STAC6_Hardware_Manual_920 0029
Contents
1. Status INPUT1 INPUT2 INPUTS INPUTA INPUTS INPUT6 INPUT7 INPUT8 OUT1 OUT2 OUT3 OUT4 ANALOG IN 920 0029 5 2 2012 STAC6 Hardware manual Block Diagram STAC6 S STAC6 Q STAC6 QE STAC6 S 220 5 6 0 220 5 6 QE 220 120 VAC 160 X1 STEP X2 DIR X3 ENABLE X4 ALMRST X5 X6 CCWLIM X7 CWLIM Y1 FAULT Y2 MOTION Status ANALOG IN PC MMI INPUT1 INPUT2 INPUT3 INPUT4 5 INPUT6 INPUT7 INPUT8 OUT1 OUT2 OUT3 OUT4 RS485 422 220 VAC for STAC6 220 320 VDC for STAC6 220 ANALOG IN QE ONLY 920 0029 5 2 2012 STAC6 Hardware manual Block Diagram STAC6 C and STAC6 C 220 120 VAC 160 VDC X1 STEP X2 DIR X3 ENABLE X4 ALMRST X5 X6 CCWLIM X7 CWLIM Y1 FAULT Y2 MOTION Status 1 encoder ANALOG IN for Setup Only CAN2 0b 220 VAC for STAC6 220 320 VDC for STAC6 220 920 0029 Rev 5 2 2012 STAC6 Hardware manual Motion Control Options 5 6 5 Control Options Basic drive Analog digital and host command input e Pulse amp Direction A B Quadrature CW CCW Pulse e Velocity Oscillator Mode e Host command execution of SCL commands for control from a host PC or PLC using RS 232 or RS 485 serial communication e Compati2. ssssssssseneeenees 37 Connecting Digital Inputs on the IN OUT2 af Connecting Digital Outputs on the IN OUT2 42 Connecting Analog Inputs on the IN OUT2 connector sse 44 Recommended T 45 Motor puta anite sd rase c tad 46 ius BEI PUO NN ERR E m ER 49 52 m m T 53 Technical NER 54 Mating Connectors and Accessories BE E ad 920 0029 5 2 2012 STAC6 Hardware manual This page intentionally left blank 920 0029 5 2 2012 STAC6 Hardware manual Safety Instructions Only qualified personnel are permitted to transport assemble commission and maintain this equipment Properly qualified personnel are persons who are familiar with the trans port assembly installation commissioning and operation of motors and who have the appropriate qualifications for their jobs The qualified personnel must know and observe the following standards and regulations IEC 364 resp CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4 To minimize the risk of
3. us switch or relay 5 closed logic low Supply C 2 25 00 Use normally open momentary switch to trigger drive using Wait Input instruction Use single throw switch for parameter selection using If Input instruction Use normally open momentary switch for jogging 920 0029 Rev 5 2 2012 STAC6 Hardware manual Connecting another Si Drive When output closes drive input goes low Connecting an NPN Type Proximity Sensor to an input Proximity Sensor When prox sensor activates drive input goes low 920 0029 5 2 2012 STAC6 Hardware manual Differential Inputs The IN OUT2 connector also includes two differential optically isolated input circuits that can be used with sourcing or sinking signals 12 to 24 volts They are labeled IN7 and IN8 These inputs allow connection to PLCs sensors realys and mechanical switches Because the input circuits are isolated they require a source of power If you are connecting to a PLC you should be able to get power from the PLC power sup ply If you are using relays or mechanical switches you will need a 12 24 V power supply This also applies if you are connecting the inputs to the programmable outputs of another Si product from Applied Motion 5 24 VDC SUPPLY Connecting a Mechanical Switch to a Differential Input
4. 41 2200 X6 CCW LMT Wiring a Mechanical Limit Switch You can use normally open or normally closed limit switches Either way wire them as shown here 12 24 VDC SUPPLY o a7ewImT TACS Stepper 6 X6 CCW LMT 1 920 0029 Rev 5 2 2012 STAC6 Hardware manual Wiring a Limit Sensor Some systems use active limit sensors that produce a voltage output rather than a switch or relay closure These devices must be wired differently than switches If your sensor has an open collector output or a sinking output wire it like this 5 6 output Sensor If the sensor output goes low at the limit select the option closed in the software If the output is open or high voltage choose open Other sensors have sourcing outputs That means that current can flow out of the sensor output but not into it In that case wire the sensor this way T output Sensor STAC6 1 Stepper ft Se 920 0029 Rev 5 2 2012 STAC6 Hardware manual Connecting Digital Outputs on the IN OUT1 connector IN OUT 1 Front View Analog IN 1 BRAKE 2 MOTION FAULT Y COMMON 5V OUT GND X6 CCW Limit X5 X4 Alarm Reset X3 Enable X COMMON X2 DIR X2 DIR X1 ST
5. 23 553 HT23 554 250 200 150 oz in 100 50 920 0029 Rev C 5 2 2012 920 0029 5 2 2012 STAC6 Hardware manual Torque Speed Curves HT34 495 496 497 STAC6 120 Step resolution 1 100 20 000 s r 1600 1400 1200 1000 800 oz in 600 400 200 rps HT34 495 496 497 STAC6 220 Connection series Step resolution 1 100 20 000 s r HT34 495 34 496 HT34 497 1600 1400 1200 1000 800 2 600 400 200 Torque Speed Curves STAC6 Hardware manual HT23 548 549 550 STAC6 120 Connection series Step resolution 1 100 20 000 s r HT23 548 23 549 HT23 550 250 200 150 oz in 100 50 rps HT34 488 489 490 STAC6 120 Connection series Step resolution 1 100 20 000 s r 134 488 34 489 HT34 490 1600 1400 1200 1000 800 oz in 600 400 200 0 50 920 0029 Rev C 5 2 2012 920 0029 Rev 5 2 2012 STAC6 Hardware manual Mounting the Drive You can mount your drive on the
6. Le 285 1 e 73 02 0 05 1 12 04 8 5 350 330 2 875 002 1 52 062 218 THRU C gt Ll 0 12 70 0 013 i 2 5000 0000 4 BS 1950 E IB EN 2 1 1 1 4 1 0 1 3 175 0 05 125 000 1254 000 o LiAl 0 M 7 9 525 0 013 31 75 0 5 Aare 3 304 0000 0251 02 77 555 000 77 86 0 5 _ 017 3480 3 384 02 MOTOR BE SHIPPED 2 1 370 WITH 1 8 X1 8 843 69 6 0 3 KEY TAPED TO SHAF 2X 2 742 01 2 4 40 UNC 5 2 DEEP 180 APART ON A 946 02 1 812 B C 920 0029 5 2 2012 STAC6 Hardware manual HT34 Motors cont Shaft Detail 1 motor with 0 5 shaft 1 25 02 2 500 0000 He Shaft Detail 2 motors with 0 625 shaft 875 010 0 6250 0000 Ki 875 010 1 25 02 705 STAC6 Hardware manual Torque Speed Curves 23 552 553 554 5 6 120 Connection parallel Step resolution 1 100 20 000 s r HT23 552 HT23 553 23 554 250 200 150 oz in 100 50 rps HT23 552 553 554 STAC6 220 Connection series Step resolution 1 100 20 000 s r HT23 552
