User Manual C 5 Appendix C Selecting the SureStep Stepping System ET Table 1 cont d Material Typical Leadscrew Data em Material u efficiency 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 7 r 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 W 2 xe xr Radius of pulleys r radius of pinion or pulleys inch Running torque Trun x r i Force total Ftotal Fext Ffriction Fgravity Force of gravity and Force of friction F gravity Wsin6 Friction HW cose Belt or Gear Reducer Equations Jmot
60. cuit fails the diode will continue to protect the power supply from over voltage RoHS SureStep Microstepping Drives Optional Accessories Part Number Description STP DRVA RC 050 Regeneration Clamp use with D C powered stepper amp servo drives 50W 24 80 VDC STP DRVA BR 100 Braking Resistor use with STP DRV RC 050 regen clamp 100W 10 ohms Do not use the regeneration clamp in an atmosphere containing corrosive gases A 2 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix A SureStep Accessories Dimensions STP D RVA RC 050 Dimensions in mm 2 50 4X 2 163 5 63 0 i 6 aasa c 4 00 3 75 101 6 o 95 3 3 69 93 7 ANONG 3X 90 12 HIN 103 0 1 9 Ie d 1 17 al o 5 29 7 124 0 0 87 131 5 30 6 22 1 Dimensions STP D RVA BR 100 Dimensions in mm 5 87 149 1 2XR0 16 5 46 R4 0 138 7 NG S 8 1 0 75 mna G 19 1 S 0 0 13 558 8 0 75 L 19 017 S gt STP DRVA RC 050 N STP DRVA BR 100 Fourth Edition 12 2012 SureStep Stepping Systems User Manual A 3 Appendix
61. d low backlash Also the motor can be repositioned back under the leadscrew if desired with a timing belt reducer C 8 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix C Selecting the SureStep Stepping System 8 Step 3 Determine the Motion Profile From Equation 1 the total pulses to make the required move is Protal Dtotal dioad X Ostep 4 5 0 6 2 x 400 6 000 pulses From Equation 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 e x 1 2 P 200 386 0 9 x 1 2 3 14 x 1 67 0 0052 Ib in sec Jscrew T X L X px r 29 3 14 23 6 x 0 28 x 0 3 2 x 386 0 0002 Ib in sec The inertia of the load and screw reflected to the motor is J screw load to motor screw Jw i 0 0002 0 0052 2 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 0 1 0 4 Ib in Next we nee
62. d 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 Feotal 2 0 P preload i Ftotal Fext Friction Foravity 0 uWcos0 0 0 05 200 10 Ib Trun 2 10 gt 2 3 14 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 Fourth Edition 2 SureStep Stepping Systems User Manual C 9 Appendix C 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 FJtotal X Aspeed Atime x 0 1 0 00135 0 00024 x 603 0 2 x 1 0 48 Ib in so that Tmotor Taccel Trun 0 48 0 48 0 96 Ib in 16 02 160 STP MTR 23055 140 120 f 100 8 1 10 Stepping 2000 steps rev S 80 7 o o EF 60 40 Required Torque vs Speed LI 0 150 300 450 600 750 900 1050 1200 1350 1500
63. down menu from the menu bar and then selecting SCL Terminal qur 4 eX Serial Command Language ESI 4 14 l SureStep Stepping Systems User Manual Fourth Edition 2 Chapter 4 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 Defaults resets the drive to out of the box status SCL Terminal Allows SCL commands to be tested by typing them in HyperTerminal 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 O status Set Quick Decel Rate Used when the drive encounters faults or overtravel limits Fourth Edition 12 2012 SureStep Stepping Systems User Manual 5 Chapter 4 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 l
64. e 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 efficient When you see the exclamation mark icon in the left hand margin the paragraph to its immediate right will be aWARNING This information could prevent injury loss of property or even death in extreme cases 1 2 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 1 Getting Started 8 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 Part Number Explanation STP M TRH 23079 x L Motor Shaft Type blank single D dual 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 6575 65V 7 5A 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 stepp
65. e e Power ON LEDs Integrated input and output fusing Matched to SureStep drives for maximum voltage The stepping system power supplies can supply power for multiple SureStep STP D RV xxxx microstepping motor drives depending on step motor size and application requirements 6 2 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 6 SureStep Stepping System Power Supplies SH Specifications SureStep Power Supply Specifications Part Number 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 Fusel 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 gt 24A 120 VAC lt 40A 240 VAC lt 50A Motor Supply Output unregulated fuse protected 1 power on LED indicator 32VDC 4A full load 35 VDC 1A load 41 VDC no load Fusel 6A 46 5 VDC 5A full load 52 06 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 QG 5A full load 79 VDC Q 1A load 86 5 VDC Q no load Fusel 8A
