Automation Direct SureStep Owner's Manual

Stepping Systems

User Manual

Manual #: STP-SYS-M-WO

7th Edition, Rev D

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~ WARNING ~

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.

At a 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 the failure to follow all applicable codes and standards. We do not guarantee the products described in this publication are suitable for your particular application, nor do we assume any responsibility for your product design, installation, or operation.

Our products are not fault-tolerant and are not designed, manufactured or intended for use or resale as on-line control equipment in hazardous environments requiring fail-safe performance, such as in the operation of nuclear facilities, aircraft navigation or communication systems, air traffic control, direct life support machines, or weapons systems, in which the failure of the product could lead directly to death, personal injury, or severe physical or environmental damage (“High Risk

Activities”). AutomationDirect specifically disclaims any expressed or implied warranty of fitness for

High Risk Activities.

For additional warranty and safety information, see the Terms and Conditions section of our catalog.

If you have any questions concerning the installation or operation of this equipment, or if you need additional information, please call us at 770-844-4200.

This publication is based on information that was available at the time it was printed. At

AutomationDirect we constantly strive to improve our products and services, so we reserve the right to make changes to the products and/or publications at any time without notice and without any obligation. This publication may also discuss features that may not be available in certain revisions of the product.

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Copyright 2004-2022 – 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.

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AVERTISSEMENT

~

Nous vous remercions d’avoir acheté l’équipement d’automatisation de Automationdirect.com

® , en faisant des affaires comme AutomationDirect. Nous tenons à ce que votre nouvel équipement d’automatisation fonctionne en toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les autres publications pertinentes) avant de l’installer ou de l’utiliser.

Afin de réduire au minimum le risque d’éventuels problèmes de sécurité, vous devez respecter tous les codes locaux et nationaux applicables régissant l’installation et le fonctionnement de votre

équipement. Ces codes diffèrent d’une région à l’autre et, habituellement, évoluent au fil du temps. Il vous incombe de déterminer les codes à respecter et de vous assurer que l’équipement, l’installation et le fonctionnement sont conformes aux exigences de la version la plus récente de ces codes.

Vous devez, à tout le moins, respecter toutes les sections applicables du Code national de prévention des incendies, du Code national de l’électricité et des codes de la National Electrical

Manufacturer’s Association (NEMA). Des organismes de réglementation ou des services gouvernementaux locaux peuvent également vous aider à déterminer les codes ainsi que les normes

à respecter pour assurer une installation et un fonctionnement sûrs.

L’omission de respecter la totalité des codes et des normes applicables peut entraîner des dommages

à l’équipement ou causer de graves blessures au personnel. Nous ne garantissons pas que les produits décrits dans cette publication conviennent à votre application particulière et nous n’assumons aucune responsabilité à l’égard de la conception, de l’installation ou du fonctionnement de votre produit.

Nos produits ne sont pas insensibles aux défaillances et ne sont ni conçus ni fabriqués pour l’utilisation ou la revente en tant qu’équipement de commande en ligne dans des environnements dangereux nécessitant une sécurité absolue, par exemple, l’exploitation d’installations nucléaires, les systèmes de navigation aérienne ou de communication, le contrôle de la circulation aérienne, les équipements de survie ou les systèmes d’armes, pour lesquels la défaillance du produit peut provoquer la mort, des blessures corporelles ou de graves dommages matériels ou environnementaux («activités à risque élevé»). La société AutomationDirect nie toute garantie expresse ou implicite d’aptitude à l’emploi en ce qui a trait aux activités à risque élevé.

Pour des renseignements additionnels touchant la garantie et la sécurité, veuillez consulter la section

Modalités et conditions de notre documentation. Si vous avez des questions au sujet de l’installation ou du fonctionnement de cet équipement, ou encore si vous avez besoin de renseignements supplémentaires, n’hésitez pas à nous téléphoner au 770-844-4200.

Cette publication s’appuie sur l’information qui était disponible au moment de l’impression. À la société AutomationDirect, nous nous efforçons constamment d’améliorer nos produits et services.

C’est pourquoi nous nous réservons le droit d’apporter des modifications aux produits ou aux publications en tout temps, sans préavis ni quelque obligation que ce soit. La présente publication peut aussi porter sur des caractéristiques susceptibles de ne pas être offertes dans certaines versions révisées du produit.

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La présente publication peut contenir des références à des produits fabriqués ou offerts par d’autres entreprises. Les désignations des produits et des entreprises peuvent être des marques de commerce et appartiennent exclusivement à leurs propriétaires respectifs. AutomationDirect nie tout intérêt dans les autres marques et désignations.

Copyright 2004-2022 – Automationdirect.com

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Incorporated

Tous droits réservés

Nulle partie de ce manuel ne doit être copiée, reproduite ou transmise de quelque façon que ce soit sans le consentement préalable écrit de la société Automationdirect.com

® Incorporated.

AutomationDirect conserve les droits exclusifs à l’égard de tous les renseignements contenus dans le présent document.

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WARNING

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W arning : Read this manual thoroughly before using Sure Step™ Stepping System drives, motors, and power supplies.

W arning

: 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.

W arning

: 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.

W arning : Ground the Sure Step™ 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 & Component Layout” in the

Power Supply chapter.

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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 Date: 03/17/2022

Publication History

Issue Date Description of Changes

First Edition

1st Ed, Rev A

1st Ed, Rev B

7/28/04 Original

8/26/04

AC power fuse changed from 2A slow blow to 3A fast acting, plus other minor changes and corrections.

3/28/07

Second Edition 11/2008

Added wiring diagrams for both sink and source for indexers and PLCs with

12-24 VDC outputs. Also corrected value for r 4 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-PWR-4805, -4810, -7005

2 new drives: STP-DRV-4850, -80100

5 new motors: STP-MTR-17040, STP-MTRH-23079, -34066, -34097, -34127

2 new cables: STP-EXTH-020, STP-232RJ11-CBL

Other minor changes throughout.

2nd Ed, Rev A 06/2009 Advanced drives RS-232 communication port pin-out; pages 3-4 & B-7

2nd Ed, Rev B 09/2009 Advanced drives Digital Output max current rating; page 3-10

2nd Ed, Rev C 02/2011

2nd Ed, Rev D 11/2011

Ch 2,3: drive storage temperature specs

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

Ch 3: Connection Locations & Pin-out; 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 & accessories; chapter renumberings

Fifth Edition 07/2018

Manual update throughout for Integrated Motors/Drives additions. New

Chapter 5, 8, and 9 added.

Issue

Publication History, continued

Date Description of Changes

5th Ed, Rev A 10/2018 Addition of SureStep Encoders and NEMA 14 motors.

5th Ed, Rev B 01/2019 Addition of SureStep IP65 motors.

Sixth Edition 11/2019 Addition of AC drives and step motors.

Seventh Edition 04/2020 Addition of CUI encoders

7th Ed, Rev A 06/2020

Chapter 6: Update sourcing output connection diagram

Appendix B: Change serial connection diagram comm port from RJ12 to RJ11

7th Ed, Rev B 11/2020 Addition of Linear SureStep Actuators.

7th Ed, Rev C 06/2021 Addition of NEMA 42 MTRAC(H) motors.

7th Ed, Rev D 03/2022

Change of factory default for jumper S4 on STP-DRV-4845 and STP-DRV-6575 from 150kHz to 2MHz.

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Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . w–1

Chapter 1: Getting Started . . . . . . . . . . . . . . . . . . . . . . . 1–1

Manual Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Overview of this Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Who Should Read this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

Special Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–2

SureStep™ System Introduction . . . . . . . . . . . . . . . . . . . . . . . 1–3

SureStep™ Part Number Explanation . . . . . . . . . . . . . . . . . . . . . . . 1–3

SureStep™ System Recommended Component Compatibility . . . . 1–5

Drive and Motor Compatibility . . . . . . . . . . . . . . . . . . . . . . . . 1–6

Microstepping Drives Introduction . . . . . . . . . . . . . . . . . . . . . 1–9

Standard Microstepping Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–9

High Bus Voltage Microstepping Drives . . . . . . . . . . . . . . . . . . . . 1–11

Advanced Microstepping Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12

Standard Integrated Motors/Drives . . . . . . . . . . . . . . . . . . . . . . . 1–13

Advanced Integrated Motors/Drives . . . . . . . . . . . . . . . . . . . . . . . 1–14

Step Motor Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–15

Stepping System Power Supply Introduction . . . . . . . . . . . . . 1–16

Selecting the Stepping System . . . . . . . . . . . . . . . . . . . . . . . 1–17

Use with AutomationDirect PLCs . . . . . . . . . . . . . . . . . . . . . . 1–17

High-Speed Pulse Output Control (Standard Drives) . . . . . . . . . . 1–17

Serial Communication Control (Advanced Drives) . . . . . . . . . . . . 1–17

Chapter 2: SureStep STP-DRV-4830,-4845,-6575 Standard

DC Microstepping Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Table of Contents

Typical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

Wiring Connections and Configuration Switches . . . . . . . . . . . 2–5

STP-DRV-4830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5

STP-DRV-4845 and STP-DRV-6575 . . . . . . . . . . . . . . . . . . . . . . . . . 2–6

Connecting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–7

Connecting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 2–8

SureStep™ Drive Digital Inputs and Outputs . . . . . . . . . . . . . . . . . 2–9

Connecting the Input Signals: STEP and DIR . . . . . . . . . . . . . . . . . 2–9

Connecting the Input Signals – EN Input . . . . . . . . . . . . . . . . . . . 2–10

Connecting the Fault Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11

Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12

Drive Configurations Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–12

DIP Switch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–13

Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–16

Mounting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19

Drive Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19

Dimensions and Mounting Slot Locations . . . . . . . . . . . . . . . 2–19

STP-DRV-4830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19

STP-DRV-4845 and STP-DRV-6575 . . . . . . . . . . . . . . . . . . . . . . . . 2–20

Chapter 3: SureStep STP-DRV-4035 Microstepping Drive 3–1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–3

Typical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–4

Connection and Adjustment Locations . . . . . . . . . . . . . . . . . . 3–4

Connecting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–5

Connecting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–6

Connecting the Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–7

Using Logic That is Not 5 volt TTL Level . . . . . . . . . . . . . . . . . . . . 3–9

The Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–9

Setting Phase Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10

Current Setting Formula . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–10

Current Setting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–11

Microstepping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–12

Idle Current Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13

TC–ii SureStep TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Table of Contents

Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–13

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–15

Chapter 4: SureStep Advanced Microstepping Drives . . . 4–1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–3

Typical Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–4

Connection Locations & Pin-out . . . . . . . . . . . . . . . . . . . . . . . 4–4

Connecting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 4–6

Connecting the I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7

SureStep™ Drive Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–7

Connecting STEP and DIR to 5V TTL Logic . . . . . . . . . . . . . . . . . . 4–7

Connecting STEP and DIR to Logic Other Than 5V TTL Level . . . . . 4–8

Connections to the EN Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–9

Connecting the Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10

Connecting the Digital Output . . . . . . . . . . . . . . . . . . . . . . . . . . 4–10