7. STACG Hardware Manual STAC6 S STAC6 S 220 STAC6 Q STAC6 Q 220 STAC6 QE STAC6 QE 220 6 1 STAC6 Si 220 5 6 STAC6 C 220 Applied Motion Products 920 0029 Rev C 5 2 2012 920 0029 Rev 5 2 2012 STAC6 Hardware manual Contents Safety o cesa pP GRE lg dnt RC 4 sean otii meti ug E catene esl es etus bcne pnta 5 Block aca ME M EE 6 idu eben nantan eea achte deiade bte binaire 9 ie ct 10 Connecting to the PC USING RS 232 11 Connecting to the PC USING 85 285 12 Connecting to the CANopen NetWork usui tonta esses eee 15 Connecting AG oem e t OE tau 17 18 Connecting Other aa iot 20 EMCO N itai 22 Wiring Inputs and Outputs 24 Connecting Digital Inputs on the IN OUT1 25 Connecting Digital Outputs on the IN OUT1 33 Connecting Analog Inputs on the IN OUT1 connector sse 35 Connecting Inputs and Outputs to IN OUT2
8. settings match those of your drive Click on the Motion button then select the SCL operating mode If you have Q drive you may want to select Q Programming Either way you ll see the RS 485 Address pane appear Just click on the address character of your choice You can use the numerals 0 9 or the spec ial characters amp lt gt Just make sure that each drive on your network has a unique address If you are using a 2 wire network you may need to set the Transmit Delay too 10 milliseconds works on the adapters we ve tried Once you ve made your choices click Download to save the ettings to your drive 920 0029 Rev C 5 2 2012 STAC6 Hardware manual Connecting to the CANopen Network GND CAN_L SHLD CAN_H CANopen Connector The CANopen connector is a 4 pin spring lock type connector The CANopen network should be connected in a daisy chain fashion with a 120 ohm terminating resistor at each end of the network Please see the CANopen manual for more information Node ID Range m Node ID Range 0x01 0 0 10 01 O F 0x10 Ox1F 0 20 Ox2F 1 0x50 Ox5F 0x60 5F 0x70 7 4 OK Cancel 524 Node ID Switch Each node on a CANopen network must have a unique Node ID On the 5 6 this is set using both the Configurator software above left as well as the sixteen
9. 32 158 F HUMIDITY 9096 non condensing 920 0029 Rev 5 2 2012 STAC6 Hardware manual INPUTS AND OUTPUTS IN OUT 1 connector All Drives 7 Inputs 1 X2 Optically Isolated Differential 5 Volt Minimum pulse width 250ns Maximum pulse frequency 2 MHz Function Step amp Direction Encoder Following Sensor Home or Branch Select gt lt 99 Optically isolated 12 24V sourcing or sinking Function Motor Enable Sensor Home or Branch Select X3 X7 have shared common gt lt Optically isolated 12 24V sourcing or sinking Function Alarm Reset Sensor Home Branch Select X3 X7 have shared common gt lt O1 Optically isolated 12 24V Function Function general Purpose Input X3 X7 have shared common 6 7 Optically isolated 12 24V Function CW 4 CCW Limits Sensor Home or Branch Select 7 have shared common 3 Outputs lt Optical darlington 100mA max NPN sinking shared common with 2 amp Function Brake or general purpose programmable Optical darlington 30V 100mA max NPN sinking shared common with Y1 amp Function Motion tach or general purpose programmable Optical darlington 30V 100mA max NPN sinking shared common with Y1 amp Y2 Function Fault or general purpose programmable lt lt Analog Inputs Software selectable O 5V 5 0 10 10 RESOLUTION 12 bits with 10V
10. 1 green 0000000090 7 red 2 green 0000000090 8 red 1 green Error no alarm motor disabled no alarm motor enabled motor stall optional encoder only move attempted while drive disabled subroutine stack overflow Si only ccw limit cw limit subroutine stack underflow Si only drive overheating internal voltage out of range blank Q segment power supply overvoltage power supply undervoltage bad instruction in Si program over current short circuit motor resistance out of range open motor winding bad encoder signal optional encoder only serial communication error flash memory error internal voltage out of range Applied Motion Products Inc 404 Westridge Drive Watsonville CA 95076 Tel 831 761 6555 800 525 1609 www appliedmotionproducts com Fax 831 761 6544
11. a 120 ohm terminating resistor be connected between RX and RX at the farthest drive from the host to PC GND to PC RX 2 H TrH to PC TX to PC 5999909 990 RX TX GND RX TX GND RX TX GND Drive 1 Drive 2 Drive 3 Two wire systems transmit and receive on the same pair of wires The host must not only disable its transmitter before it can receive data it must do so quickly before a drive begins to answer a query The 920 0029 Rev 5 2 2012 STAC6 Hardware manual STAC6 drives include a transmit delay parameter that can be adjusted to compensate for a host that is slow to disable its transmitter This adjustment can be made over the network using the TD command or it can be set using the STAC Configurator software It is not necessary to set the transmit delay in a four wire system We recommend a 120 ohm terminating resistor be connected between the two transmit receive wires at the farthest drive from the host to PC GND to PC TX A to PC TX B 9999 GND RX GND RX TX GND Drive 1 Drive 2 Drive 3 RS 232 to RS 485 2 wire Converter Model 485 25E from integrity Instruments 800 450 2001 works well for converting your PC s RS 232 port to RS 485 It comes with everything you need Connect the adaptor s pin to the drive s TX and RX terminals Connect A to the drive s a
12. is present as standard on the Si version of the drive It is also standard on the QE version Connecting Digital Inputs on the IN OUT2 connector IN OUT 2 Digital Inputs Single Ended Inputs The STAC6 Si and STAC6 QE include single ended optically isolated input circuits that can be used with sourcing or sinking signals 12 to 24 volts The IN OUT 2 connector has 6 of these inputs IN1 IN6 These inputs allow connection to PLCs sensors relays and mechanical switches Because the input circuits are isolated they require a Source of power If you are connecting to a PLC you should be able to get power from the PLC power supply If you are using relays or mechanical switches you will need a 12 24 V power supply This also applies if you are connecting the inputs to the programmable outputs of another Si product from Applied Motion What is COM is an electronics term for an electrical connection to a common voltage Sometimes common means the same thing as ground but not always In the case of the STAC6 if you are using sourcing PNP input signals then you will want to connect COM to ground power supply If you are using sinking NPN signals then COM must connect to power supply 920 0029 5 2 2012 STAC6 Hardware manual N 1 INA A AAA 2200 AV oer 01106 a AAA 2200 AW CWJOG a