66. e Belden 9841 or equivalent cable and wire according to the Automation Direct STP 232RJ12 CBL 2 diagram shown above B 8 SureStep Stepping Systems User Manual Fourth Edition 12 2012 SELECTING THE PPEN DIX SureStep STEPPING SYSTEM In This Appendix Selecting the SureStep Stepping System C 2 The Selection Procedure iss os rrr ky wes C 2 How many pulses from the PLC to make the move C 2 What is the positioning resolution of the load C 3 What is the indexing speed to accomplish the move time C 3 Calculating the Required Torque a C 4 Leadscrew Example Calculations C 8 Step 1 Define the Actuator and Motion Requirements C 8 Step 2 Determine the Positioning Resolution of the Load C 8 Step 3 Determine the Motion Profile C 9 Step 4 Determine the Required Motor Torque C 9 Step 5 Select amp Confirm Stepping Motor amp Driver System C 10 Belt Drive Example Calculations C 11 Step 1 Define the Actuator and Motion Requirements C 11 Step 2 Determine the Positioning Resolution of the Load C 11 Step 3 Determine the Motion Profile C 12 Step 4 Determine the Required Motor Torque C 12 Step 5 Select amp Confirm Stepping Motor amp Driver System C 13 Index Table Example Calculations C 14 Ste
67. e 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 DO0 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 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 06DD1 Commons 4 inputs per common Outputs 16 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 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 0 06002 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 s
68. e 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 AutomationD irect 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 discuss features that m
69. e 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 T run 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 Fourth Edition 12 2012 SureStep Stepping Systems User Manual C 15 Appendix C 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 0 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 0 75 150 225 300 375 450 525 600 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 0 001
70. eae ew en 4 10 Drive Configuration a sa xa nA CREER ROCCO Re RL Oo RC 4 11 SureStep Pro Software ces eo XR OR ACE a 4 13 Choosing a Power Supply gt 4 16 Mounting the Drive 0 00 eee 4 17 Dimensions and Mounting Slot Locations 4 17 Chapter 5 SureStep Stepping Motors 5 1 PSS 5 ich SCR es 0 9 RA ERO et P RO Me ots 5 2 Design and Installation Tips 0 00 cee eee ees 5 2 SDECITICOEHOFIS sacr aod paaa ea RC EdUR EO ee NE WG HA IUE Er 5 3 Power Supply and Step Motor Drive sss 5 5 MOUNTING the MOF 2 9 4 5 5 Connecting the MOOF 2 4 ess 49 x ows Owe bebe EX BOR 5 5 Extension Cable Wiring Diagram amp xa ska KKK E oes 5 5 Motor Dimensions and Cabling llis 5 6 Torque vs Speed Charts 1 cece wee euch cine shade RE 5 8 TC IV l SureStep Stepping Systems User Manual Fourth Edition 2 Table of Contents NSl Chapter 6 SureStep Stepping System Power Supplies 6 1 poco PEE E E E EE 6 2 SEERE iog e us 05 50 AA 6 3 Power Supply Terminal amp Component Layout 6 4 Mounting the Power Supply eee eee 6 5 0 Sac eee TIT IIT 6 6 Appendix A SureStep Accessories A 1 Braking Accessories A 2 Regeneration Clamp ure aman eh ded d RCROR GR R ee TRUE Ropa A 2 Braking RESO AA A 2 Appendix B Using SureStep with AutomationDirect PLCs 0 rrr B 1 Compa
71. east 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 are 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
72. ect PLCs 1 and module part numbers that are suitable to work with the SureStep Stepping Systems D0 05AD D0 05DD 1 Any Direct OGIC PLC capable of RS 232 D0 05DD D ASCII communication can write serial D0 06DD1 commands to the SureStep Advanced M icrostepping Drives STP DRV 4850 amp D0 06DD2 80100 These PLCs include DL 05 06 250 1 D0 06DD1 D 260 350 6 450 P3 550 H2 DM1 E or D0 06DD2 D CLICK However of the Directi 0 GIC PLCs we strongly recommend using 106 or DL260 HO CTRIO PLCs for serial commands due to their more F1 130AD advanced ASCII instruction set which includes F1 130DD PRINTV and VPRINT commands F1 130DD D pa 2 The H2 CTRIO and T1H CTRIO High Speed H2 CTRIO Counter I O Interface Modules can also be H2 CTRIO2 used to control the SureStep Stepping System D2 CTRINT in PC Based Control systems with Think amp Do Studio or with our embedded WinPLC EBC T1H CTRIO 2 module plugged into the CPU slot of the H4 CTRIO DL205 base P3 HSO 1 10 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 SURESTEP STP DRV 6575 MiCROSTEPPING DRIVE In This Chapter PTT 2 2 Block DIGGIN s eae s a ine E duci mus Gerace ee RN 2 2 Specifications sca Na acea LAG ABG thee as deos 2 3 Typical Wiring Diagram uic danas cow dew A AKUN GNG 2 4 Wiring Connections and Configuration Switches 2 4 Connecting the 1000 eee eee 2 5 Connecting the Power Supply 2
73. er channel pulse and direction or CW CCW pulses Table continued next page B 2 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix B Using SureStep with AutomationDirect PLCs ee 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 Outputs 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 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 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 n