LED Display Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–12

Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–15

Mounting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–17

Drive Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–17

Dimensions and Mounting Slot Locations . . . . . . . . . . . . . . . 4–17

Chapter 5: SureStep STP-DRVAC-24025 Microstepping Drive

5–1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–3

Mounting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–4

Wiring Connections and Configuration Switches . . . . . . . . . . . 5–5

STP-DRVAC-24025 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–5

Connecting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 5–6

Connecting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–7

Selecting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–8

Connecting the I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–9

Step/Direction Mode and CW/CCW Mode Jumper . . . . . . . . . . . . 5–9

Connecting the Input Signals - Step and Direction . . . . . . . . . . . . 5–9

7th Ed. Rev D – 03/17/2022

SureStep

TM

Stepping Systems User Manual TC–iii

Table of Contents

The Enable Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–10

Connecting the Fault Output Setting . . . . . . . . . . . . . . . . . . . . . . 5–11

Drive Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–12

Microstepping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13

Setting Running Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–13

Idle Current Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14

Step Noise Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14

Load Inertia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14

Smoothing Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–14

Self Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–15

Alarm Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–16

Chapter 6: SureStep Integrated Motors/Drives . . . . . . . . 6–1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

General Features: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

Standard Drive Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

Advanced Drive Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–3

Features Comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–4

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–5

Getting Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11

Installing Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11

Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–11

Additional Reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–12

Mating Connectors and Accessories . . . . . . . . . . . . . . . . . . . 6–12

Using a Regulated Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . 6–17

LED Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–18

STP-MTRD Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . 6–22

Input/Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–25

The Step (STEP) and Direction (DIR) Inputs . . . . . . . . . . . . . . . . . 6–26

The Enable (EN/IN3) Digital Input . . . . . . . . . . . . . . . . . . . . . . . . 6–28

The Analog (AIN) Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–29

The Digital Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–30

Using the Optional Encoder . . . . . . . . . . . . . . . . . . . . . . . . . 6–31

Configuring the Standard STP-MTRD . . . . . . . . . . . . . . . . . . 6–32

Drive/Motor Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–37

TC–iv SureStep TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Table of Contents

Torque Speed Graphs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–40

Dimensions and Mounting Slot Locations . . . . . . . . . . . . . . . 6–43

Chapter 7: SureStep Stepping Motors . . . . . . . . . . . . . . . 7–1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–2

Design and Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–4

Power Supply and Step Motor Drive . . . . . . . . . . . . . . . . . . . . 7–8

Mounting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8

Connecting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–8

Extension Cable Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 7–9

Connecting a STP-MTRAC-23x or STP-MTRAC-34x Motor . . . . . . 7–10

Connecting a STP-MTRAC(H)-42 Motor . . . . . . . . . . . . . . . . . . . . 7–11

Motor Dimensions and Cabling . . . . . . . . . . . . . . . . . . . . . . . 7–12

Typical Dimension & Cable Diagrams . . . . . . . . . . . . . . . . . . . . . 7–12

Typical Dimension & Cable Diagram for STP-MTRH . . . . . . . . . . 7–15

Typical Dimension & Cable Diagram for STP-MTRAC . . . . . . . . . 7–18

Typical Dimension & Cable Diagram for STP-MTRAC(H)-42x . . . 7–20

Torque vs . Speed Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–21

Chapter 8: SureStep Linear Actuators . . . . . . . . . . . . . . . 8–1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–2

Design and Installation Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

Model Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . 8–3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–4

Power Supply and Step Motor Drive . . . . . . . . . . . . . . . . . . . . 8–8

Mounting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8

Journal Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–8

Connecting the Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–10

Extension Cable Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . 8–10

Motor Dimensions and Cabling . . . . . . . . . . . . . . . . . . . . . . . 8–12

Thrust vs . Speed Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–16

Chapter 9: SureStep System Power Supplies . . . . . . . . . . 9–1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–3

Drive Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–4

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SureStep

TM

Stepping Systems User Manual TC–v

Table of Contents

Choosing a Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–5

Power Supply Terminal & Component Layout . . . . . . . . . . . . . 9–7

Mounting the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . 9–8

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–9

Dimensions (continued) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–10

Chapter 10: SureMotion Pro Configuration Software . . . 10–1

Sure

Motion™ Pro Software . . . . . . . . . . . . . . . . . . . . . . . . . 10–2

Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2

Motor Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–2

Motion and I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–3

Drive Pull-down Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–4

Chapter 11: SureStep Communications . . . . . . . . . . . . . 11–1

Connecting to a Host Using RS-485 . . . . . . . . . . . . . . . . . . . 11–2

Four-Wire Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–2

Two-Wire Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3

Assigning RS-485 Addresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–3

Connecting to an STP-MTRD-xxxxR using the STP-USB485-4W

Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11–4

Connecting to a drive using RJ12 . . . . . . . . . . . . . . . . . . . . . . . . . 11–5

Appendix A: Accessories . . . . . . . . . . . . . . . . . . . . . . . . . A–1

Braking Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2

Regeneration Clamp Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–2

Cables and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–5

Encoder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–10

Encoder Mounting Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . A–15

Encoder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–16

Differential Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . A–18

Wiring Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–19

Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A–24

Appendix B: Using SureStep with AutomationDirect PLCs B–1

Compatible AutomationDirect PLCs and Modules . . . . . . . . . . B–2

Typical Connections to a Productivity PLC . . . . . . . . . . . . . . . . B–6

Typical Connections to a DL05 PLC . . . . . . . . . . . . . . . . . . . . . B–7

Typical Connections to an H0-CTRIO . . . . . . . . . . . . . . . . . . . B–8

TC–vi SureStep TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Table of Contents

Typical Connections – Multiple Drives/Motors . . . . . . . . . . . . . B–9

Typical

Direct

LOGIC PLC RS-232

Serial Connections to an Advanced SureStep Drive . . . . . . . . B–10

Typical CLICK, P-Series, & BRX PLC RS-232

Serial Connections to an Advanced SureStep Drive . . . . . . . . B–11

Typical RS-485 Connections to

Integrated Motor/Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . B–12

Appendix C: Selecting the SureStep Stepping System . . . C–1

Selecting the SureStep™ Stepping System . . . . . . . . . . . . . . . C–2

The Selection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . 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–9

Step 3 – Determine the Motion Profile . . . . . . . . . . . . . . . . . . . . . . C–9

Step 4 – Determine the Required Motor Torque . . . . . . . . . . . . . . C–9

Step 5 – Select & Confirm the Stepping Motor & Driver System . C–10

Belt Drive – Example Calculations . . . . . . . . . . . . . . . . . . . . . C–15

Step 1 – Define the Actuator and Motion Requirements . . . . . . . C–15

Step 2 – Determine the Positioning Resolution of the Load . . . . . C–16

Step 3 – Determine the Motion Profile . . . . . . . . . . . . . . . . . . . . . C–16

Step 4 – Determine the Required Motor Torque . . . . . . . . . . . . . C–16

Step 5 – Select & Confirm the Stepping Motor & Driver System . C–17

Index Table – Example Calculations . . . . . . . . . . . . . . . . . . . . C–19

Step 1 – Define the Actuator and Motion Requirements . . . . . . . C–19

Step 2 – Determine the Positioning Resolution of the Load . . . . . C–19

Step 3 – Determine the Motion Profile . . . . . . . . . . . . . . . . . . . . . C–20

Step 4 – Determine the Required Motor Torque . . . . . . . . . . . . . C–20

Step 5 – Select & Confirm the Stepping Motor & Driver System . C–21

Engineering Unit Conversion Tables,

Formulae, & Definitions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . C–22

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Table of Contents

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PAGE

TC–viii SureStep TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

G

ettinG

S

tarted

C hapter

1

In This Chapter...

Manual Overview � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �1–2

Overview of this Publication � � � � � � � � � � � � � � � � � � � � � � � � � � � �1–2

Who Should Read this Manual � � � � � � � � � � � � � � � � � � � � � � � � � �1–2

Technical Support � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �1–2

Special Symbols � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �1–2

SureStep™ System Introduction � � � � � � � � � � � � � � � � � � � � � �1–3

SureStep™ Part Number Explanation � � � � � � � � � � � � � � � � � � � � �1–3

SureStep™ System Recommended Component Compatibility � �1–5

Microstepping Drives Introduction � � � � � � � � � � � � � � � � � � � �1–9

Standard Microstepping Drives � � � � � � � � � � � � � � � � � � � � � � � � � �1–9

High Bus Voltage Microstepping Drives � � � � � � � � � � � � � � � � � � �1–11

Advanced Microstepping Drive � � � � � � � � � � � � � � � � � � � � � � � � �1–12

Standard Integrated Motors/Drives � � � � � � � � � � � � � � � � � � � � � �1–13

Advanced Integrated Motors/Drives � � � � � � � � � � � � � � � � � � � � �1–14

Step Motor Introduction � � � � � � � � � � � � � � � � � � � � � � � � � � �1–15

Stepping System Power Supply Introduction � � � � � � � � � � �1–16

Selecting the Stepping System � � � � � � � � � � � � � � � � � � � � � �1–17

Use with AutomationDirect PLCs � � � � � � � � � � � � � � � � � � � �1–17

High-Speed Pulse Output Control (Standard Drives) � � � � � � � � �1–17

Serial Communication Control (Advanced Drives) � � � � � � � � � � �1–17

Chapter 1: Getting Started

Manual 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 the “notepad” icon in the left-hand margin, the paragraph to its immediate right will be a special note which presents information that may make your work quicker or more efficient.

When you see the “exclamation mark” icon in the left-hand margin, the paragraph to its immediate right will be a WARNING. This information could prevent injury, loss of property, or even death (in extreme cases).