13. is present on Si and QE models High Speed Digital Inputs 5 6 drives include two high speed inputs called STEP and DIR They accept 5 volt single ended or differential signals up to 2 MHz Normally these inputs connect to an external controller STAC6 Hardware manual Connecting Digital Inputs on the IN OUT1 connector that provides step amp direction command signals You can also connect a master encoder to the high speed inputs for follow ing applications Or you can use these inputs with Wait Input If Input Feed to Sensor Seek Home and other such commands Connection diagrams fo Indexer with Sourcing Outputs Connecting to indexer with Sourcing Outputs Indexer with Sinking Outputs low Connecting to Indexer with Sinking Outputs STEP STEP 920 0029 Rev C 5 2 2012 5 inside drive c 111 amp _ vow 2 5 6 Drive IN OUT 1 920 0029 5 2 2012 STAC6 Hardware manual with CDIR CDIR gt Differential Outputs STEP STEP mE oF Connecting to Indexer with Differential Outputs Many high speed indexers have differential outputs Master L Encoder lt Wiring for Encoder Following Encoder power can be supplied from the 5V OUT terminal on IN OUT 1 if the encoder requires no more t
14. read back to the Host using the IA immediate type and RA buffered type Host commands See Host Command Reference for more information 5 volt DC is provided for powering potentiometers A 1000 to 10000 ohm potentiometer is recommended A 0 to 5 volt analog signal may also be used Usually this signal comes from PLC a PC with data acquisi tion card or a motion controller Connections are shown below The 5V terminal is an output Do not connect it to a power supply 0 5V speed signal signal return Connecting an Analog Input to an Active Signal 920 0029 Rev 5 2 2012 STAC6 Hardware manual Recommended Motors Applied Motion offers 12 recommended motors for use with the STAC6 drives All 12 of these motors are recommended for use with the STAC6 120 drives but the connection to the drive should be series or parallel depending on the motor See the Connecting the Motor section for details 6 of these motors are recommended for the STAC6 220 drives These motors have their characteristics stored in the STAC Configurator software making it easy to setup and configure them For reference below is additional information about these motors All recommended STAC6 motors have 10ft shielded cables which act as part of the over current protection circuit See Over Current Protection section earlier in this manual for details Recommended Motors NEMA 23 5 6
15. signal range 11 bits with O 10V or 5V signal range 10 bits with O 5V signal range OUT 1 4 Optical darlington 30V 100mA max sinking or sourcing Function general purpose programmable 1 Analog Input O 5VDC analog input for use with Q or SCL applications only 920 0029 5 2 2012 STAC6 Hardware manual Mating Connectors and Accessories Mating Connector Type Included with Drive Additional Recommended Phoenix Contact 1757048 Motor 5 position screw terminal 1792786 AC Power 3 screw Phoenix Contact 1832426 terminal Phoenix Contact 1767012 1832536 RS485 Logic 3 position screw terminal Phoenix Contact 1827622 Norcomp 171 025 103L001 connector IN OUT1 DB 25 male Mouser 40 9725HS shell kit Norcomp 171 025 203L011 connector IN OUT2 DB 25 female Mouser 40 9725HS shell kit Norcomp 180 015 102 001 con Encoder HD 15 male nector 5 748678 1 shell kit Accessories Breakout Box for DB 25 Connectors BOB 1 includes cable connects to IN OUT 1 BOB 2 includes cable connects to IN OUT 2 Screw Terminal Connectors that mate directly to the DB 25 connector on the front panel of the drive Phoenix Contact P N This connector is not available from Applied Motion You must purchase it from a Mating Cable for IN OUT2 connector with flying leads Black Box P N BC00702 This cable is not available from Applied Motion You must purchase it from Useful for custom wired applications Th
16. wide or the narrow side of the chassis using 6 screws If possible 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 other devices cause the surrounding air to be more than 55 Never put the drive where it can get wet or where metal or other electrically conductive particles can get on the circuitry Always provide air flow around the drive When mounting multiple STAC6 drives near each other maintain at least one half inch of space between drives STAC6 Hardware manual Mechanical Outline IN OUT 1 AC Power 920 0029 Rev C 5 2 2012 25 7 345 920 0029 Rev 5 2 2012 STAC6 Hardware manual Technical Specifications POWER AMPLIFIER SECTION AMPLIFIER TYPE MOSFET Dual H Bridge 4 Quadrant CURRENT CONTROL 4 state PWM at 20 Khz OUTPUT CURRENT STAC6 0 5 6 0 amps in 0 01 amp increments 6A peak of sine STAC6 220 0 5 3 2 amps in 0 01 amp increments 3 2A peak of sine POWER SUPPLY STAC6 Line Operated Nominal 120 VAC 50 60 Hz STAC6 220 Line Operated Nominal 220 VAC 50 60 Hz AC INPUT VOLTAGE 5 6 94 135VAC 50 60Hz STAC6 220 94 265VAC 50 60Hz PROTECTION Over voltage under voltage over temp external outp
17. you to the problem 920 0029 Rev 5 2 2012 STAC6 Hardware manual Encoder Feedback Options The following encoder feedback options are configured and enabled using the STAC Configurator soft ware Stall Detection continuously compares the actual motor position as reported by the encoder against the theoretical motor position If the motor lag reaches 7 2 mechanical degrees behind the target position a position fault occurs This includes a motor at rest being driven out of position by an external force Stall Prevention can prevent many stalls before they occur The STAC6 achieves this by using the encoder to monitor the lead angle of the motor a measure of torque utilization If the motion profile begins to demand more torque than the motor can produce the velocity is automatically reduced before the motor stalls To engage stall prevention simply check the Stall Prevention box in the STAC Contigurator software and enter the maximum torque utilization you want to allow In the event that the motor cannot move at all such as hitting a hard stop you may want to fault the drive after a given amount of time by checking the Hard Stop box and entering a time limit 920 0029 5 2 2012 Wiring Inputs and Outputs STAC6 Hardware manual The 5 6 drives come with a number of inputs and outputs for interfacing to external control hardware High speed digital inputs for step amp directio