74. er drive DRVA drive accessory EXT motor extension cable EXTH high power motor extension cable MTR stepper motor MTRA motor accessory MTRH high power stepper motor PWR power supply SureStep Series Designation STP Fourth Edition 12 2012 SureStep Stepping Systems User Manual 1 3 Chapter 1 Getting Started ET SureStep System Recommended Component Compatibility SureStep Power Supply Drive Compatibility Drive 1 2 Recommended Power Supply 1 2 Model Number STP PWR 3024 STP PWR 4805 STP PWR 4810 STP PWR 7005 STP DRV 4035 40 VDC max input NI No No No STP DRV 4850 48 VDC max input No STP DRV 6575 65 VDC max input No STP DRV 80100 80 VDC max input 4 NI NI NI 1 Do NOT use a power supply that exceeds the drive s input voltage range If using a non STP linear power supply ensure that the unloaded voltage does not float above the drive s maximum input range 2 For best performance use the lowest voltage power supply that supplies the required speed and torque SureStep Drive Motor Compatibility Motor 1 2 Recommended Drive 1 Model Number 1 2 41 STP DRV 4850 1 5 0A max output STP DRV 6575 1 7 5A max output STP DRV 80100 1 10 0A max output 17 y y 2 0 2 0 2 8 2 8 2 8 5 6 6 3 STP MTR 17040 D STP MTR 17048 D STP MTR 17060 D STP MTR 23055 D STP MT
75. er is 140 W Current Controller Dual H bridge Bipolar Chopper 4 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 0 or 50 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 5 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 with AWG 18 maximum wire size Weight 9 3 oz 264g Storage Temperature 20 80 C 4 176 F Chassis Operating Temper
76. er 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 syst mes d a
77. er 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 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 SureStep STP PWR xxxx power supplies from AutomationD irect are the best choices of DC power supply to use with SureStep STP DRV xxxx D microstepping drives 12 2012 SureStep Stepping Systems User Manual l 2 13 Chapter 2 SureStep STP DRV 6575 Microstepping Drive ET Mounting the Drive You can mount your drive on the wide or the narrow side of the chassis using 2 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 s
78. erate an inertia from one speed to another and the calculation of running torque for common mechanical actuators C 4 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix C Selecting the SureStep Stepping System EEE 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 Aspeed Atime x 27 60 Jtotal is the motor inertia plus load inertia reflected to the motor Velciy Aseel IndexingVelociy pecel 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 W hat 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 Taccei 0 002 Ib in sec x 600 RPM 0 05 seconds x 27 60 2 5 Ib in Leadscrew Equations Description Equations Motor RPM Nmotor Vioad X P X i Nmotor RPM Vigag in min Torque required to accelerate and decelerate the load Motor total inertia Jtotal Jmotor Jgear Ucoupting Jscrew Jw P Inertia of the load Jw W gx e 2 gt 1 P Pitch and Effi
79. 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 5 6 6 ide White isad A White loud motor motor A areen n c Green Red Red Red Black Wht Red Black Wht B mc B B B ne 6 Leads Series Connected 6 Leads Center Tap Connected Step motor wire lead colors vary from one manufacturer to another Fourth Edition 12 2012 SureStep Stepping Systems User Manual 2 5 Chapter 2 SureStep STP DRV 6575 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 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 40 above rated current Care should be taken in either case to assure that the motor does not overheat As Orange ka Orange BIk Org Wht 8 Wht 8 lead lead Org BIk Wht motor Wht motor A A Black Black Red Red Yel Yellow Red Yellow Wht Wht Yell Rsgi B B B Wht wht B 8 Le
80. hanical 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 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 4 12 l SureStep Stepping Systems User Manual Fourth Edition 2 Chapter 4 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 Runson Windows 98 2000 ME NT Vista XP 2 SureStep PRO 0 0 22 untitled B x File Drive Help pia Motion 8 I O Motion Mode Dedicated 0 ST Motor
81. hooting 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 NN NN Self Test ON Self Test OFF Factory Default test ignores the STEP and DIRECTION inputs while operating The ENABLE input continues to function normally Fourth Edition 12 2012 SureStep Stepping Systems User Manual 3 13 Chapter 3 SureStep STP DRV 4035 Microstepping Drive 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 you choose an unregulated power supply do not exceed 30 volts DC This is because unregulated supplies are rated at full load c
82. ide not to use one of these recommended power supplies then please read the section entitled Choosing a Power Supply in the STP DRV 6575 Drive chapter of this user manual A source of step pulses Signal may be sinking NPN sourcing PNP or differential The step inputs can be CW CCW or Step amp Direction e A compatible step motor such as an AutomationDirect SureStep STP M TR H Motor extension cables STP EXT H 020 are also available A small flat blade screwdriver for tightening the connectors The STP DRV 6575 standard microstepping drive is an enclosed design STP DRV 6575 Refer to the SureStep STP D RV 6575 Microstepping Drive chapter of this user manual for complete details on the installation configuration and wiring of this drive Fourth Edition 12 2012 SureStep Stepping Systems User Manual 1 5 Chapter 1 Getting Started ee Standard Microstepping Drives continued STP D RV 4035 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 AutomationDirect is the best choice If you decide not to use the STP PW R 3204 please read the section entitled Choosing a Power Supply in the STP DRV 4035 Drive chapter of thi