1–2 SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 1: Getting Started

SureStep™ System Introduction

SureStep open-loop and inclusive position verification (semi-closed 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 AutomationDirect 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

Drives

STP- D R V - 6575

Component Capacity

2-digit max nominal voltage followed by

max current with 1 implied decimal place

4035: 40VDC, 3.5 A

4830: 48VDC, 3.0 A

4845: 48VDC, 4.5 A

4850: 48VDC, 5.0 A

6575: 65VDC, 7.5 A

80100: 80VDC, 10.0 A

24025: 120/240VAC, 2.5 A

Component Type

DRV: DC powered stepper drive

DRVAC: AC powered stepper drive

DRVA: drive accessory

Sure Step Series Designation: STP

Motors

STP- M T R x - 23079 x

Motor Shaft Type/Variant

blank: single shaft

D: dual shaft

E: encoder pre-mounted

W: IP65 (washdown)

Component Capacity

2-digit NEMA frame size followed by

approximate stack* length in mm

Component Type

MTRL: low-power DC stepper motor

MTR: high-power stepper motor

MTRH: higher-power stepper motor

MTRA: motor accessory

MTRAC: high-bus voltage stepper motor**

MTRACH: high-power high-bus voltage stepper motor

Sure Step Series Designation: STP

* The length of the motor that produces torque (not including shaft)

** NEMA 23/34 motors optimized for use with DRVAC drives

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Chapter 1: Getting Started

Power Supplies

STP- P W R - 3204

Component Capacity

2-digit output voltage followed by

output current

Component Type

PWR: power supply

Sure Step Series Designation: STP

Integrated Motors/Drives

STP- M T R D - 23042 x

Integrated Drive Type

blank: Standard

R: Advanced

V: Variable I/O

E: Encoder included

Component Capacity

2-digit NEMA frame size followed by

approximate stack* length in mm

Component Type

MTRD: integrated motor/drive

Sure Step Series Designation: STP

* The length of the motor that produces torque

Cables and Accessories

Part Number

STP-EXTx-xx

STP-DRVA-xx

Sure

Step Cables & Accessories

Description

Motor extension cable, xx = cable length in feet, x=H for high power, L for low power, W for IP65

Drive accessory, xx= accessory descriptor

STP-MTRA-xx Motor accessory, xx = accessory descriptor

Note: See Appendix A for the full range of SureStep accessories

1–4 SureStep

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Chapter 1: Getting Started

SureStep™ System Recommended Component Compatibility

Sure

Step Power Supply / DC Powered Drive Compatibility

Drive (1)(2)(4) Recommended Linear Power Supply (1)(2)(4)

Model Number

STP-PWR

-3024

STP-PWR

-4805

STP-PWR

-4810

STP-PWR

-7005(3)

STP-DRV-4035

12-32 VDC input (40V max)

STP-DRV-4830

12-48 VDC Input (48V max)

STP-DRV-4845

24-48 VDC Input (48V max)

STP-DRV-4850

24-48 VDC input (48V max)

STP-DRV-6575

24-75 VDC input (85V max)

STP-DRV-80100

24-80 VDC input (80V max)

STP-MTRD-17

12-48 VDC input

√

√

√

√

√

√

√

No

√

√

√

√

√

√

No

√

√

√

√

√

√

No

No

No

No

No

√

No

STP-MTRD-23, -24

12-70 VDC input

√ √ √ √

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.

3) An unloaded STP-PWR-7005 can float above the allowable input voltages of some drives if it is fed with a high AC input voltage (greater than 120VAC).

4) STP-DRV AC -x drives are AC powered and cannot be powered by DC power supplies. Please see

Chapter 5 for use of AC power drives and motors.

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Chapter 1: Getting Started

Drive (1)(2)(3)

Sure

Step Power Supply / Drive Compatibility

Recommended Switching Power Supply (1)(2)(3)

Model Number PSB12-xxxS PSB24-xxxS PSB48-xxxS

STP-DRV-4035

12-32 VDC input (40V max)

STP-DRV-4830

12-48 VDC Input (48V max)

STP-DRV-4845

24-48 VDC Input (48V max)

STP-DRV-4850

24-48 VDC input (48V max)

STP-DRV-6575

24-75 VDC input (85V max)

√

√

No

No

No

√

√

√

√

√

No

√

√

√

√

STP-DRV-80100

24-80 VDC input (80V max)

STP-MTRD-17

12-48 VDC input

No

√

√

√

√

√

STP-MTRD-23, -24

12-70 VDC input

√ √

1) Do NOT use a power supply that exceeds the drive’s input voltage range.

√

2) For best performance, use the lowest voltage power supply that supplies the required speed and torque.

3) STP-DRV AC -x drives are AC powered and cannot be powered by DC power supplies. Please see

Chapter 5 for use of AC power drives and motors.

Drive and Motor Compatibility

The following pages detail which SureStep drives are compatible with which

SureStep motors.

Bipolar Steppers are very universal in their compatibility. If you would like to use

SureStep motors with a different brand of drives (Leadshine, for example) or use

SureStep drives with other motors, you need to follow some basic guidelines:

1) Ensure the drive can supply enough phase current to meet the motor’s rated current. Example: we recommend STP-DRV-6575 (7.5 A max current) and STP-

DRV-80100 (10A max current) to drive the STP-MTRH-34xxxx motors (6.3 A rated current). Technically, a smaller drive can power a larger motor, but the motor will not be able to produce its rated torque.

2) Ensure the applied drive voltage does not exceed the design voltage for the stepper motor. SureStep MTR motors are designed to be driven with drive input voltages less than 75VDC. MTRAC/MTRACH motors can also be driven by these low voltages, but are wound so that they can take advantage of higher voltages

(110VAC or 220VAC drive input). The speed torque curves for high voltage input result in higher torque at much higher speeds. For a clear example, see the speedtorque curves for the NEMA 42 MTRAC/MTRACH motors. Compare the 24V torque curves for those motors vs the 160V curves. The higher voltage results in much higher speeds/torques.

1–6 SureStep

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Chapter 1: Getting Started

Sure

Step DC Drive / Motor Compatibility(3)

Motor (1) Recommended Drive (1)

Model Number(2)

STP-MTR L -14026x 0.35

STP-

STP-MTR L -14034x 0.8

EXT L -

0xx

√

√

√

√ √

√

√

–

–

–

–

STP-MTR-17040x 1.7

√ √ √ √ √ √

STP-MTR-17048x

STP-MTR-17060x

STP-MTR-23055x

2.0

2.0

2.8

STP-

EXTx-

0xx

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

√

STP-MTR-23079x

STP-MTR-34066x

2.8

2.8

√

√

√

√

√

√

√

√

√

√

√

√

STP-MTR H -23079x 5.6

STP-MTR

STP-MTR

H

H

-34066x

-34097x

6.3

6.3

STP-

EXT H x-

0xx

–

√

√

√

√

√

√

STP-MTR H -34127x 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.

MTRL motors have connectors compatible with the EXTL extension cables.

W-series motors have connectors compatible with the EXTW and EXTHW extension cables.

3) Not applicable to integrated motor/drives as drives and motors are already paired.

Sure

Step AC Motor/Drive Compatibility

STP-DRVAC-24025

Model Number

Series Wired Motor Parallel Wired Motor

STP-MTRAC-23044x

STP-MTRAC-23055x

STP-MTRAC-23078x

Yes

Yes

Yes

No

No

No

STP-MTRAC-34075x

STP-MTRAC-34115x

Yes

Yes

No

No

STP-MTRAC-34156x Yes No

Note: Always use series motor wiring with STP-DRVAC-24025. The drive has an internal voltage doubler circuit, so it will output a very high bus voltage if fed with 120VAC or 240VAC.

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Stepping Systems User Manual 1–7

Chapter 1: Getting Started

Sure

Step DC Drive / Motor Compatibility(3)

Motor Recommended Drive

Model Number

STP-MTRAC-42100x 8.4

STP-MTRAC-42151x 12

STP-MTRAC-42202x 12

STP-MTRACH-

12

42100x

STP-MTRACH-

42151x

STP-MTRACH-

42202x

1) Series wound only

16

16

4.2

6

6

6

8

8

6

9.4

9

8.5

11.3

11.5

STP-

EXT42-x

STP-

EXT42H-x

√ (1) √ (1) √ (1)

√

(1)

√ (1)

√ (1)

√

√

(1)

√ (1)

√ (1)

√ (1)

√

(1)

Note: The SureStep drives not listed on this table (STP-DRV-4035, STP-DRV-4830, STP-DRVAC-24025) do not supply enough current for the NEMA42 motors and will NOT work.

Unlike the smaller MTR motors, all 8 motor leads are available on the NEMA 42 motors. These motors can be wired in Bipolar Parallel, Bipolar Series, or Unipolar Series.

1–8 SureStep

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Chapter 1: Getting Started

Microstepping Drives Introduction

There are two different basic types of microstepping drives offered in the

SureStep™ series. DIP-switch configurable models with pulse inputs are available, as well as two software configurable advanced models with multiple operating modes. Descriptions of integrated motor/drives (a drive integrally attached to the motor) follow the drive-only section.

Standard Microstepping Drives

STP-DRV-4830, -4845, -6575

These SureStep™ standard microstepping drives use pulse input signals, and are configured with DIP switches on the drive. These are fully enclosed drives, not open frame. To use these drives in a step motor control system, you will need the following:

• A 24–48 VDC power supply for the STP-DRV-4830/4845 or a 24–75 VDC power supply for the STP-DRV-6575. SureStep STP-PWR-x linear power supplies or PSBx

Rhino regulated power supplies from AutomationDirect are good choices. If you decide not to use one of these recommended power supplies, then please read the section entitled “Choosing a Power Supply” in Chapter 8, “SureStep System Power

Supplies.”

• A source of step pulses. Signal may be sinking (NPN), sourcing (PNP), or differential.

• The step inputs can be CW/CCW or Step & Direction. CW and CCW are viewed from the end opposite the drive end of the motor (looking out of the shaft).

• A compatible step motor, such as an AutomationDirect SureStep STP-MTRx.

(Motor extension cables STP-EXTx are also available.)

• A small flat blade screwdriver for tightening the connectors.

STP-DRV-4830

STP-DRV-6575

STP-DRV-4845

Refer to the “SureStep STP-DRV-4830/4845/6575 Microstepping Drive” chapter of this user manual for complete details on the installation, configuration, and wiring of this drive.

7th Ed. Rev D – 03/17/2022

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Chapter 1: Getting Started

Standard Microstepping Drives (continued)

STP-DRV-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-PWR-3204 linear power supply from AutomationDirect is the best choice. If you decide not to use the STP-PWR-3204, please read the section entitled “Choosing a Power

Supply” in Chapter 7, “SureStep System Power Supplies.”

• 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.

• A compatible step motor, such as an AutomationDirect SureStep STP-MTRx.

(Motor extension cables STP-EXTx are also available.)

• A small flat blade or phillips screwdriver for tightening the connectors.

The STP-DRV-4035 standard microstepping drive is an open frame design.

STP-DRV-4035

Refer to the “SureStep STP-DRV-4035 Microstepping Drive” chapter of this user manual for complete details on the installation, configuration, and wiring of this drive.

1–10 SureStep

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Chapter 1: Getting Started

High Bus Voltage Microstepping Drives

STP-DRVAC-24025

These SureStep™ high bus voltage drives use pulse input signals, and are configured with DIP switches on the drive. These are fully enclosed drives, not open frame. To use these drives in a step motor control system, you will need the following:

• A 90-240 VAC single phase power source (there is a 115/230V voltage selector switch on the drive.

• A source of step pulses. Signal may be sinking (NPN), sourcing (PNP), or differential.

• The step inputs can be CW/CCW or Step & Direction. CW and CCW are viewed from the end opposite the drive end of the motor (looking out of the shaft).