18. 0029 Rev 5 2 2012 Motor Dimensions HT23 Motors 470 10 MIN 2X 44 40 UNC TAP THRU EQ SP ON A 919 05 B C a 2 x 4 40 UNC ON 01 82 BCD 2X 2 56 UNC TAP THRU 180 APART ON A 019 05 15 50 2 4 8 0 3 1 60 2 I 15 40 2 1 73971 1 16 1 2X 2 56 UNC TAP THRU EQ SP ON A 932 5 B C 120 0 5 STAC6 Hardware manual 220V MOTORS DO NOT HAVE A CONNECTOR AND BOOT 0 771 96 35 0 013 accel 2 0 5 X 45 2 1 856 38 1 0 05 0 2 4 95 110 2x i Ht 2X 47 14 0 20 5 8 401 2X 28 2 2 56 4 920 0029 5 2 2012 STAC6 Hardware manual Motor Dimensions HT34 Motors 220V MOTORS DO NOT HAVE A CONNECTOR AND BOOT 4x 2X 2 56 UNC 5 2 DEEP ONA 011 28 32 5 B C 2X 84 40 5 2 DEEP 180 3 38 9246 02 1 812
19. 120 5 6 220 Motor Part No Drive Current Setting Drive Current Setting RET breed rem Connection amps phase Connection amps phase HT23 548 series 1 50 do not use 84 4 1 70E 03 1 71 43 5 HT23 549 series 1 50 do not use 167 4 25E 03 2 17 55 HT23 550 series 1 80 do not use 255 6 80E 03 3 05 77 5 HT23 552 parallel 1 50 series 0 75 84 4 1 70E 03 1 71 43 5 HT23 553 parallel 1 50 series 0 75 167 4 25E 03 2 17 55 HT23 554 parallel 1 80 series 0 90 255 6 80E 03 3 05 77 5 Recommended Motors NEMA 34 5 6 120 STAC6 220 Front Shaft Motor Part No Torque Rotor inertia Length Diameter Drive Current Setting Drive Current Setting inch mm inch mm Connection amps phase Connection amps phase HT34 488 series 5 10 do not use 555 2 2 02 3 11 79 0 5 12 7 34 489 series 5 10 1110 4 53E 02 4 63 117 5 0 5 12 7 do not use HT34 490 series 5 80 1694 6 80E 02 6 14 156 0625 do not use i i 15 875 HT34 495 parallel 5 10 series 2 55 555 2 2 02 3 11 79 0 5 12 7 HT34 496 parallel 5 10 series 2 55 1110 4 53E 02 4 63 117 5 0 5 12 7 0 625 HT34 497 parallel 5 80 series 3 20 1694 6 80E 02 6 14 156 15 875 Note The Drive Current Setting shown here differs from the rated current of each motor because the rated current is RMS the drive current setting is peak sine If you are using a motor not listed here for best results set the drive current at the motor s rated current x 1 2 920
20. But the device to which you connect must have an RS 422 or RS 485 port ew GND Pin diagram is shown to the right Wiring diagrams can be found on this and the next S TX page We recommend the use of Category 5 cable It is widely used for computer net works it is inexpensive easy to get and certified for quality and data integrity 2 The 5 6 drives can be used with either two wire or four wire RS 485 implementations The connection can be point to point i e one drive and one host or a multi drop network one host and up to 32 drives Four wire systems utilize separate transmit and receive wires One pair of wires must connect the host computer s transmit signals to each drive s RX and RX terminals Another pair connects the and TX drive terminals to the host computer s receive signals A logic ground terminal is provided on each drive and can be used to keep all drives at the same ground potential This terminal connects internally to the DC power supply return V so if all the drives on the RS 485 network are powered from the same supply it is not necessary to connect the logic grounds You should still connect one drive s GND terminal to the host computer ground Four wire systems are better than two wire types because the host can send and receive data at the same time increasing system throughput Furthermore the host never needs to disable its transmitter which simplifies your software We recommend that
21. EP X1 STEP GND GND GND 5V OUT 12V OUT All 5 6 drives feature three digital outputs on the IN OUT 1 connector Y1 Brake controls an electric brake relay automatically releasing and engaging as the drive requires Y2 Motion indicates that the drive has achieved a desired goal such as a target position Y3 Fault closes when a drive fault occurs The red and green LEDs will flash an error code 14 inside 5 6 171 Lace Y Y3 FAULT Day d 7 47 Y2 MOTION Y These outputs can be used to drive LEDs relays and the inputs of other electronic devices like PLCs and counters These outputs can only sink current The COM terminal must be tied to power supply 920 0029 5 2 2012 STAC6 Hardware manual Diagrams of different connections follow Do not connect the outputs to more than 30VDC The current through each output terminal must not exceed 100 mA 5 24 VDC Power Supply 5 24 VDC Power Supply 920 0029 Rev 5 2 2012 STAC6 Hardware manual Connecting Analog Inputs on the IN OUT1 connector IN OUT 1 Front View Analog IN Analog IN Y1 BRAKE Y2 MOTION X7 CW Limit Jm Y3 FAULT X6 COW p Y COMMON X4 Alarm Reset Cur X3 Enable X COMMON X2 DIR X2 DIR X1 STEP 45V OUT 1 412V OUT GND All 5 6 drives have two analog input p
22. HT34 496 HT34 497 e Use with STAC6 120 drives and the following motors e HT23 548 HT23 549 23 550 e HT34 488 HT34 489 HT34 490 YELLOW a White Orange 8 T lead E Brown Sae Green lt A Red Black B B B Series Connected 920 0029 Rev C 5 2 2012 STAC6 Hardware manual Parallel connection e Do not use parallel connection with STAC6 220 drives e Use with STAC6 120 drives and the following motors e 23 552 HT23 553 HT23 554 e HT34 495 HT34 496 HT34 497 White YELLOW Brown 8 lead SHLD 0 motor pe range A Green B B 8 Leads Parallel Connected 920 0029 5 2 2012 STAC6 Hardware manual Connecting Other Motors We can t stress enough the wisdom in using one of the recommended motors We re not just trying to make money here we want your application to be successful and the odds of that are highest when you have a high quality motor whose torque rotor inertia and harmonic waveform content are precisely known Further more our motors include shielded cables to reduce electrical emissions and enhance safety and come with pre wired mating connectors which further reduces the risk of error If you do want to connect other motors here is some information that will help Four lead motors can only be connected one way Please follow the sketch below Red A 4 lead motor Blue Yellow White 4 Leads Six lead mot