83. ing 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 digag i step Example 4 W hat is the positioning resolution for the system in example 3 Lo dioad 71 Ostep 10 MM reVecreyw 2 IEV motor EV screw 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 Fourth Edition 2 SureStep Stepping Systems User Manual C 3 Appendix C Selecting the SureStep Stepping 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 trotal 10 000 pulses 0 8 seconds 12 500 Hz For higher speed operation the Trapezoidal Profile trapezoidal motion profile includes maexing u control
84. irect 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 M odule 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 w PEI m PORT1 PORT2 RUN STOP 0 Step Motor Power Supply STP PWR xxxx AC Power Step Motor Drive 3 Step Motor i STP MTR H xxxxx Connector 1 Front View n Cable with Connector 12 Motor Pigtail STP EXT H 020 with Connector Fourth Edition 12 2012 SureStep Stepping Systems User Manual l B 5 Appendix B Using SureStep with AutomationDirect PLCs een ee Typical Connections Multiple Drives 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 M odule User Manual p n Hx CTRIO M for detailed programming instructions when using the H2 CTRIO module Step Mo
85. irements C 11 Step 2 Determine the Positioning Resolution of the Load C 11 Step 3 Determine the Motion Profile C 12 Step 4 Determine the Required Motor Torque C 12 Step 5 Select amp Confirm Stepping Motor amp Driver System C 13 Index Table Example Calculations C 14 Step 1 Define the Actuator and Motion Requirements C 14 Step 2 Determine the Positioning Resolution of the Load C 14 Step 3 Determine the Motion Profile C 15 Step 4 Determine the Required Motor Torque C 15 Step 5 Select amp Confirm Stepping Motor amp Driver System C 16 Engineering Unit Conversion Tables Formulae amp Definitions C 17 IC Vi l SureStep Stepping Systems User Manual Fourth Edition 12 2012 GETTING STARTED In This Chapter Manual Overview ees 1 2 Overview of this Publication cece ees 1 2 Who Should Read this Manual 00 an 1 2 Technical Support 2 372733 a ham bho ee Se eee ee RES a 1 2 Special d st aca Gon von om C KARIN NANA AS ha LA SD 1 2 SureStep System Introduction lesse 1 3 SureStep Part Number Explanation 1 3 SureStep System Recommended Component Compatibility 1 4 Microstepping Drives Introduction 1 5 Standard Microstepping Drive 3 1 5 Advanced Microstepping Drive
86. is switched off When using a motor not supplied by AutomationDirReEcT 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 28 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 d motor motor Green Green 9 bin war Red 36 Wht Red 806 Wht B NC B B B NC 6 Leads Series Connected 6 Leads Center Tap Connected j N ote Be aware that step motor wire lead colors vary from one manufacturer to
87. ise problems There is no electrical 220pF ee connection between the control and power circuits within the drive and input signal communication between the two circuits is achieved by infrared light Externally the drive s motor power and control circuits should be supplied from separate sources such as from a step motor power supply with separate power and logic outputs For bidirectional rotation supply a source of step pulses to the drive at the STEP and STEP gt terminals and a directional signal at the DIR and caue M 2 aY DIR terminals rs ee ee The ENABLE input allows the logic to turn off the Drive Digital Input Circuit 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 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 Connecting the Input Signals STEP and DIR Connecting Inputs to an Indexer with Sinking O utputs 6 STP DRV 6575 Indexer IR DIR Drive with Q9 Q9 Sinking EN Outputs Kr I NcC STEP R 6 9H N C STP DRV 6575 Indexer Drive with 2 Sourcing EN Outputs G94 N C TEP R RH N C Fourth Edition 12 2012 SureStep Stepping Systems User Manual l 2 7 Chapter 2 SureStep STP DRV 6575 Microstepping Drive ET Connecting the Input Signals STEP and DIR continued Co
88. led acceleration amp Seed 77 deceleration and an initial non zero starting speed With the acceleration Sun p and deceleration periods equally set l the indexing speed can be found 1 Deceleration using the equation Move Time Equation 4 frpap Ptotal fstart X tramp total tramp for trapezoidal motion profiles faart 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 Required 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 decel
89. lies Power Supply Terminal amp Component Layout STP PW R 3204 Voltage Selection Switch Voltage range switch is factory set to 240 VAC AC input fuse STP PWR 3204 Q GND S 2 it SA lu 240V 120v 9 ja 5 Transformer Fo 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 h El Linear DC Power LED F2 Transformer OCA 120V 240V OVA Ovc Oc I AC input fuse Voltage range switch is factory set to 240 VAC Voltage Selection Switch 6 4 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 6 SureStep Stepping System Power Supplies 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 PWR 4810 and 7005 Since power supplies generate heat they should be mounted in a location that allows air flow They also should be securely fas