• A compatible step motor, such as an AutomationDirect SureStep STP-MTRAC-

23x or STP-MTRAC-34x. The STP-MTRAC(H)-42x motors are not compatible with the STP-DRVAC-24025 (the motors can accept the high voltage, but the drive does not supply enough current).

NOTE: The drive always outputs a high bus voltage (~340V) that is compatible with our STP-MTRAC-x motors. This drive is not to be used with low-voltage STP-MTR-x motors. Always wire motors in series configuration with this drive. When supplied

115VAC, the drive has an internal voltage doubler, so the output voltage could be near 340V peak (whether supplied 115VAC or 230VAC).

Refer to “Chapter 5: SureStep STP-DRVAC-24025 Microstepping Drive” of this user manual for complete details on the installation, configuration, and wiring of this drive.

7th Ed. Rev D – 03/17/2022

STP-DRVAC-24025

SureStep

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Stepping Systems User Manual 1–11

Chapter 1: Getting Started

Advanced Microstepping Drive

The SureStep™ advanced microstepping drives (STP-DRV-4850 & -80100) are capable of accepting several different forms of input signals for control: pulse, analog, serial communication, or internal indexing. These drives are configured by computer with software which is included with the drive. To use one of these drives in a step motor control system, you will need the following:

• A DC power supply for the motor drive. A compatible SureStep STP-PWR-xxxx linear power supply from AutomationDirect is the best choice.

• A source of input control signals, such as a PLC from AutomationDirect.

• A compatible step motor, such as an AutomationDirect SureStep STP-MTRx.

(Motor extension cables STP-EXTx 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.

1–12 SureStep

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Chapter 1: Getting Started

Standard Integrated Motors/Drives

The SureStep™ STP-MTRD standard series integrated motors/drives

(STP-MTRD-17 and -23) use pulse input signals, and are configured with DIP switches on the drive. To use this motor/drive in a step motor control system, you will need the following:

• 12-48 volt (for 17 series) or 12-70 volt (for 23 series) DC power supply for the motor/drive. The SureStep linear power supplies from AutomationDirect are the best choice. If you decide not to use a STP-PWR-xxxx, please read the section entitled “Choosing a Power Supply” in Chapter 7, “SureStep System Power

Supplies.”

• 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.

• A small flat blade screwdriver (3/32”) for tightening the connectors.

The SureStep standard integrated motors/drives are enclosed with removable wiring terminal blocks. Models with external encoders (for position feedback to a

PLC, motion controller, etc.) are available.

STP-MTRD-17038RE

Refer to Chapter 5: “SureStep Integrated Motors/Drives” for complete details on the installation, configuration, and wiring of this motor/drive.

7th Ed. Rev D – 03/17/2022

SureStep

TM

Stepping Systems User Manual 1–13

Chapter 1: Getting Started

Advanced Integrated Motors/Drives

The SureStep™ STP-MTRD advanced series integrated motors/drives (STP-MTRD-

17R, -23R, and -24R) are capable of accepting several different forms of input signals for control: pulse, analog, serial communication, or internal indexing (via serial communications). These motors/drives are configured with software which is included with the drive. To use one of these motors/drives in a step motor control system, you will need the following:

• A DC power supply for the motor drive (12-48 volt for 17 series, 12-70 volt for 23 and 24 series). A compatible SureStep STP-PWR-xxxx linear power supply from

AutomationDirect is the best choice.

• A source of input control signals, such as a PLC from AutomationDirect.

• A small flat blade screwdriver for tightening the connectors.

The SureStep advanced integrated motors/drives are enclosed with removable wiring terminal blocks. Models with internal encoders (for position verification and stall prevention inside the motor/drive) are available.

STP-MTRD-23042

Refer to Chapter 5: “SureStep Integrated Motors/Drives” for complete details on the installation, configuration, and wiring of this motor/drive.

1–14 SureStep

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Stepping Systems User Manual

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Chapter 1: Getting Started

Step Motor Introduction

AutomationDirect offers many different models of bipolar1 step motors with mounting flanges in two different shaft configurations (single and dual-shaft), and in five different NEMA frame sizes (14, 17, 23, 34, and 42). There are a variety of motor types available: low torque (STP-MTRL), high torque (STP-MTR, STP-

MTRAC), and higher torque (STP-MTRH, STP-MTRACH). Models that have a “D”,

“E”, or “W” variant represent a dual shaft option (D), an encoder pre-mounted to the motor (E), or IP65 washdown rated (W) respectively. The “D” variants are encoder ready with pre-drilled and tapped holes on the rear face for encoder mounting. All low-voltage motors have a 12-inch connectorized cable, and optional matching 6, 10, or 20-foot connectorized extension cables (STP-EXTx) are also available. The IP65 motors (W models) have IP65 rated connectors. The high bus voltage NEMA 23 and 34 MTRAC motors have integrated 8-lead 10-foot cables. The NEMA42 motors have 12-inch connectorized cables that accept

8-lead extension cables in 6, 10, and 20 ft lengths (STP-EXT42x).

Refer to Chapter 6: “SureStep™ Stepping Motors” in this user manual for complete details on the specifications, installation, mounting, dimensions, and wiring of the

SureStep step motors.

1

: All SureStep motors are bipolar wound, but STP-MTRAC(H)-42x motors can be wired for bipolar series, bipolar parallel, or unipolar use. Automation Direct does not have a drive that can run a unipolar wired motor.

STP-MTRx

NEMA 14, 17, 23, 34, 42

Frame Sizes

STP-MTRx Motors available in Single-shaft, Dual-shaft (encoder ready), Encoder Mounted, and IP65 (washdown) Models. STP-MTRAC-x Motors available in Single-shaft or Dual-shaft

(encoder ready) models.

7th Ed. Rev D – 03/17/2022

STP-MTRAC-42x

SureStep

TM

Stepping Systems User Manual 1–15

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. Automation Direct switching power supplies PSB12-xxxS, PSB24xxxS, and PSB48-xxxS are good non-linear supplies. A regen clamp may be needed if using these supplies. For more information on using the power supplies please see Chapter 8: “SureStep System Power Supplies”.

Linear Power

Supplies

1–16

Switching Power Supplies

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.

Further information about braking accessories and regeneration clamping can be found in Appendix A: “SureStep Accessories” and the STP-DRVA-RC-050 or STP-

DRVA-RC-50A REGENERATION CLAMP datasheet.

SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 1: Getting Started

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 AutomationDirect PLCs for detailed information on wiring the SureStep Stepping System components to

AutomationDirect PLCs and high-speed counter modules.

The following is a summary of the AutomationDirect PLCs and module part numbers that are suitable to work with the SureStep Stepping Systems:

High-Speed Pulse Output Control (Standard Drives)

Any AutomationDirect PLC with high speed pulse output can control the SureStep

Standard and Advanced stepper drives and integrated motor/drives. Certain highspeed PLC outputs are 24VDC and may require dropping resistors to work with

5VDC stepper inputs. See Appendix B in this manual and the appropriate PLC

User Manual for more detailed information.

AutomationDirect PLCs that can use pulse train outputs with SureStep drives:

BRX Series (all models with DC outputs on the CPU module)

Productivity Series (all P2 and P3 CPUs - with the P2-HSO/P3-HSO modules)

Do-More Series (all models that can use the H2-CTRIO2)

DirectLogic Series

• All CPU models that can use the H2-CTRIO2 (and other CTRIO models)

• Models with built-in high speed outputs (DL05, DL06)

Serial Communication Control (Advanced Drives)

AutomationDirect PLCs with an RS-232 port can control an Advanced stepper drive (STP-DRV-4850, STP-DRV-80100) with serial communication (one drive per PLC communication port). A PLC with an RS-485 port can control multiple

Advanced integrated stepper motor/drives.

The Click Series , BRX Series , Productivity Series , and Do-More Series of PLCs allow for simple ASCII control of the Advanced drives and motor/drives. Of the

DirectLogic Series of PLCs, we recommend only using the DL06 and D2-260

CPUs due to their advanced ASCII instruction set which includes PRINTV and

VPRINT commands.

See Appendix B and the appropriate PLC User Manual for more detailed information.

7th Ed. Rev D – 03/17/2022

SureStep

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Stepping Systems User Manual 1–17

Chapter 1: Getting Started

BLANK

PAGE

1–18 SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

S

ure

S

tep

™

Stp-DrV-4830,

-4845, -6575

S

tanDarD

DC

M

iCroStepping

D

riVeS

C hapter

2

In This Chapter...

Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–2

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–3

Typical Wiring Diagram � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–5

Wiring Connections and Configuration Switches � � � � � � � � �2–5

STP-DRV-4830 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–5

STP-DRV-4845 and STP-DRV-6575 � � � � � � � � � � � � � � � � � � � � � � �2–6

Connecting the Motor � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–7

Connecting the Power Supply � � � � � � � � � � � � � � � � � � � � � � �2–8

SureStep™ Drive Digital Inputs and Outputs � � � � � � � � � � � � � � � �2–9

Connecting the Input Signals: STEP and DIR � � � � � � � � � � � � � � � �2–9

Connecting the Input Signals – EN Input � � � � � � � � � � � � � � � � �2–10

Connecting the Fault Output � � � � � � � � � � � � � � � � � � � � � � � � � �2–11

Drive Configuration � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–12

Drive Configurations Settings � � � � � � � � � � � � � � � � � � � � � � � � � �2–12

DIP Switch Settings � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–13

Alarm Codes � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–16

Mounting the Drive � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–19

Drive Heating � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–19

Dimensions and Mounting Slot Locations � � � � � � � � � � � � � �2–19

STP-DRV-4830 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �2–19

STP-DRV-4845 and STP-DRV-6575 � � � � � � � � � � � � � � � � � � � � � �2–20

Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

STP-DRV-4830

STP-DRV-6575

STP-DRV-4845

Features

• Low cost, digital step motor driver in compact package

• Operates from Step & Direction signals, or Step CW & Step CCW. CW and CCW rotation are viewed from the end opposite the drive end of the motor (looking out of the shaft)

• Enable input & Fault output (STP-DRV-4830 does not have a fault output)

• Optically isolated I/O

• Digital filters prevent position error from electrical noise on command signals; selectable: 150 kHz or 2MHz (-4845 and -6575 models), 150kHz or 500kHz

(-4830 model)

• Rotary switch for selecting several SureStep motors or phase current settings

• Electronic damping and anti-resonance (-4845 and -6575 only)

• 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); up to 20,000 (for

-4845 and -6575) or up to 25600 (for the -4830) steps per revolution

• Switch selectable step input signal smoothing (microstep emulation) provides smoother, more reliable motion in full and half-step modes for the -4845 and

-6575, and all step resolutions for the -4830

• Automatic self test (switch selectable)

• Drives operate from 12 or 24 to 48 or 72 VDC power supplies

• Running current ranges from 0.35 to 7.5A depending on drive

2–2 SureStep

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Stepping Systems User Manual

7th Ed. Rev C – 06/30/2021

Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Specifications

Part Number

Input Power

Output Current

Current Controller

SureStep™ Microstepping Drive Specifications

STP-DRV-4830 STP-DRV-4845 STP-DRV-6575

12–48 VDC (53VDC max)

(external power supply required; fuse at 3A fastacting)

0.35–3.0 A/phase (peak of sine)

24–48 VDC (60VDC max)

(external power supply required; fuse at 4A fastacting)

0.8–4.5 A/phase (peak of sine)

24–75 VDC (85VDC max)

(external power supply required; fuse at 7A fastacting)

1.0–7.5 A/phase (peak of sine)

Dual H-bridge digital

MOSFET, 4-quadrant PWM at 16kHz

Dual H-bridge digital MOSFET, 4-quadrant PWM at

20kHz

Step Function

Step

Electrical

Specs

Step or Step CW pulse

5 –24 VDC nominal (range: 4–30 VDC); (5mA @ 4V; 15 mA @ 30V); Optically isolated, differential.