23. OUT 1 connector and inputs IN1 ING on the IN OUT 2 connector This allows connection to PLCs sensors relays and mechanical switches Because the input circuits are isolated they require a source of power If you are connecting to a PLC you should be able to get power from the PLC power supply If you are using relays or mechanical switches you will need a 12 24 V power supply This also applies if you are connecting the inputs to the programmable outputs of another Si product from Applied Motion inside IN OUT1 com t 2200 AV 17 X3 ENABLE NVN 1 2200 XA ALRM RST 5 2200 A AW 3 2200 X7 CW LMT 41 2200 X6 CCW LMT T 920 0029 5 2 2012 STAC6 Hardware manual What is COM is an electronics term for an electrical connection to a common voltage Sometimes common means the same thing as ground but not always In the case of the STAC6 if you are using sourcing PNP input signals then you will want to connect COM to ground power supply If you are using sinking NPN signals then COM must connect to power supply Note If current is flowing into or out of an input the logic state of that input is low or closed If no current is flowing or the input is not connected the logic state is high or open Digital Input Connection Examples ee 12 24 VDC switch relay closed logic
24. STAC6 Hardware manual NPN Proximity Sensor Connecting a PNP Proximilty Sensor to a Differential Input 920 0029 Rev C 5 2 2012 920 0029 5 2 2012 STAC6 Hardware manual Connecting Digital Outputs on the IN OUT2 connector IN OUT 2 Digital Outputs The expanded 1 0 board adds four additional programmable outputs The outputs can be used to drive LEDs relays and the inputs of other electronic devices like PLCs and counters On the IN OUT 2 connector outputs both the collector and emitter terminals of each transistor are available on the connector pins This allows you to configure each output for current sourcing or sinking 2 0 12 La 21 Y i QW 0014 Diagrams of each type of connection follow 920 0029 Rev 5 2 2012 STAC6 Hardware manual Do not connect the outputs to more than 30VDC The current through each output terminal must not exceed 100 mA 12 24 VDC Power Supply 5 6 51 5 6 5 24 VDC Power Supply STAC6 Si STAC6 QE 5 24 VDC Power Supply Using output to control a relay 920 0029 5 2 2012 STAC6 Hardware manual Connecting Analog Inputs on the IN OUT2 connector IN OUT 2 Connecting to the Aux Analog Input Ain 1 The auxiliary analog input on the STAC6 IN OUT 2 connector can be
25. ble with SiNet Hub 8 and SiNet Hub 444 for multi axis Si programming STAC6 Q 5 6 0 Control Options Programmable drive Built in Q controller e Comprehensive single axis programming language Powerful feature set Complex motion and machine control Math functions Register manipulation Multi tasking Host interrogation interface while executing internal programs STAC6 QE comes with expanded 1 0 STAC6 Si Control Options Programmable Drive Built in Si indexer Easy to use Si Programmer software Graphical point and click format combines motion 1 0 and operator interface Stand alone operation Integrated Configurator for motor setup encoder setup and alarm history Easily integrates with other devices such as sensors PLCs etc Software and programming cable included STAC6 C Control Options Node Compliant to CANopen standards DS301 Supports the following DSP402 operating modes Profile Position Mode Profile Velocity Mode Homing Mode Additionally supports stand alone Q Programming with CANopen execution 920 0029 5 2 2012 STAC6 Hardware manual Getting Started This manual describes the use of 5 6 series of step motor drives What you need to know and what you must have depends on the drive model For all models you ll need the following 120VAC or 220VAC single phase power A compatible step motor see recommended motors section A small flat blade screwdriver
26. e there are deadly hazards that could possibility cause severe damage to health or the product n operation depending on the degree of enclosure protection the product can have bare components that are live or have hot surfaces Control and power cables can carry a high voltage even when the motor is not rotating 920 0029 Rev 5 2 2012 STAC6 Hardware manual e Never pull out or plug in the product while the system is live There is a danger of electric arcing and danger to persons and contacts e After powering down the product wait at least ten minutes before touching live sections of the equipment or undoing connections contacts screwed connections Capacitors can store dangerous voltages for long periods of time after power has been switched off To be safe measure the contact points with a meter before touching Be alert to the potential for personal injury Follow the recommended precautions and safe operating practices Safety notices in this manual provide important information Read and be familiar with these instructions before attempting installation operation or maintenance The purpose of this section is to alert users to possible safety hazards associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury and damage to the equipment Failure to observe these precautions could result in serious bodily injury damage to the equipment or ope
27. for tightening the connectors included A personal computer running Microsoft Windows 98 2000 NT Me XP or Vista or 7 The Applied Motion CD included If you ve never used a STAC6 drive before you ll need to get familiar with the drive and the set up software before you try to deploy the system in your application We strongly recommend the following 1 For S drives install the STAC Configurator software application from the CD For Q and QE drives install the STAC Configurator and Q Programmer software applications from the CD For Si drives install and use the S Programmer software for configuration and programming For C drives install the STAC Configurator and the CANopen Example Program software applications from the CD Q Programmer software may also be installed if needed Launch the software by clicking Start Programs Applied Motion Connect the drive to your PC with the programming cable Connect the drive to the motor Connect the drive to the AC power Apply power to the drive w 920 0029 Rev 5 2 2012 STAC6 Hardware manual Connecting to the PC using RS 232 Locate your computer within 8 feet of the drive e Your drive was shipped with a communication cable Plug the large end into the serial port of your PC and the small end into the jack on your drive Secure the cable to the PC with the screws on the sides CAUTION 1 Neve