90. nnecting Inputs to an Indexer with Differential O utputs Indexer with Differential Outputs STEP 09 N C N C Many high speed indexers have differential also known as line driver outputs Connecting the Input Signals EN Input The ENABLE input allows the user to turn off the current to the motor by providing a 5 24 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 24VDC 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 Proximity gt Sensor STP DRV 6575 Drive 2 8 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 2 SureStep STP DRV 6575 Microstepping Drive Connecting ENABLE Input to PNP Proximity Sensor Proximity Sensor 29 j Leave the ENABLE input unconnected if you do not need to disable the amplifiers Connecting the Fault Output The SureStep advanced drives have one digital output that has separate and terminals and can be used to sink or source current
91. 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 E 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 3 14 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 3 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 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
92. olution 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 01 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 Fourth Edition 12 2012 CE RoHS SureStep Stepping Systems User Manual 4 3 Chapter 4 SureStep Advanced Microstepping Drives Typical Wiring Diagram Step Motor Power Supply SureStep Typical Wiring Diagram
93. olution 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 6 STEPS REV 18 1 50 400 J rS 15 2 000 mx STEPS REV 18 6 HALF Factory 1 000 JA 18 10 000 Default STEPS REV 5 G STEPS REV efault 1 5 n 1 50 3 12 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 3 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 Current Reduction Selected Factory Default Self Test The SureStep drive includes a self test feature This is used for trouble s
94. onnectors and cover to access Jumpers S3 and 54 They are located on the upper left corner of the circuit board Jumper S4 Step Pulse Noise Filter Jumper S3 Step Pulse Type Jumper S3 Step Pulse Type Jumper in 1 2 position Step amp Direction factory default Jumper in 1 3 position Step CW Step CCW Jumper 54 Step Pulse oise Filter Jumper in 1 2 position 2MHz Jumper in 1 3 position 150 kHz factory default Rotary Switch Settings Motor Current Settings STP DRV 6575 Motor Selection Table Motor Data Drive Configuration Data a Rotary Switch Position Bf T N reserved custom NEMA 17 custom NEMA 23 custom NEMA 34 17040 3 03 1 60 434 17048 2 65 140 6 17060 3 30 2 00 883 23055 2 36 0 08 1172 23079 3 82 1 10 1949 34066 7 70 1 11 3065 H 23079 5 1 18 0 40 5 H 34066 6 1 52 0 25 1 7 2 07 0 03 5668 H 34127 4 14 0 49 9123 ou CON OF A WwW Fourth Edition 12 2012 SureStep Stepping Systems User Manual l 2 11 Chapter 2 SureStep STP DRV 6575 Microstepping Drive ET Alarm Codes In the event of a drive fault or alarm the green LED will flash one or two times followed by a series of red flashes The pattern repeats until the alarm is cleared STP DRV 6575 Alarm Codes Status LED Alarm Code Erro
95. or 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 phase based on the step motor showing a phase 0 2 Lo current of 2 2 Amps You need the base current of 0 4 Amps plus another 1 6 and 0 2 Amps 0 4 m 22 204416402 0 8 CH Slide the 1 6 and 0 2 Amp DIP switches toward the 1 6 o labels as shown in the figure to the right N 3 10 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 3 SureStep S
96. ors Motor Dimensions and Cabling Typical Dimension amp Cable Diagram for STP MTR H xxxxx D Step Motors gt H4 lt gt F lt gt H gt ye a B ad K PIN COLOR PHASE UNSHIELDED CABLE 7 4 CONDUCTORS L 5 GREEN B 4 BLACK B Dimension H5 applies only to dual shaft STP xxxxxD motors Dimension D is the same for both front and rear shafts PIN 1 of dual shaft motors Dimensions J amp K do NOT apply to rear shafts of dual shaft motors all rear shafts are round style PIN 3 PIN 2 PIN 4 CONNECTOR NEMA 17 ROUND SHAFT VIEW FROM WIRE ENTRANCE NEMA 23 front shaft ONE FLAT 000 9 NEMA 34 front shaft TWO FLATS 90 APART i ok Dimensions High Torque Motors STP MTR xxxxx D in mm STP MTR 17040 D STP MTR 17048 D STP MTR 17060 D STP MTR 23055 D STP MTR 23079 D STP MTR 34066 D 1 67 42 3 1 22 31 0 0 0 87 22 1 0 20 5 0 M3 x 0 5 thread 0 15 3 8 min depth 1 58 40 1 1 89 48 0 2 34 59 5 0 94 24 0 0 39 9 9 n a n a 2 25 57 2 1 86 47 2 1 50 38 1 0 25 6 4 0 0 20 5 1 through 2 22 56 4 3 10 78 7 0 81 20 6 0 63 16 0 0 59 15 0 0 23 5 8 3 39 86 1
97. ot 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 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 M odule 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 one 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 I O High Speed Counter I O Interface M odule 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
98. p Stepping Systems User Manual l C 7 Appendix C 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 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 Diotal total move distance sep driver step resolution steps reVinotor i gear reduction ratio reVmotor reVeearsnar 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 calculate the required stepping drive resolution Ostep dioad TI 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 an
99. p 1 Define the Actuator and Motion Requirements C 14 Step 2 Determine the Positioning Resolution of the Load C 14 Step 3 Determine the Motion Profile C 15 Step 4 Determine the Required Motor Torque C 15 Step 5 Select amp Confirm Stepping Motor amp Driver System C 16 Engineering Unit Converson Tables Formulae amp Definitions C 17 Appendix C 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 fad Deceleration Move Time eee positioning resolution of the load indexing 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