Maximum pulse frequency

= 150 kHz or 500 kHz

(user selectable).

Minimum pulse width:

3 usec at 150 kHz setting

SW12, 1 usec at 500 kHz setting SW12

Maximum pulse frequency = 150 kHz or 2MHz (user selectable).

Minimum pulse width:

3 usec at 150 kHz setting jumper 4

1 usec at 2 MHz setting jumper 4

Input

Signals

DIR Function Direction or Step CCW pulse

5 –24 VDC nominal (range: 4–30 VDC); (5mA @ 4V; 15 mA @ 30V); Optically isolated, differential.

DIR Electrical

Specs

Max pulse frequency:

500 kHz

Minimum pulse width:

3 usec at 150 kHz setting

SW12, 1 usec at 500 kHz setting SW12

Maximum pulse frequency = 150 kHz or 2MHz (user selectable).

Minimum pulse width:

3 usec at 150 kHz setting jumper 4

1 usec at 2 MHz setting jumper 4

EN Function

EN Electrical

Specs

Output

Signal

Fault

Rotary Switch Selectable

Function

Disable motor when closed

5 –24 VDC nominal (range: 4–30 VDC); (5mA @ 4V; 15 mA @ 30V); Optically isolated, differential. Max pulse frequency: 10 kHz

Minimum pulse width: 500 usec n/a n/a

30 VDC / 80mA max, optically isolated photodarlington, sinking or sourcing.

Function = closes on drive fault.

Select motor based on part number, or by motor current.

7th Ed. Rev C – 06/30/2021

SureStep

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Stepping Systems User Manual 2–3

Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Specifications, continued

SureStep™ Microstepping Drive Specifications

Part Number

Step Pulse

Type

Step Pulse

Noise Filter

Current

Reduction

(DIP switch)

Jumper and

DIP Switch

Selectable

Functions

Idle Current

Reduction

(DIP switch)

Load Inertia

(DIP switch)

Step

Resolution

(DIP switch)

Self Test

(DIP switch)

Smoothing

Filter

(DIP switch)

Drive Cooling Method

Mounting

Removable Connectors

Weight

Operating Temperature

Ambient Temperature

Humidity

Agency Approvals

STP-DRV-4830 STP-DRV-4845 STP-DRV-6575

Step and Direction: Step signal = step/pulse; Direction signal = direction.

Step CW & CCW: Step signal = CW step; Direction signal = CCW step (Internal jumper for -4845 and -6575; DIP switch for -4830)

150kHz or 500kHz (switch to 500kHz if pulsing faster than 150kHz (DIP switch)

150 kHz or 2MHz (switch to 2MHz if pulsing faster than 150kHz)(internal jumper) n/a

Reduce power consumption and heat generation by limiting motor running current to 100%, 90%, or 80%,

(70% possible for STP-DRV-4845 only and 120% possible for the -6575 only) of maximum. Current should be increased to the maximum current reduction setting if microstepping. (Torque is reduced/increased by the same %.)

Reduce power consumption and heat generation by limiting motor idle current to

90% or 50% of running current. (Holding torque is reduced by the same %.) n/a

Anti-resonance and damping feature improves motor performance. Set motor and load inertia range to 0–4x or 5–10x.

200, 400, 800, 1000,

1600, 2000, 3200, 4000,

5000, 6000, 6400, 8000,

10000, 12800, 20000,

200, 200 smooth, 400, 400 smooth, 2000, 5000,

12800, 20000

25600.

Automatically rotate the motor back and forth two turns in each direction in order to confirm that the motor is operational.

Softens the effect of immediate changes in velocity and direction, making hte motion of the n/a motor less jerky. Can cause a small delay in following the control signal.

Natural convection (mount drive to metal surface)

Use (2) #6 screws to mount to metal surface

DEGSON 15EDGK-5.08-

02P-14-00AH 2-pin power connector

DEGSON 15EDGK-

3.1.04P-14-00A(H) 4-pin motor connector

Motor & Power Supply: Screw term blocks Phoenix

Contact 1757051 (30–12AWG)

Signals: Screw terminal blocks Phoenix Contact

1803633 (30–14 AWG)

AutomationDirect part number STP-CON-1 contains these replacement connectors.

DEGSON 15EDGK-3.5-

06P-14-00A(H) 6-pin I/O connector

Part number STP-CON-5 contains replacements

3.0 oz [85.9g]

0 to 85 °C [32 to 185 °F] – (Interior of electronics section)

0 to 40 °C [32 to 104 °F]

10.8 oz [306g]

0 to 50 °C [32 to 122 °F]

Maximum 90% non-condensing

CE

CE cURus

2–4 SureStep

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7th Ed. Rev C – 06/30/2021

Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Typical Wiring Diagram

Step Motor

Power Supply

–

+

Logic Power 5VDC

STP-PWR-xxxx

Cable Color Code

Term

A+

A–

B+

B–

Wire

Red

White

Green

Black

Pin #

3

4

1

2

Sure Step Typical

Wiring Diagram

VDC +

VDC –

A +

A –

B +

B –

STP-

DRV-xxxx

Stepper Drive

Extension Cable with Connector

STP-EXTx

12" Motor Pigtail with Connector

Step Motor

STP-MTRx

Wiring Connections and Configuration Switches

STP-DRV-4830

Factory use comm port

Terminal block part #s (shown) are

Phoenix Contact (www.phoenixcontact.com)

All three terminal blocks are included in

STP-CON-5 for replacement connectors

External wiring is connected using three separate pluggable screw terminal connectors. The power connections are on the 2-position connector, the motor connection is on the 4-position connector, and the digital inputs are on the

6-position connector.

7th Ed. Rev C – 06/30/2021

SureStep

TM

Stepping Systems User Manual 2–5

Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

STP-DRV-4845 and STP-DRV-6575

Terminals, Switches, Indicators

Status LEDs

Rotary Switch

FAULT–

FAULT+

EN–

EN+

DIR–

DIR+

STEP–

STEP+

DIP Switches

B–

B+

A–

A+

V–

V+

Terminal block part #s (shown) are

Phoenix Contact (www.phoenixcontact.com)

Both terminal blocks are included in STP-CON-1 for replacement connectors

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.

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Connecting the Motor

Warning: When connecting a step motor to a Sure Step™ 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.)

CW and CCW are viewed from the end opposite the drive end of the motor (looking out of the shaft).

Four Lead Motors

Four lead motors can only be connected one way, as shown below.

A+

Red

4 lead motor

A–

White

Green

B+

4 Leads

B–

Black

All AutomationDirect SureStep™ motors are four lead bipolar step motors except STP-

MTRAC-x 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 30% less than rated current to prevent overheating.

A–

Grn/Wht

A–

Grn/Wht n/c

White

A+

Green

6 lead motor

A+

White n/c

Green

6 lead motor

Red Black

B– n/c B+

Red/

Wht Red

B–

Black

B+ n/c

Red/

Wht

6 Leads Series Connected 6 Leads Center Tap Connected

Step motor wire lead colors vary from one manufacturer to another.

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

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.

A+

Orange

Org/Wht

Blk/Wht

8 lead motor

Orange

A+

Blk/

Wht

Org/

Wht

8 lead motor

A–

Black

A–

Black

Red Red/

Wht

B+

Yel/

Wht

Yellow

B–

8 Leads Series Connected

Red Yellow

B+

Yel/

Wht

Red/

Wht B–

8 Leads Parallel Connected

Step motor wire lead colors vary from one manufacturer to another. The example above only pertains to STP-MTRAC-34075(x) and 34115(x) SureStep Motors. For

NEMA 42 wire colors, see “Connecting a STP-MTRAC(H)-42 Motor” in Chapter 7.

Connecting the Power Supply

An STP-PWR-xxxx power supply from AutomationDirect is the best choice to power the step motor drive. If you need information about choosing a different power supply, refer to the section entitled “Choosing a Power Supply” in Chapter

7 of 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 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**

+

VDC

–

* External fuse not required when

using an STP-PWR-xxxx P/S; fuse is internal.

** CE use requires an EMI line filter.

Further information about EMI line filters, braking accessories, and regeneration clamping can be found in Appendix A: “SureStep Accessories” and the STP-

DRVA-RC-050A or STP-DRVA-RC-050 REGENERATION CLAMP datasheet.

Do NOT use STP-PWR-70xx power supplies with an STP-DRV-6575 drive, because those power supplies can exceed the voltage limit of this drive if supplied with a higher than normal 120VAC supply. STP-DRV-6575 overvoltage fault is 85V.

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Connecting the I/O

SureStep™ Drive Digital Inputs and Outputs

The Sure Step STP-DRV-4830, -4845, and -6575 drives include two high-speed

5–24 VDC digital inputs (STEP & DIR), one standard-speed 5–24 VDC digital input (EN), and one 30 VDC digital output (Fault). The -4830 does not have an output.

STEP+

STEP–

220pF

Internal to the

STP-DRV-xxxx

The digital inputs are optically isolated to reduce electrical noise problems. There is no electrical connection between the control and power circuits within the drive, and input

DIR+

DIR–

EN+

EN–

220pF

220pF 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.

FAULT+

FAULT–

Applies to -4845 and -6575 drives ONLY

Drive Digital Input Circuit

For bidirectional rotation, supply a source of step pulses to the drive at the STEP+ and STEP– terminals, and a directional signal at the DIR+ and DIR– terminals.

The ENABLE input allows the logic to turn off the current to the step motor by providing a signal to the EN+ and EN– terminals. The EN+ and EN– terminal can be left unconnected if the 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.