28. han 100mA 920 0029 Rev 5 2 2012 STAC6 Hardware manual Using High Speed Inputs with 12 24 Volt Signals Most PLCs don t use 5 volt logic You can connect signal levels as high as 24 volts to the STEP and DIR inputs if you add external dropping resistors as shown below For 12 volt logic add 820 ohm 1 4 watt resistors For 24 volt logic use 2200 ohm 1 4 watt resistors WARNING The maximum voltage that can be applied directly to a high speed input terminal is 24 volts Never apply high voltage AC to an input terminal PLC with Sourcing Outputs PLC with Sinking Outputs Connecting to PLC with Sinking NPN Outputs Most PLC s use 24 volt logic 920 0029 5 2 2012 STAC6 Hardware manual direction switch 07 0 A 2200 run stop switch closed run 2200 Using Mechanical Switches at 24 Volts Standard Digital Inputs As we mentioned above the high speed STEP and DIR inputs are configured for five volt logic All other digital inputs are designed for operation between 12 and 24 volts DC This includes five inputs on the IN OUT 1 connector of all drives X3 X7 and the eight digital inputs on the IN OUT 2 connector of Si and QE drives only inputs IN1 IN8 Single Ended Inputs The STAC6 drives include single ended optically isolated input circuits that can be used with sourcing or sinking signals 12 to 24 volts This includes inputs X3 X7 on the IN
29. ins that can be used separately as two single ended analog inputs or together as one differential analog input Whether separate or together the maximum range that can be applied to these pins is 10V The analog input s can be used by the drive for a number of dedicated purposes for controlling the motor or can be used for general purpose analog input signals 4104 to 10V Signal The analog input can be used for Analog Velocity Mode Analog Positioning Mode Both of these modes use the analog input for commanding the stepper drive Other uses include using an analog signal to stop a move when using any of the Feed to Sensor type moves and waiting on an analog signal using the Wait on Input 920 0029 5 2 2012 STAC6 Hardware manual Basic Specifications The analog input can accept 10 Volts The input has an impedance of 20K ohms Because of the nature of the design the input will exhibit a 1 4V offset when not driven by an analog 80166 e Low source impedance is important for minimizing analog errors 100 ohms lower is recommended WARNING The analog input must be used with care It is not optically isolated and may operate improperly or could be damaged when system grounds are not compatible Connecting an Analog Input to a Potentiometer or Joystick 920 0029 Rev 5 2 2012 STAC6 Hardware manual Connecting Inputs and Outputs to IN OUT2 The IN OUT2 connector
30. is shielded cable has a DB 25 connector on each end You can cut off the female end to create a 6 foot DB 25 to flying lead cable It ll be easier to wire if you get the Recommended USB Adapter C drives only This adapter is not available from Applied Motion Products Note Prolific based USE serial adapters do not work with Vista 64 or Windows 7 64 bit operating systems Suggested adapters are Byterunner USB COMi M or Byterunner USB COM CBL or USB COMi USB Serial Adapters For 32 bit Windows operating systems Port Authority USB Serial DB9 Adapter from Cables ToGo com USB SW1301 from SewellDirect com USB 104 from Sewell Direct PCMCIA For 64 bit and 32 bit Windows operating systems Byterunner USB COM CBL or USB COMi USB Alarm Codes STAC6 Hardware manual 920 0029 Rev C 5 2 2012 In the event of an error the green LED on the main board will flash one or two times followed by a series of red flashes The pattern repeats until the alarm is cleared Code solid green flashing green 1 red 1 green 1 red 2 green i red 3 green 2 red 1 green Q9 000 2 red 2 green 90000 2 red 3 green 3 red 1 green 3 red 2 green 0900000 3 red 3 green 90000 4 red 1 green 0900000 4 red 2 green 0000000 4 red 3 green 0900000 5 red 1 green 0000000 5 red 2 green 0000000 6 red 1 green 090000000 red 2 green 0900000090 7 red
31. low Supply C 5 59 C 3 17 Connecting an Input to a Switch or Relay 920 0029 5 2 2012 Proximity Sensor STAC6 Hardware manual rr m Connecting an NPN Type Proximity Sensor to an input When prox sensor activates input goes low i 12 24 output VDC Proximity roximi Power Sensor Supply 1 Connecting a PNP Type Proximity Sensor to an input 920 0029 Rev 5 2 2012 STAC6 Hardware manual Connecting Limit switches to the STAC6 Drive The X7 CW LIMIT and X6 CCW LIMIT inputs are used for connecting end of travel sensors These inputs are differential which allows you to use signals that are sinking NPN sourcing PNP or differential line driver By connecting switches or sensors that are triggered by the motion of the motor or load you can force the motor to operate within certain limits This is useful if a program or operator error could cause damage to your system by traveling too far The limit inputs are optically isolated This allows you to choose a voltage for your limit circuits of 12 to 24 volts DC This also allows you to have long wires on limit sensors that may be far from the drive with less risk of introducing noise to the drive electronics The schematic diagram of the limit switch input circuit is shown below inside STAC6 IN OUT 1 Connector C X60M 20 3
32. n commands or encoder following 5V logic These inputs X1 STEP and X2 DIR are available on all models They can also be used to connect sensors and other types of devices Connections to these inputs can be sourcing sinking or differential Lower speed digital inputs for other signals 12 24 volt logic accepting sourcing sinking or differential signals All STAC6 models have 5 of these inputs on the IN OUT1 connector STAC6 QE and Si models only have a total of 13 of these inputs 5 on the IN OUT 1 connector and 8 on the IN OUT 2 connector Analog inputs for analog speed and positioning modes included on all drives Can be configured for 0 10V 0 5V 10V or 5V with or without offset The STAC6 QE and Si models have an extra analog input rated at 0 5VDC for use in SCL and Q applications only e Digital Outputs rated at 30V 100mA There are three outputs on IN OUT1 which is present on all models STAC6 QE and Si models only have an additional 4 digital outputs on the IN OUT2 connector Connector Pin Diagrams IN OUT 1 Front View Analog IN Analog IN M MOTION 7 CW Limit FAULT X6 COW E Y COMMON X4 Alarm Reset 7 X3 Enable X COMMON X2 DIR X2 DIR4 X1 STEP 5V OUT X1 12V OUT IN OUT1 connector this connector is present on all models IN OUT 2 Out 4 Out 4 Out 3 Out 3 Out 2 Out 2 Out 1 Out 1 Ain Com C Ain 1 45V IN OUT2 connector this connector