100. pace where there is no air flow or where the ambient temperature exceeds 50 C 122 F e When mouting multiple STP D RV xxxx drives near each other maintain at least one half inch of space between drives e Never put the drive where it can get wet Never allow metal or other conductive particles near the drive Dimensions and Mounting Slot Locations 4 66 Dimensions in mm 118 4 0 13 4 40 3 2 111 8 4 4 03 6 tg 6 2 98 089 75 6 22 7 T o 1 04 chi 99590999 26 5 112 3 2 EC 7 54 10 5 UUYUUUUUUY AE 0 re 2 14 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 SURESTEP STP DRV 4035 MICROSTEPPING DRIVE In This Chapter n CT v m 3 2 Block Diagram 20 294 519 AKNG NG 0002058 eh Dale cece 3 2 Specifications AA 3 3 Typical Wiring Diagram 2d na sates 6 MANA chews 3 4 Connection and Adjustment Locations 3 4 Connecting the Motor 4 gt O99 UE ER Pao EE RE HUE RC WA KA 3 5 Connecting the Power Supply 00 0 e ee eens 3 6 Connecting the Logic ccc ees 3 7 Using Logic That is Not 5 volt TTL Level 3 9 The Enable Input 1 mh Kan PB dene Roi KAKA 3 9 Setting Phase Current 7777 3 10 Current Setting 3 10 Cur
101. 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 O utputs Indexer 9 STP DRV xxxx Indexer with Drive with Sinking 8 2 Sourcing Outputs Outputs ENABLE STEP ENABLE STEP 4 8 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 4 SureStep Advanced Microstepping Drives Connecting to a PLC with Sink or Source 12 24 VDC Outputs PLC 6 4 STP DRV xxxx with NB 2 Drive Sinking T Outputs ENABLE STEP 2 9 24VDC Power Supply Connections to the EN Input O run stop switch closed run Sourcing Outputs ENABLE STEP 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 Fourth Edition 12 2012 switch or relay closed logic low ST
102. r solid green no alarm motor disabled flashing green no alarm motor enabled flashing red configuration or memory error 1 green 4red 8 power supply voltage too high 1 green 5 red lover current short circuit T 1 green 6red X open motor winding 2 green 3red internal voltage out of range 2 green 4 red power supply voltage too low Does not disable the motor The alarm will clear about 30 seconds after the fault is corrected Disables the motor Cannot be cleared until power is cycled T The over current short circuit alarm typically indicates that an electrical fault exists somewhere in the system external to the drive This alarm does not serve as motor overload protection 2 12 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 2 SureStep STP DRV 6575 Microstepping Drive Choosing a Power Supply Fourth Edition 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
103. reStep STP M TR H Xxxxx D 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 Fourth Edition 12 2012 SureStep Stepping Systems User Manual 1 7 Chapter 1 Getting Started ET Bipolar Step Motor Introduction AutomationDirect offers twenty different models of bipolar step motors with mounting flanges in two different shaft configurations single and dual shaft and in three different NEMA frame sizes 17 23 and 34 There are twelve High Torque STP M TR xxxxx D motors available as well as eight Higher Torque STP M TRH xxxxx D 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 MTR H xxxxx NEMA 17 23 34 Frame Sizes STP MTR H xxxxx D Motors Available in Single shaft and Double shaft Models 1 8 SureStep Stepping Systems User Manual Fou
104. rent Setting Table 00 0a 3 11 Vilege ia ola CRETE PSP PEPE 3 12 Idle Current Reduction 44 makaawa 8208 a tadsdons 3 13 ccc PP 3 13 Choosing a Power Supply mawa mamaw d e ka Nak EN 3 14 Mounting the Drive 4 sawa RAE 240 a UA SEADNG 3 15 Dimensions 2 2 26 vee 4 at arai ha 3 16 Chapter 3 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 i Optical i Steps Rev 777 1 2 1 5 1 10 or 1 50 Connections to Bipolar Step Motor 50 Idle Logic Connections Current Reduction from PLC or Indexer 3 2 SureStep Stepping Systems User Manual Fourth Edition 12 Chapter 3 SureStep STP DRV 4035 Microstepping Drive Specifications SureStep Microstepping Drives Specifications Part Number STP DRV 4035 Input Power with red Power On LED 12 42 VDC including ripple voltage Output Power Output current selectable from 0 4 to 3 5 Amps phase motor current maximum output pow
105. rmes 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 appartiennent exclu
106. rs because motor performance will be reduced and the warranty will be voided DO NOT connect or disconnect the step motor during operation The motor can be mounted in any orientation horizontal or vertical Mount it 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 5 2 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 5 SureStep Stepping Motors 8 Specifications E SureStep Series Specifications Connectorized Bipolar Stepping Motors ae High Torque Motors stepping Motors STP MTR STP MTR STP MTR STP MTR STP MTR STP MTR 17040 D 17048 D 17060 D 23055 D 23079 D 34066 D NEMA Frame Size 17 17 17 23 23 34 Max bin 3 81 5 19 719 10 37 17 25 27 12 Holding ozin 61 83 115 166 276 434 Torque N m 0 43 0 59 0 81 1 17 1 95 3 06 Rotor oz in 0 28 0 37 0 56 1 46 2 60 7 66 Inertia kg cm 0 05 0 07 0 10 0 27 0 48 1 40 Rated Current A phase 1 7 2 0 2 0 2 8 2 8 2 8 1 6 1 4 2 0 0 8 dad 11 mH phase 3 0 2 7 33 24 3 8 6 6 Insulation Class 130 C 266 F Class B 300V rms Basic Step Angle 1 8 Shaft Runout 0 002 in 0 051 mm Max Shaft Radial Play 1lb load Perpendicularity 0 003 in 0 076 mm Concentricity 0 002 in 0 05