Connecting the Input Signals: STEP and DIR

Connecting Inputs to an Indexer with Sinking Outputs

+V OUT DIR+

DIR DIR–

STP-DRV-xxxx

Drive Indexer with

Sinking

Outputs

STEP+ EN+

STEP STEP– EN–

N/C

N/C

Connecting Inputs to an Indexer with Sourcing Outputs

COM DIR–

DIR DIR+

STP-DRV-xxxx

Drive Indexer with

Sourcing

Outputs

STEP– EN+

STEP STEP+ EN–

N/C

N/C

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Connecting the Input Signals – STEP and DIR (continued)

Connecting Inputs to an Indexer with Differential Line Driver Outputs

DIR+ DIR+

Indexer with

Differential

Outputs

DIR–

STEP+

DIR–

STEP+

STP-DRV-xxxx

Drive

EN+

N/C

STEP– STEP– EN–

N/C

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.

+

5-24 VDC

Supply

-

EN+ switch or relay

(closed = logic low)

STP-DRV-xxxx

Drive

EN–

+

5-24 VDC

Supply

-

+ output

-

NPN

Proximity

Sensor

EN+

EN–

STP-DRV-xxxx

Drive

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+

5-24 VDC

Power

Supply

-

-

+ output

PNP

Sensor

EN+

STP-DRV-xxxx

Drive

EN–

Leave the ENABLE input unconnected if you do not need to disable the amplifiers.

Connecting the Fault Output

The Sure Step STP-DRV-4845 and -6575 drives have one digital output that has separate positive (+) and negative (-) terminals, and can be used to sink or source current. There is no digital output on the STP-DRV-4830.

FAULT+

Drive

FAULT–

FAULT+

Drive

FAULT–

Load

+

5-24 VDC

Power

Supply

-

+

5-24 VDC

Power

Supply

-

FAULT+

Drive

FAULT– Load

+

5-24 VDC

Power

Supply

-

Do not connect more than 30 VDC. Current must not exceed 80 mA.

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Drive Configuration

You need to configure your drive for your particular application before using the drive for the first time. The Sure Step STP-DRV-4830, -4845, and -6575 microstepping drives offer several features and configuration settings, including:

Drive Configurations Settings

Feature

Motor Phase

Current

Mode of

Operation

(Step Pulse

Type)

Step Pulse

Noise Filter

Current

Reduction

Idle Current

Reduction

Load Inertia

Step

Resolution

Description

Select motor based on part number, or set by motor current.

Drive Configuration Settings

Configuration Method

STP-DRV-4830 STP-DRV-4845 STP-DRV-6575

Set current via

DIP switch

1,2,3

Set current via rotary switch

Select motor via rotary switch

Step and Direction (default): Step signal = step/ pulse; Direction signal = direction.

Step CW & CCW: Step signal = CW step;

Direction signal = CCW step.

Select 150 kHz or 2MHz for -4845 and -6575 or

Select 150 kHz or 500 kHz for -4830

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 %.)

Reduce power consumption and heat generation by limiting motor idle current to 90% or 50% of running current. (Holding torque is reduced by the same %.)

Anti-resonance and damping feature improve motor performance.

Set motor and load inertia range to 0–4x or 5–10x.

DIP switch 11

DIP switch 12

N/A

N/A

Jumper S3

(see details later in this section)

Jumper S4

(see details later in this section)

DIP switch 1,2

DIP switch 4

DIP switch 3

For smoother motion and more precise speed, set the pulse per revolution value as needed.

DIP switch

5,6,7,8

DIP switch 5,6,7

Self Test

Step

Smoothing

Filter

Automatically rotates the motor back and forth 1/2 a revolution in each direction in order to confirm that the motor is operational.

Softens the effect of immediate changes in velocity and direction, making the motion of the motor less jerky. Can cause a small delay in following the control signal.

DIP switch

9

DIP switch

10

DIP switch 8

N/A (step smoothing is available using the “200 smooth” or “400 smooth” setting for DIP switch 5,6,7

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

DIP Switch Settings

STP-DRV-4830

(Factory default = switches 1-4 ON, switches 5-12 OFF)

Current Setting

Step Resolution (steps/rev)

Idle Current

Reduction

Self Test

Smoothing

Filter

Control

Mode

Step

Filter

ON 4

50%

4

90%

ON 9

Enable

9

Disable

ON 10 10

Enable Disable

ON 11

CW/CCW

11

Step/Dir

ON 12

150kHz

12

500kHz

STP-DRV-4845 and STP-DRV-6575

(Factory default = all switches OFF)

Step Resolution (steps/rev)

ON

5 6 7

20000

5 6 7

12800

5 6 7

5000

5 6 7

2000

5 6 7

400

SMOOTH

5 6 7

400

5 6 7

200

SMOOTH

5 6 7

200

Current Reduction Load Inertia Idle Current Reduction

ON 1 2 1 2 1 2 1 2

100% 90% 80% 120%

(Use 120% when microstepping)

ON 3

5-10x

3

0-4x

ON

4

50%

4

90%

Self Test

ON 8

ON

8

OFF

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Jumper Settings for STP-DRV-4845 and STP-DRV-6575

Jumpers S3 and S4 are located on the internal circuit board, and they can be accessed by removing the drive’s front cover.

Remove connectors and cover to access Jumpers

S3 and S4. 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 & Direction (factory default)

• Jumper in “1-3” position – Step CW / Step CCW

Jumper S4 – Step Pulse Noise Filter

• Jumper in “1-2” position – 2MHz

• Jumper in “1-3” position – 150 kHz (factory default)

Rotary Switch Settings – Motor/Current Settings

65

4 3 2

7 8 9

1 0 F E

Rotary Switch

Position

STP-DRV-4845 Motor Selection Table

(A/Phase)(Peak of Sine A)

SW1 & SW2

@100%

SW1 & SW2

@90%

SW1 & SW2

@80%

BA

E

F

C

D

A

B

8

9

6

7

4

5

2

3

0

1

3.8

4.0

4.3

4.5

2.8

3.1

3.4

3.6

2.0

2.2

2.4

2.6

1.1

1.3

1.5

1.7

3.4

3.6

3.9

4.1

2.5

2.8

3.1

3.2

1.8

2.0

2.2

2.3

1.0

1.2

1.4

1.5

3.0

3.2

3.4

3.6

2.2

2.5

2.7

2.9

1.6

1.8

1.9

2.1

0.9

1.0

1.2

1.4

SW1 & SW2

@70%

2.7

2.8

3.0

3.2

2.0

2.2

2.4

2.5

1.4

1.5

1.7

1.8

0.8

0.9

1.1

1.2

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STP-DRV-6575 Motor Selection Table

Motor Data Drive Configuration Data

2 ) 2 )

Rotary Switch

Position n/a n/a n/a n/a

-17040

1.3

4.0

4.0

1.7

reserved custom NEMA 17 custom NEMA 23 custom NEMA 34

61 0.28 3.03 1.60

434

-17048

-17060

-23055

2.0

83 0.37 2.65 1.40

2.0

125 0.56 3.30 2.00

2.8

586

883

166 1.46 2.36 0.08

1172

-23079

-34066

2.8

2.8

H-23079 5.6

H-34066 6.3

276

434

287

428

2.60 3.82 1.10

7.66 7.70 1.11

2.60 1.18 0.40

7.66 1.52 0.25

1949

3065

2025

3021

H-34097 6.3

803 14.80 2.07 0.03

5668

H-34127 6.3

1292 21.90 4.14 0.49

9123

51

82

37

271

475

1402

371

1402

2708

4008

2.04

2.40

2.40

3.36

3.36

3.36

6.72

7.56

7.56

7.56

C

D

A

B

E

F

7

8

9

0–2

3

4

5

6

65

4 3 2

7 8 9

1 0 F E

BA

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

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-xxxx Alarm Codes

Alarm

Code

SG

LED Sequence

Solid green

Alarm Description

No alarm, motor disabled

FG

Fast green

Factory use

01

Flashing green

No alarm, motor enabled

10

Flashing red

Configuration or memory error1

11

1 red, 1 green

Motor stall (optional encoder only)4

12

1 red, 2 green

Move attempted while drive disabled

21

2 red, 1 green

CCW limit

22

2 red, 2 green

CW limit

31

3 red, 1 green

Drive overheating

32

3 red, 2 green

Internal voltage out of range2

33

3 red, 3 green

Factory use

41

4 red, 1 green

Power supply overvoltage2

42

4 red, 2 green

Power supply undervoltage

43

51

61

62

4 red, 3 green

5 red, 1 green

6 red, 1 green

6 red, 2 green

Flash memory backup error

Over current / short circuit2, 3

Open motor winding2

Bad encoder signal (optional encoder only)4

Serial communication error5 71

7 red, 1 green

72

7 red, 2 green

1 - Does not disable the motor.

The alarm will clear about 30 seconds after the fault is corrected.

2 - Disables the motor. Cannot be cleared until power is cycled.

Flash memory error

3 - 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.

4 - This alarm only occurs on STP-MTRD advanced integrated motor/drives

5 - This alarm only occurs on drives with serial communication.

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01

10

11

12

21

22

31

32

Alarm Code Definitions

Alarm Code

SG

Error

No alarm, motor disabled

No alarm, motor enabled

Configuration or memory error

Motor stall

(optional encoder only)

Description

No faults active, Circuit is closed between EN+ and

EN-.

No faults active, Circuit is open between EN+ and EN-.

Memory error detected when trying to load config from flash on powerup.

Motor torque demand exceeded capability and the motor skipped steps. This is configured in SureMotion

Pro.

Drive is disabled and move attempted.

N/A

N/A

Corrective Action

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

Increase torque utilization if it’s not already maxed out, otherwise decrease the torque demand by modifying the move profile, or put in a larger motor.

Move attempted while drive disabled

CCW limit

Reset alarm, enable motor, and move again.

CW limit

Drive overheating

Internal voltage out of range

CCW limit is reached. The digital input that has been assigned CCW limit has been activated.

CW limit is reached. The digital input that has been assigned CW limit has been activated.

The drive’s internal temperature is too high.

Unblock the CCW sensor (open the circuit) or redifine the input with

SureMotion Pro.

Unblock the CCW sensor (open the circuit) or redefine the input with

SureMotion Pro.

Gate voltage, 5V rail, or 3V rail are out of spec.

If the drive is operating within its standard range (input voltage and output current are OK), more heat must be removed from the drive during operation. For Advanced drives (see

“Mounting the Drive” on page 4-14), ensure the drive is mounted to a metal surface that can dissipate the drive’s heat. For Integrated motor/drives, see

“Mounting” on page 5-13. For both types of drives: If the mounting surface cannot pull enough heat away from the drive, forced airflow (from a fan) may be required to cool the drive.

Ensure adequate supply voltage (in very rare cases, low input voltages combined with fast accelerations can draw down the gate voltage) and try again. If persistant, RMA is required.

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

Alarm Code

41

42

43

51

61

62

71

72

Error

Power supply overvoltage

Power supply undervoltage

Description

The DC voltage feeding the drive is above the allowable level.

The DC voltage feeding the drive is below the allowable level.

Corrective Action

Decrease the input voltage.

