Chapter 3 - AutomationDirect
Contents
1. 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 Grm Wht A Grn Wht White eed White motor motor Green Green Bea 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 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 lead2. 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 o current of 2 2 Amps You need the base current of 0 4 Amps plus another 1 6 and 0 2 Amps 0 4 2 2 2 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 STP 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
3. 8 22 2 Dimensions in mm 3 16 l SureStep Stepping Systems User Manual Fourth Edition 12 2012
4. ea BIk Wht map ri motor X A a Black Black Rea Red Ye Yellow 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 fuse between the drive and power supply Install the fuse on the power supply lead Connect the motor power supply terminal to the driver terminal labeled VDC Connect power supply to the drive terminal labeled VDC Use no smaller than 18 gauge wire Be careful not to reverse the wires Reverse connection will destroy your drive and void the warranty Step Motor Power Supply 12 42 VDC 8 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 D RV 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 C
5. 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 resolution push both switches toward the proper label For example if you want 1 10 step push switch 2 toward the 1 10 label to the left and push switch 3 toward 1 10 on the right Please refer to the table below and set the switches for the resolution you want 10 6 STEPS REV 18 1 50 400 J fase 18 2 000 2 ae STEPS REV 18 6 HALF Factory 1 000 2 18 10 000 Default STEPS REV 13 G STEPS REV efault 1 5 4 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
6. 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 Temperature 0 55 C 32 131 F recommended 70 C 158 F maximum use fan cooling if necessary 90 non condensing maximum humidity Agency Approvals 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
7. 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 current At lesser loads like when the motor is not moving the actual voltage can be up to 1 4 times the voltage list on the power supply label The STP PWR 3204 power supply is designed to provide maximum voltage approximately 32 VDC while under load without exceeding the upper limit of 42 VDC when unloaded Current The maximum supply current you will need is the sum of the two phase currents However you will generally need a lot less than that depending on the motor type voltage speed and load conditions That s because the SureStep drive uses switching amplifiers converting a high voltage and low current into lower voltage and higher current The more the power supply voltage exceeds the motor voltage the less current you ll need from the power supply We re
8. 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 3 and Self Test Logic Connector STEP DIR EN 3 4 l 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 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 pa at Note All AutomationDirect SureStep Motors are four lead bipolar step motors
9. SURESTEP STP DRV 4035 MICROSTEPPING DRIVE In This Chapter P eon AeA Sees 3 2 Block DIO daan hom AKNG NG cade ae eh Dale cece 3 2 Specifications AA 3 3 Typical Wiring Diagram lt zumba na sates 6 MANA chews 3 4 Connection and Adjustment Locations 3 4 Connecting the Motor 4 gt 2 22 0 0 4 4 seve eeee EL WA KA 3 5 Connecting the Power Supply 4 3 6 Connecting the Logic ccc ees 3 7 Using Logic That is Not 5 volt TTL Level 3 9 The Enable Input mh Kan PB dene Gm KAKA 3 9 Setting Phase Current 7777 3 10 Current Setting 3 10 Current Setting Table 00 0a 3 11 Vilege ia ola CRETE PSP PEPE 3 12 Idle Current Reduction 44 makaawa 8208 a tadsdons 3 13 COW NE 2 2 00 20 200205000 294 3 13 Choosing a Power Supply mawa mamaw 04 3 14 Mounting the Drive 4 sawa RAE 240 fe tandseens 3 15 Dimensions 2 2 26 vee 4 bad Ree ha 3 16 Chapter 3 SureStep STP DRV 4035 Microstepping Drive ET Features e Drives sizes 17 through 34 step motors Pulse width modulation MOSFET 3 state switching amplifiers Phase current from 0 4 to 3 5 amps switch selectable 32 settings Optically isolated step direction and enable inputs e Half 1 5 1 10 1 50 step switch selectable Automatic 50 idle current reduction can be switched off Block Diagram STP DRV 4035 Conne
10. 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 motor label The SureStep drive current is easy to set If you wish you can learn a simple formula for setting current and never need the manual again Or you can skip to the table on the next page find the current setting you want and set the DIP switches according to the picture Current Setting Formula Locate the bank of tiny switches near the motor connector Five of the switches DIP switch positions 5 9 have a value of current printed next to them such as 0 1 0 2 0 4 0 8 and 1 6 Each switch controls the amount of current in amperes A that its label indicates in addition to the minimum current value of 0 4 Amps There is always a base current of 0 4 Amps even with all five DIP switches set to the off position away from their labels To add to that
11. commend 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 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 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 Microst
12. ctto a 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 power 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
13. epping 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 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 0 125 1 50 2 50 03 2 gt 38 1 gt oe gt 63 5 S 4 2x 0 125 03 2 3 70 3 75 4 00 94 0 95 3 101 6 0 25 0 6 4 7 0 15 6 4 0 875 3
14. epping 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 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 e 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
15. 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 shooting If you are unsure about the motor or signal connections to the drive or if the SureStep drive isn t responding to your step pulses you can turn on the self test To activate the self test slide switch 1 toward the TEST label The drive will slowly rotate the motor 1 2 revolution forward then 1 2 rev backward The pattern repeats until you slide the switch away from the TEST label The SureStep drive always uses half step mode during the self test no matter how you set switches 2 and 3 The self 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
16. onnecting 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 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 PNP or differential On the next couple of pages are examples for connecting various forms of outputs from both indexers and PLCs 12 2012 SureStep St
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