107. rth Edition 2 Chapter 1 Getting Started Stepping System Power Supply Introduction 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 Fourth Edition 12 2012 SureStep Stepping Systems User Manual 1 9 Chapter 1 Getting Started ET Selecting the Stepping System Refer to Appendix C Selecting the SureStep Stepping System for detailed information on how to calculate requirements for various applications using stepping motors for motion control Use with AutomationDirect 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 AutomationDir
108. run 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 calculate the required stepping drive resolution Ostep joad F1 Lg 3602 25 0 0369 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 C 14 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Appendix C Selecting the SureStep Stepping System eee Step 3 Determine the Motion Profile From Equation 1 the total pulses to make the required move is Protal 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 7 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 Torque 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 p X r 29 3 14 2 x 0 28 x 1296 2 x 386 2 95 b in sec The inertia of th
109. s user manual A source of step pulses Signal may be sinking NPN sourcing PNP or differential The step inputs can be CW CCW step and direction or quadrature e A compatible step motor such as an AutomationDirect SureStep STP M TR H Motor extension cables STP EXT H 020 are also available e 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 1 6 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 1 Getting Started 8 Advanced Microstepping Drive The SureStep advanced microstepping drives STP D RV 4850 amp 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 AutomationDirect is the best choice A source of input control signals such as a DirectLogic PLC from AutomationD irect e A compatible step motor such as an AutomationDirect Su
110. series bipolar microstepping motor drives Mounting the Motor We 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 MTRH 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 2 pin 1 240 4 2007 e 1 0 ref 5 CONNECTORS wO 02045200 CABLE STP EXT 020 Molex 0430450412 HEAT SHRINK STP EXT 020 4 20 AWG cond STP EXTH 020 Molex 0039012041 STP EXTH 020 n 18 AWG cond Fourth Edition 12 2012 SureStep Stepping Systems User Manual 5 5 Chapter 5 SureStep Stepping Mot
111. shafts are round style 9 PIN 3 PIN 2 PIN 4 CONNECTOR NEMA 17 ROUND SHAFT VIEW FROM WIRE ENTRANCE NEMA 23 front shaft ONE FLAT 0 O 0 Dimensions NEMA 34 front shaft TWO FLATS 90 APART Higher Torque Motors STP M TRH xxxxx D STP MTRH in mm STP MTRH 34097 STP MTRH 34127 2 25 57 2 3 39 86 1 1 86 47 2 2 74 69 6 0 1 50 38 1 2 88 73 0 0 25 6 4 0 0 50 12 7 0 20 5 1 through 0 26 6 6 through 3 10 78 7 0 81 20 6 0 63 16 0 0 59 15 0 0 23 5 8 2 64 67 1 3 82 97 0 1 46 37 1 1 13 28 7 0 98 25 0 0 45 11 4 12 305 4 18 AWG Connector Molex 39 01 3042 Pin Molex 39 00 0039 mm dimensions are for reference purposes only Dimension D shaft diameter is the same for both front and rear shafts of STP xxxxxD dual shaft motors Dimension H applies only to dual shaft motors Dimensions J 8 K do NOT apply to rear shafts of dual shaft motors all rear shafts are round style High Torque STP MTR xxxxx D motors are shown in a separate table 5 00 127 0 Fourth Edition 2 SureStep Stepping Systems User Manual 5 7 Chapter 5 SureStep Stepping Motors eee Torque vs Speed Charts Torque oz in Torque oz in STP MTR 17xxx D NEMA 17 Step Motors STP MTR 17040 D Torque vs Speed 1 8 step
112. sivement a leurs propri taires respectifs AutomationDirect nie tout int r t dans les autres marques et d signations Copyright 2004 2007 2008 2009 2011 2012 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 lt lt 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
113. 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 8 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 680 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 232 111 6P4C receptacle Non volatile Memory Storage Configurations are saved in FLASH memory on board the DSP Idle Current Reduction reduction range of 0 90 of running current after delay selectable in ms Microstep Res
114. tened to a smooth flat metal surface that will dissipate heat Wide Side Mount Narrow Side Mount Ca sheet metal mounting screws 5 6 6 ba GA gt 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 Fourth Edition 12 2012 SureStep Stepping Systems User Manual 6 5 Chapter 6 SureStep Stepping System Power Supplies Dimensions STP PW R 3204 0 250 kag 6 500 165 1 Bea Ll 0 600 15 2 l d 8 ps 5 4 thru holes 2 400 Dimensions fit 10 screws 61 0 inches mm 0 250 6 4 E 3 250 82 6 0 1 4 000 101 6 Terminals J Transformer Circuit Board o 7 000 177 8 HG 6 6 SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 6 SureStep Stepping System Power Supplies eee Dimensions continued STP PW R 4805 4810 7005 STP PWR 4805 only E Transformer Circuit Board 0 E E L Py thru holes 8 STP PWR 4805 7 STP PWR 4810 B 7 STP PWR 7005 Fourth Edition Dimensions for STP PWR 4805 STP PWR 4810 STP PWR 7005
115. tep 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 DO0 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 DO0 06DD2 D outputs 12 24VDC current sourcing 1 0A 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 DL05 DLO6 High Speed Counter I O Module DL05 06 High Speed Counter I O 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 p