Linear power supplies do not output a fixed voltage: the lighter the output current, the higher the output voltage will float. If a linear supply’s voltage floats above the drive’s max voltage, you can install a small power resistor across the linear power supply’s output to provide some load that will help pull down the floating voltage.

Consider using a switching power supply such as the Rhino PSB power supply series.

Overvoltage can also be fed back into a system by regeneration (when an overhauling load pushes energy back into the motor). In an application with regen problems, install an STP-DRVA-

RC-050 regen clamp to help dissipate the extra energy. (The regen clamp will not help with the floating linear power supply that floats too high, but it will help with excess voltage generated from an overhauling load.)

Correct the power supply. If this error occurs during operation, the power supply is most likely undersized. A sudden high current demand can cause an undersized power supply to dip in output voltage.

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

Check and fix motor wiring.

Flash memory backup error

Over current / short circuit

Open motor winding

Bad encoder signal (optional encoder only)

Serial communication error

Flash memory error

Memory error detected when trying to load config from flash on powerup.

Motor leads shorted - only checked on powerup.

Motor leads not connected - only checked on powerup.

Noisy or otherwise incorrectly formatted encoder signal (lack of A or

B, lack of differential signal).

Catch-all error for something wrong with serial communications. See CE command in HCR for details.

Memory error detected when trying to load config from flash on powerup.

Check and fix motor wiring.

Check encoder wiring, always use differential encoders (or use checkbox in SureMotion Pro to disable this error when using single ended).

If drive can communicate, CE can give a precise diagnosis. If not, refer to the

Serial Communications part of the HCR for troubleshooting.

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

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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 space where there is no air flow or where the ambient temperature exceeds 50 °C (122 °F).

• When mouting multiple STP-DRV-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.

Drive Heating

For information on drive heating, please see Chapter 8: SureStep System Power

Supplies.

Dimensions and Mounting Slot Locations

STP-DRV-4830

Dimensions = in [mm]

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Chapter 2: SureStep™ STP-DRV-4830/4845/6575 DC Microstepping Drives

STP-DRV-4845 and STP-DRV-6575

Dimensions = in [mm]

0.13

[3.2]

4X Ø0.14

[Ø3.6]

2.98

[75.6]

0.89

[22.7]

4.66

[118.4]

4.40

[111.8]

0.22

[5.6]

1.04

[26.5]

0.41

[10.5]

0.35

[8.9]

1.30

[33.0]

4.42

[112.3]

2 X R0.09

[R2.2]

2–20 SureStep

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S ure

S

tep

tM

Stp-DRV-4035

B

aSic

Dc

M

icRoStepping

D

RiVe

C hapter

3

In This Chapter...

Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–2

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–3

Typical Wiring Diagram � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–4

Connection and Adjustment Locations � � � � � � � � � � � � � � � � �3–4

Connecting the Motor� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–5

Connecting the Power Supply � � � � � � � � � � � � � � � � � � � � � � � � � � �3–6

Connecting the Logic � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–7

Using Logic That is Not 5 volt TTL Level � � � � � � � � � � � � � � � � � � �3–9

The Enable Input � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–9

Setting Phase Current � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–10

Current Setting Formula � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–10

Current Setting Table � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–11

Microstepping � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–12

Idle Current Reduction � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–13

Self Test � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–13

Dimensions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �3–15

Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

Features

• 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

• Half, 1/5, 1/10, 1/50 step (switch selectable)

• Automatic 50% idle current reduction (can be switched off)

3–2 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

Specifications

Sure

Step™ Microstepping Drives Specifications

Part Number

Input Power

(with red Power On LED)

STP-DRV-4035

12-42 VDC (including ripple voltage)

Output Power

Current Controller

Output current selectable from 0.4 to 3.5 Amps/phase motor current

(maximum output power is 140 W)

Dual H-bridge Bipolar Chopper

(4-state 20 kHz PWM with MOSFET switches)

Input Signal

Circuit

Opto-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 4VDC or higher (see page 3-9 for using input voltages higher than 5VDC)

Input

Signals

Direction

Signal

Self Test

Off or On (uses half-step to rotate 1/2 revolution in each direction at 100 steps/second)

DIP Switch

Selectable

Functions

Microstepping 400 (200x2), 1,000 (200x5), 2,000 (200x10), or 10,000 (200x50) steps/rev

Idle Current 0% or 50% reduction (idle current setting is active if motor is at rest for 1 second or more) Reduction

Phase Current

Setting

Drive Cooling Method

0.4 to 3.5 Amps/phase with 32 selectable levels

Natural convection (mount drive to metal surface if possible)

Dimensions

Mounting

Pulse Signal

Enable Signal

Motor steps on falling edge of pulse and minimum pulse width is 0.5 microseconds

Needs to change at least 2 microseconds before a step pulse is sent. CW and CCW are viewed from the end opposite the drive end of the motor

(looking out of the shaft).

Logic 1 will disable current to the motor

(current is enabled with no hook-up or logic 0)

3 x 4 x 1.5 inches [76.2 x 101.6 x 38.1 mm]

Use #4 screws to mount on wide side (4 screws) or narrow side (2 screws)

Connectors

Weight

Storage Temperature

Chassis Operating

Temperature

Agency Approvals

Screw terminal blocks with AWG 18 maximum wire size

9.3 oz. [264g]

-20–80 °C [-4–176 °F]

0–55 °C [32–131 °F] recommended; 70 °C [158 °F] maximum

(use fan cooling if necessary); 90% non-condensing maximum humidity

CE

Note: The STP-DRV-4035 Microstepping Drive works with 4, 6, and 8 lead bipolar step motors. All A utomAtion D irect Sure Step™ motors are four-lead bipolar step motors.

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 3–3

Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

Typical Wiring Diagram

Step Motor

Power Supply

–

+

Logic Power 5VDC

STP-PWR-3204

STP-

DRV-4035

VDC +

VDC –

A +

A –

B +

B –

Stepper Drive

STP-DRV-4035

Typical Wiring

Diagram

Cable Color Code

Term

A+

A–

B+

B–

Wire

Red

White

Green

Black

Pin #

3

4

1

2

Extension Cable with Connector

STP-EXTx

12" Motor Pigtail with Connector

Step Motor

STP-MTRx

Connection and Adjustment Locations

The diagram 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

Power On

LED

Logic

Connector

(STEP+/-, DIR+/-, EN+/-)

3–4 Sure Step TM Stepping Systems User Manual

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Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

Connecting the Motor

W arning : When connecting a step motor to the Sure Step™ STP-DRV-4035 microstepping drive, be sure that the motor power supply is switched off. When using a motor not supplied by a utomation D irect , secure any unused motor leads so that they can’t short out to anything. Never disconnect the motor while the drive is powered up.

Never connect motor leads to ground or to a power supply. (See the Typical Wiring

Diagram shown on page 2-4 of this chapter for the step motor lead color code of a utomation

D irect

supplied motors.)

You must now decide how to connect your stepping motor to the SureStep TM

STP-DRV-4035 microstepping drive.

A+

Red

4 lead motor

Four Lead Motors

Four lead motors can only be connected one way. Please follow the wiring diagram shown to the right.

A–

White

B–

Black

Note: All A utomAtion D irect Sure Step™ motors are four lead bipolar step motors.

Green

B+

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

NC

White

A+

Green

6 lead motor

A–

Grn/Wht

A+

White

6 lead motor

NC

Green

Red Black

B– NC B+

Red/

Wht

6 Leads Series Connected

Red

B–

Black

B+

Red/

Wht

NC

6 Leads Center Tap Connected

Note: Be aware that step motor wire lead colors vary from one manufacturer to another.

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Sure Step TM Stepping Systems User Manual 3–5

Chapter 3: Sure Step TM 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.

A+

Orange

Org/Wht

Blk/Wht

8 lead motor

A–

Black

Red Red/

Wht

B+

Yel/

Wht

Yellow

B–

8 Leads Series Connected

Orange

A+

Blk/

Wht

Org/

Wht

A–

Black

8 lead motor

Red

B+

Yel/

Wht

Yellow

Red/

Wht B–

8 Leads Parallel Connected

Note: Be aware that step motor wire lead colors vary from one manufacturer to another.

The example above only pertains to STP-MTRAC-34075(x) and 34115(x) SureStep

Motors.

Connecting the Power Supply

The STP-PWR-3204 power supply from a utomation

D irect

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 Chapter

7: “SureStep System Power Supplies”.

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.

+

Fuse *

Step Motor

Power Supply

12 - 42 VDC –

* External fuse not required when using an

STP-PWR-3204 P/S; fuse is internal.

Do NOT use STP-PWR-48xx or -70xx power supplies with an STP-DRV-4035 drive, because those power supplies exceed the voltage limit of this drive.

3–6 Sure Step TM Stepping Systems User Manual

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Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

Further information about braking accessories and regeneration clamping can be found in Appendix A and the STP-DRVA-RC-050 REGENERATION CLAMP datasheet.

Connecting the Logic

The SureStep drive contains optical isolation circuitry to prevent the electrical noise inherent in switching amplifiers from interfering with your circuits. Optical isolation is accomplished by powering the motor driver from a different supply source than your control circuits. There is no electrical connection between the

STEP+ 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.

STEP–

220 ohms

220 ohms

Internal to the

STP-DRV-4035

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.

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 3–7

Connecting to an Indexer with Sinking Outputs

Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

Connecting to an Indexer with Sinking Outputs

Indexer with

Sinking

Outputs

+5V OUT

DIR

DIR+

DIR–

STP-DRV-4035

Drive

EN+

STEP STEP– EN–

N/C

N/C

Connecting to an Indexer with Sourcing Outputs

COM

Indexer with

Sourcing

Outputs

DIR

STEP

DIR–

DIR+

STP-DRV-4035

Drive

STEP+

EN+

EN–

N/C

N/C

Connecting to an Indexer with Differential Outputs

DIR+

Indexer with

Differential

Outputs

DIR–

STEP+

STEP–

DIR+

DIR–

STP-DRV-4035

Drive

STEP+

STEP–

EN+

EN–

N/C

N/C

Note: Many high speed indexers have differential outputs.

3–8 Sure Step TM Stepping Systems User Manual

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Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

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.

• For 24 volt logic, use 2200 ohm, 1/4 watt resistors

Connecting to an Indexer with Sink or Source 12-24 VDC Outputs

Indexer with

Sinking

Outputs

+12-24V

DIR

ENABLE STEP

R

R

DIR+

STP-DRV-4035

DIR–

STEP+

STEP–

Drive

EN+

EN–

R

(If enable function is used)

Connecting to PLC with 12 - 24 VDC Sinking Outputs - stretched

Indexer with

Sourcing

Outputs

COM

DIR

ENABLE STEP

R

R

DIR–

STP-DRV-4035

DIR+

STEP–

STEP+

Drive

EN–

EN+

R

(If enable function is used)

Connecting to PLC with 12 - 24 VDC Sourcing Outputs - stretched

Connecting to a PLC with Sink or Source 12-24 VDC Outputs

COM +12-24V

PLC with

Sinking

Outputs

DIR

– +

12-24 VDC

R

ENABLE STEP

R

R

DIR+

STP-DRV-4035

Drive

STEP+

STEP–

EN+

EN–

(If enable function is used)

PLC with

Sourcing

Outputs

COM

DIR

+ –

12-24 VDC

R

ENABLE STEP

R

R

DIR–

STP-DRV-4035

Drive

STEP–

STEP+

EN–

EN+

(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.