33. nd RX terminals Converting USB to RS 485 The USB COMi M from is an excellent choice for USB to RS 485 conversion It can be used with 2 wire or 4 wire systems For two wire RS 485 set SW1 to ON and SW2 4 to OFF On the USB COMi M screw terminal connector Pint goes to RX and TX Connect pin 2 to RX and Pin 6 is ground The DB 9 is not used For four wire RS 485 set SW1 3 4 to ON and SW2 to OFF On the USB COMi M screw terminal connector USB COMi M 5 6 Drive pin 1 RX pin 2 3 4 6 920 0029 Rev 5 2 2012 USB Note Sugg STAC6 Hardware manual 0 1 Switch Settings 4 Wire 2 Wire RS 232 Nudus f 17 2 j ad 2 J 223 000 18500 OBA Prolific based USB serial adapters do not work with Vista 64 Windows 7 64 bit operating systems ested adapters are Byterunner USB COMi M or Byterunner USB COM CBL Assigning Addresses in Multi axis Systems Before wiring the entire system you ll need to connect each drive individually to the host computer so that a unique address can be assigned to each drive Use the programming cable and the STAC Configurator software that came with your drive for this purpose Conn have tor ect the drive to your PC then launch STAC Configurator Finally apply power to your drive If you already configured your drive then you should click the Upload button so that the STAC
34. ors can be connected series 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 3096 less than the rated current to prevent overheating Winding diagrams for both connec tion methods are shown below NC means not connected 2 Grn Wht 2 Grn Wht Whit 42 icd motor motor Red Red Wht Red Black B NC B B B NC 6 Leads Series Connected 6 Leads Center Tap Connected 920 0029 5 2 2012 STAC6 Hardware manual Eight lead motors can also be connected in two ways series and parallel As with six lead motors series operation gives you less torque at high speeds but may result in lower motor losses and less heating series operation the motor should be operated at 30 less than the unipolar rated current The wiring diagrams for eight lead motors are shown below Orange A Orange A BIK Wht Org Wht 8 di 8 lead lead BIK Wht Org motor motor Wit A Black Black Yel Red low Red Red lye Yellow Yel 8 Leads Series Connected 8 Leads Parallel Connected 920 0029 5 2 2012 STAC6 Hardware manual Connecting an Encoder The motors recommended for use with STAC6 drives are available with rear shaft mounted encoders Note remember to always order a double shaft motor if yo
35. position hardware switch on the front of the drive above right CANopen Node IDs are seven bits long with a range of 1 127 or 0x01 Ox7F in hexadeci mal notation The lower four bits 0x0 0xF are set using the hardware switch and the upper three bits 0 0 0x7 are set using Configurator A Node ID of 0x39 for example may be set by turning the switch on the drive to 9 and setting the Configu rator software to a range of 0x30 Ox3F 920 0029 5 2 2012 STAC6 Hardware manual Bit Rate Switch The CANopen network bitrate is set by the rotary switch on the front of the drive The bitrate must be the same for all nodes on the CANopen network The table below shows the various bitrates supported by Applied Motion Products and their corresponding switch settings Please note any changes to the bitrate require either a powercycle or a CANopen reset command to take effect 920 0029 5 2 2012 STAC6 Hardware manual Connecting AC Power Using the connector supplied connect to the AC supply per the diagram below Use 16 AWG wire for Line L and Neutral Use 14 AWG for Earth Ground Care should always be taken when working with high voltages In regions where the single phase supply is higher an auto transformer can be used to drop the voltage to the correct level Fusing The STAC6 contains an internal 8A fast acting fuse The STAC6 220 contains an in
36. 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 it is your responsibility to determine which codes should be followed and to verify that the equipment installa tion and operation are in compliance with the latest revision of these codes Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes and standards We do not guarantee the products described in this publication are suitable for your particu lar application nor do we assume any responsibility for your product design installation or operation Read all available documentation before assembly and commissioning Incorrect handling of products in this manual can result in injury and damage to persons and machinery Strictly adhere to the technical information on the installation requirements e t is vital to ensure that all system components are connected to earth ground Electrical safety is impos sible without a low resistance earth connection The 5 6 contains electrostatically sensitive components that can be damaged by incorrect handling Discharge yourself before touching the product Avoid contact with high insulating materials artificial fabrics plastic film etc Place the product on a conductive surface During operation keep all covers and cabinet doors shut Otherwis