116. tible DirectL OGIC PLCs and Modules B 2 Typical Connections to aDLO5 PLC 4 Typical Connections to an HO CTRIO B 5 Typical Connections Multiple Drivey Motors B 6 Typical DirectLOGIC PLC Serial Connections to an Advanced SureStep Drive ccc re Gh LAKARAN KALA KA o B 7 Typical CLICK amp P3000 PLC Serial Connections to an Advanced SureStep DAVE s waaa KANA WA OR IER ERG B 8 Fourth Edition 12 2012 SureStep Stepping Systems User Manual TC v Table of Contents ET Appendix C Selecting the SureStep Stepping System C 1 Selecting the SureStep Stepping System C 2 The Selection Procedure iiu uu cdo paaa o6eGudadeeesee ace aww C 2 How many pulses from the PLC to make the move C 2 What is the positioning resolution of the load C 3 What is the indexing speed to accomplish the move time C 3 Calculating the Required Torque 4 Leadscrew Example Calculations C 8 Step 1 Define the Actuator and Motion Requirements C 8 Step 2 Determine the Positioning Resolution of the Load C 8 Step 3 Determine the Motion Profile C 9 Step 4 Determine the Required Motor Torque C 9 Step 5 Select amp Confirm Stepping Motor amp Driver System C 10 Belt Drive Example Calculations C 11 Step 1 Define the Actuator and Motion Requ
117. tor Power Supply STP PWR xxxx GND 5 VDC xx VDC 2 E AC Power Step Motor Drive STP DRV xxxx K2 VDC ioc Fe Step Motor Drive STP DRV xxxx VDC Te V Lra 4 n 3 NG A 2 1 B Front View 8 Cable Color Code Extension Cable with Connector STP EXT H 020 B 6 SureStep Stepping Systems User Manual E no m ro S15 gt mm o o z m o o TOOTH lz ANG 515 slo gt a essasssao SSXSSSOSGS 5 52 N gt U to UJ 6 6 6 6 6 8 6 S 9 En GE Nic 2D EN G N C DIR D 0 DIR G STEP STEP Step Motor STP MTR H xxxxx En K NIC EN G NIC DIR NG DIR 9 STEF STEP Step Moo STP MTR H XXXXX 12 mat Pigtail with Connector 12 2012 Fourth Edition Appendix B Using SureStep with AutomationDirect PLCs Typical DirectLOGIC 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 Ca
118. ugh overhauling load on the motor the DC voltage will go above the drive and or power supply limits This can trip the overvoltage protection of a switching power supply or a drive and cause it to shut down To solve this problem AutomationDirect offers a regeneration clamp and a braking resistor as optional accessories The regeneration clamp has a built in 50W braking resistor For additional braking power larger overhauling loads an optional 100W braking resistor is also available Block Diagram STP D RV xxxx STP DRVA RC 050 amp STP DRVA BR 100 xx VDC Power Supply match power supply V to drive Resistor optional iSTP DRVA BR 100 1100 100W STP DRV xxxx i Drive 2 optional STP DRV XXXX Drive 1 Regeneration Clamp Features STP D RVA RC 050 Built in 50W power resistor optional 100W resistor also available Mounted on a heat sink Voltage range 24 80 VDC no user adjustments required Power 50W continuous 800W peak Wire connection 6 pin screw terminal block 12 18 AWG wire Indicators LED Green power supply voltage is present Red clamp is operating usually when stepper is decelerating Protection The external power supply is internally connected to an Input Diode in the regen clamp that protects the power supply from high regeneration voltages This diode protects the system from connecting the power supply in reverse If the clamp cir
119. urrent 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 50 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
120. use 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 3 6 l SureStep Stepping Systems User Manual Fourth Edition 12 2012 Chapter 3 SureStep STP DRV 4035 Microstepping Drive Connecting the Logic Fourth Edition 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 motor driver from a different supply source than your control circuits There is no electrical connection between the two signal communication is achieved by infrared light When your circuit turns on or turns off an infrared LED built into the 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 Internal to the STP DRV 4035
121. ut Wiring for Encoder Following Appx B PLC connection diagrams 2nd Ed Rev E 02 2012 Appx B PLC connection diagrams Third Edition 09 2012 Ch 1 4 Added new STP MTR H xxxxx D dual shaft motors Fourth Edition 12 2012 Added new drive STP DRV 6575 amp accessories chapter renumberings lstEd RevA 8 26 04 BLANK PAGE TABLE OF CONTENTS w 1 0 20 0 50 2 2 0 Chapter 1 Getting Started 1 1 Manual Overview i4c0ce0 0aS ev kr a y RARE RA EA OA 1 2 Overview of this Publication a 1 2 Who Should Read this Manual 000000 e eee ees 1 2 Technical SUDDOFE 1552 295 2 0 0 Pci ND SAANG 1 2 Special SymbolS ao i316 nd n did oe o e drin dom dri NADA 1 2 SureStep System Introduction 0 cece eee ees 1 3 SureStep Part Number Explanation eee 1 3 SureStep System Recommended Component Compatibility 1 4 Microstepping Drives Introduction 00 eee eee 1 5 Standard Microstepping Drive ees 1 5 Advanced Microstepping Drive ccc cee 1 7 Bipolar Step Motor Introduction eee eee 1 8 Stepping System Power Supply Introduction 1 9 Selecting the Stepping System eee 1 10 Use with DiredtLOGIC PLCS 2222o2ueregene snes BABAE 1 10 Table of Contents ET Chapter 2 SureStep STP DRV 6575 Microstepping Drive eae 2 1 Kc

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