37. r connect a drive to a telephone circuit It uses the same connectors and cords as telephones and modems but the voltages are not compatible 2 Drive ground and PC ground should be at the same potential Different ground potentials for the drive and PC can result in excessive current through the ground pin of the RS 232 port resulting in failure of the port If your PC does not have a serial port you should purchase a USB serial converter to convert one of your PC s USB ports into an RS 232 COM port For 32 bit Windows operating systems we have had good results with the Port Authority USB Serial DB9 Adapter from GablesToGo cor and with the SW1301 from Some laptops also have a PCMCIA slot in which case the SSP 100 from Sewell Direct is a good choice For 64 bit Windows operating systems namely Windows Vista 64 and Windows 7 64 the Prolific based adapters listed above do not work For these PCs we suggest the USB COMi M or USB CBL from Byterun ner com These adapters also work the 32 bit operating systems For USB choices refer to page 52 ground to PC ground RX to PC TX TX to PC RX No connection Pin Assignments of the Port RJ11 connector 920 0029 5 2 2012 STAC6 Hardware manual Connecting to the PC using RS 485 RS 485 allows you to connect more than one drive to a single host PC PLC HMI or other computer It also allows the communication cable to be long more than 1000 feet
38. rational difficulty Over Current Protection The STAC6 has hardware over current detection circuits that protect the drive against phase to ground and phase to phase motor shorts These circuits directly disable the amplifier in rapid fashion to prevent damage to the driver circuitry Typically the over current circuitry will react to an over current condition in 3 to 5 micro seconds For a short occurring in a motor the motor leads provide enough resistance and inductance to keep the peak current from exceeding the peak rating of the power transistors during this time period The recommended motors for the STAC6 all include 10 foot cables In essence the motor cable system is a part of the over current circuitry If the drive is directly shorted with a very short wire this condition may cause current conditions that exceed the peak current rating of our power transistors and therefore could weaken or cause failure in the drive power devices Repetitive short circuits also risk damage to the drive If a short circuit fault occurs please power off the drive and investigate carefully before restoring power 920 0029 5 2 2012 Block Diagrams Block Diagram STAC6 Si STAC6 Si 220 120 VAC X1 STEP X2 DIR X3 ENABLE X4 ALMRST 5 X6 CCWLIM X7 CWLIM Y1 FAULT Y2 MOTION Y3 BRAKE ANALOG IN RS485 422 220 VAC for STAC6 220 820 VDC for STAC6 220 EN STAC6 Hardware manual 160 VDC
39. ternal 3 5A slo blo time delay fuse If an external fuse is desired we recommend a fast acting fuse for the 120V STAC6 and a 5 amp fast acting fuse for the 220V version Line Filter For applications requiring CE EMC compliance Corcom 6ET1 line filter is required in series with the AC input Q Z BC POWER gt To Earth Ground gt To Neutral gt To Line Hot AC Power Plug 920 0029 5 2 2012 STAC6 Hardware manual Connecting the Motor Never connect or disconnect the motor while the power is on Note it is highly recommended that you use a motor with a shielded cable with the STAC6 The recommended Applied Motion motors for the STAC6 include shielded cables See the Recommended Motors section for a list of part numbers Note f you need a rear shaft on the motor for an encoder or otherwise make sure to add a D to the part number Example 23 5500 If your motor does not already have a connector attached or if you need to change the length of the cable please follow the illustrations below Be sure to connect the cable shield for safety and to minimize electrical interference Motors recommended for the STAC6 220 drives can also be used with 120V drives if they are wired in a parallel configuration See the diagram for parallel winding Series connection e Use with all STAC6 220 drives and the following motors e 23 552 HT23 553 23 554 e HT34 495
40. u need an encoder option The mating cables available for these encoders come with an HD 15 connector on one end that connects directly to the Encoder connec tor on the STAC6 and a mating connector on the other end that connects directly to the encoder Simply connect the cable between the encoder and the drive and you re done For applications where you might use your own encoder you ll need to connect to the STAC6 drive s encoder connector using the pin assignments below encoder 3 8 GND NC 9 2 encoder A encoder B 4 7 5VDC 200mA NC 10 1 encoder A encoder 7 5 6 encoder Z o G ol NC 15 11 NC 14 12 NC NC 13 If you are using an encoder with single ended outputs shame on you Differential connections are far less sensitve to electrical interference and life is too short to waste time deciphering the bizarre problems that can occur with a poor quality encoder That said single ended encoders should be connected to the and terminals Leave A and B unconnected They are internally biased to the proper voltage for best results You ll also need to select the single ended box in the Encoder button of STAC Configurator or the drive will think you have a broken encoder wire That s another good reason to use a differential encoder the STAC6 can detect a broken wire or bad signal and alert
41. ut shorts phase to phase phase to ground internal amplifier shorts IDLE CURRENT REDUCTION Reduction to any integer percent of full current after delay selectable in milliseconds MOTOR REGENERATION Built in regeneration circuit 25watts max CONTROLLER SECTION NON VOLATILE STORAGE Configurations are saved in FLASH memory on board the DSP Optically Isolated 5 Volt Minimum pulse width 200 ns Maximum pulse frequency 2MHz Raises the system damping ratio to eliminate midrange instability and allow stable Electronic Damping operation throughout the speed range and improves settling time speed torque ripple in the range 0 25 1 5 rps SELF TEST AND AUTO SETUP Checks internal amp external power supply voltages diagnoses open motor phases Measures motor parameters and configures motor current control and anti resonance gain settings MICROSTEP EMULATION Performs low resolution stepping by synthesizing fine microsteps from coarse steps COMMAND SIGNAL SMOOTHING Software configurable filtering reduces jerk and excitation of extraneous system resonances step amp direction mode only ENCODER OPTION Employs encoder hi or low resolution to provide failsafe stall detect and perform stall prevention and position maintenance Differential line receivers suitable for 500 kHz or greater Minimum encoder resolution is 1000 lines INTERFACE RS 232 and RS 485 CANopen standard on STAC6 C models AMBIENT TEMPERATURE O to 55
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