Note: If you have no need to disable the amplifiers, you don’t need to connect anything to the ENABLE input.

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 3–9

Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

Step Table

(half stepping)

DIR=1 cw

6

7

8

Step

0

1

2

3

4

5

A+ open

+

+

+ open

–

–

– open

A– open

–

–

– open

+

+

+ open

B+

+

+ open

–

–

– open

+

+

B–

–

– open

+

+

+ open

–

–

DIR=0 ccw

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, 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 phase based on the step motor showing a phase current of 2.2 Amps. You need the base current of

0.4 Amps plus another 1.6 and 0.2 Amps.

2.2 = 0.4 + 1.6 + 0.2

Slide the 1.6 and 0.2 Amp DIP switches toward the labels as shown in the figure to the right.

0.1

0.2

0.4

0.8

1.6

3–10 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Current Setting Table

Sure Step TM STP-DRV-4035 Microstepping Drive

Current Setting Table

1.2

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.3

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.4

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.5

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.6

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.7

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.8

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.9

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

0.4

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

0.5

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

0.6

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

0.7

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

0.8

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

0.9

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.0

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

1.1

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

2.0

AMPS/

PHASE

2.1

AMPS/

PHASE

2.2

AMPS/

PHASE

2.3

AMPS/

PHASE

2.4

AMPS/

PHASE

2.5

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

2.6

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

2.7

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

0.1

0.2

0.4

0.8

1.6

Factory

Default

2.8

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

2.9

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

3.0

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

3.1

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

3.2

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

3.3

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

3.4

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

3.5

AMPS/

PHASE

0.1

0.2

0.4

0.8

1.6

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 3–11

Chapter 3: Sure Step TM 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.

Next 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.

400

STEPS/REV

(HALF)

1/2

1/10

1/5

1/2

Factory

Default

1,000

STEPS/REV

(1/5)

1/2

1/10

1/5

1/2

1/5

1/50

1/10

1/50

1/5

1/50

1/10

1/50

2,000

STEPS/REV

(1/10)

1/2

1/10

1/5

1/2

10,000

STEPS/REV

(1/50)

1/2

1/10

1/5

1/2

1/5

1/50

1/10

1/50

1/5

1/50

1/10

1/50

3–12 Sure Step TM Stepping Systems User Manual

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Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

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.

50% IDLE

Idle Current Reduction

Selected

(Factory Default)

50% IDLE

No Current Reduction

Self Test

The SureStep drive includes a self test feature. This is used for trouble shooting. If you are unsure about the motor or signal connections to the drive, or if the SureStep drive isn’t responding to your step pulses, you can turn on the self test.

To activate the self test, slide switch #1 toward the TEST label. The drive will slowly rotate the motor, 1/2 revolution forward, then 1/2 rev backward. The pattern repeats until you slide the switch away from the TEST label. The SureStep drive always uses half step mode during the self test, no matter how you set switches 2 and 3. The self test ignores the STEP and DIRECTION inputs while operating. The ENABLE input continues to function normally.

TEST

Self Test ON

TEST

Self Test OFF

(Factory Default)

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Sure Step TM Stepping Systems User Manual 3–13

Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

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

Smooth Flat Surface

Narrow Side Mount

#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.

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 70 °C. Never put the drive where it can get wet or where metal particles can get on it.

3–14 Sure Step TM Stepping Systems User Manual

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Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

Dimensions

1.50

[38.1]

2x Ø0.125

[Ø3.2]

0.125

[3.2]

2.50

[63.5]

4x Ø0.125

[Ø3.2]

3.70

[94.0]

3.75

[95.3]

4.00

[101.6]

0.25

[6.4]

0.875

[22.2]

Dimensions = in [mm]

0.15

[3.8]

3.00

[76.2]

0.25

[6.4]

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 3–15

Chapter 3: Sure Step TM STP-DRV-4035 Microstepping Drive

BLANK

PAGE

3–16 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

S

ure

S

tep

™

A

dvAnced

dc

M

icroStepping

d

riveS

C hapter

4

In This Chapter...

Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–2

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–3

Typical Wiring Diagram � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–4

Connection Locations & Pin-out � � � � � � � � � � � � � � � � � � � � � �4–4

Connecting the Power Supply � � � � � � � � � � � � � � � � � � � � � � �4–6

Connecting the I/O � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–7

SureStep™ Drive Digital Inputs � � � � � � � � � � � � � � � � � � � � � � � � � �4–7

Connecting STEP and DIR to 5V TTL Logic � � � � � � � � � � � � � � � � �4–7

Connecting STEP and DIR to Logic Other Than 5V TTL Level � � �4–8

Connections to the EN Input � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–9

Connecting the Analog Input � � � � � � � � � � � � � � � � � � � � � � � � � �4–10

Connecting the Digital Output � � � � � � � � � � � � � � � � � � � � � � � � �4–10

LED Display Codes � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–12

Drive Configuration � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–15

Mounting the Drive � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–17

Drive Heating � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �4–17

Dimensions and Mounting Slot Locations � � � � � � � � � � � � � �4–17

Chapter 4: SureStep™ Advanced Microstepping Drives

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, and serial communication inputs

4–2 SureStep

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Chapter 4: SureStep™ Advanced Microstepping Drives

Specifications

SureStep™ Series Specifications – Microstepping Drives

Microstepping Drive STP-DRV-4850 STP-DRV-80100

Drive Type

Output Current

Input Voltage

(external p/s required)

Configuration Method

Amplifier Type

Current Control

Protection

Advanced microstepping drive with pulse or analog input, serial communication, & indexing capability

0.1–5.0 A/phase (in 0.01A increments) 0.1–10.0 A/phase (in 0.01A increments)

24–48 VDC (nominal) (range: 18-53 VDC)

SureMotion Pro software

24–80 VDC (nominal) (range: 18-88 VDC)

Recommended Input Fusing

Input

Signals

Input Circuit

Step/Pulse

Direction

MOSFET, dual H-bridge, 4-quadrant

4-state PWM @ 20 kHz

Over-voltage, under-voltage, over-temperature, external output faults (phase-to-phase & phase-to-ground), inter-amplifier shorts

Fuse: 4A 3AG delay (ADC #MDL4)

Fuse Holder: ADC #DN-F6L110

Fuse: 6.25A 3AG delay (ADC #MDL6-25)

Fuse Holder: ADC #DN-F6L110

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 (see pages 4-8 and

4-9 for how to use input voltages higher than 5VDC)

Optically isolated, differential, 5V, 330 Ω ; Min pulse width = 250 ns, Max pulse frequency = 2MHz

Adjustable bandwidth digital noise rejection feature

FUNCTIONS: step & direction, CW/CCW step, A/B quadrature, run/stop & direction, jog CW/CCW,

CW/CCW limits

Enable

Optically isolated, 5–12V, 680 Ω ; min pulse width = 25µs, max pulse frequency = 20kHz

FUNCTIONS: motor enable, alarm reset, speed select (oscillator mode)

Analog

Output Signal

Range: 0–5 VDC; Resolution: 12 bit; FUNCTION: speed control

Optically isolated, 24V, 100mA max; FUNCTIONS: fault, motion, tach (3kHz max)

Communication Interface RS-232; RJ11 (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 Resolution Software selectable from 200 to 51200 steps/rev in increments of 2 steps/rev

Modes of Operation Pulse (step) & direction, CW/CCW, A/B quadrature, velocity (oscillator), SCL serial commands

Features

Phase Current Setting 0.1–5.0 A/phase (in 0.01A increments)

Self Test

0.1–10.0 A/phase (in 0.01A increments)

Checks internal & external power supply voltages, diagnoses open motor phases

Additional Features

Anti-resonance (Electronic Damping)

Auto setup

Serial Command Language (SCL) Host Control

Step input signal smoothing (microstep emulation)

Waveform (Torque Ripple) Smoothing

Communication Port

Removable Connectors

RJ11 (6P4C)

Motor & Power Supply: Screw term blocks Phoenix Contact 1757051 (30–12AWG)

Signals: Screw terminal blocks Phoenix Contact 1803633 (30–14 AWG)

AutomationDirect part number STP-CON-2 contains these replacement connectors.

Maximum Humidity 90% non-condensing

Storage Temperature

Operating Temperature

Drive Cooling Method

-20–80 °C [-4–176 °F] (mount to suitable heat sink)

0–55 °C [32–158 °F] (mount to suitable heat sink)

Natural convection (mount to suitable heat sink)

Mounting

Dimensions

Weight

Agency Approvals

#6 mounting screws (mount to suitable heat sink)

3.0 x 3.65 x 1.125 inches [76.2 x 92.7 x 28.6 mm]

8 oz [227g] (approximate)

CE

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Chapter 4: SureStep™ Advanced Microstepping Drives

Typical Wiring Diagram

Step Motor

Power Supply

–

+

Logic Power 5VDC

STP-PWR-xxxx

Cable Color Code

Term

A+

A–

B+

B–

Wire

Red

White

Green

Black

Pin #

3

4

1

2

Sure Step Typical

Wiring Diagram

VDC +

VDC –

A +

A –

B +

B –

STP-

DRV-xxxx

Stepper Drive

Extension Cable with Connector

STP-EXTx

12" Motor Pigtail with Connector

Step Motor

STP-MTRx

Connection Locations & Pin-out

Removable

Terminals:

– V+ (Power)

– V- (GND)

– A+ (Motor)

– A- (Motor)

– B+ (Motor)

– B- (Motor)

– GND

– AIN

– +5V

– Out-

– Out+

– EN-

– EN+

– DIR-

– DIR+

– STEP-

– STEP+

Terminal block part #s (shown) are

Amphenol PCD (www.amphenolpcd.com)

Replacement connector kit STP-CON-2 contains all the above connectors

Ground Terminal

(not visible)

Removable

Terminal Blocks

For Wiring

Status

LEDs

RS-232

Communication

Interface

RS-232 Comm Port:

(RJ11 6P4C)

– RX

– no connection

– TX

– GND

External wiring is connected using three separate pluggable screw terminal connectors.

The power connections share a six position connector, the digital inputs share another six position connector, and the analog input and digital output share a five position connector.

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Connecting the Motor

Four lead motors

Four lead motors can only be connected one way, as shown below.

A+

Red

4 lead motor

A–

White

Green

B+

4 Leads

B–

Black

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 30% less than rated current to prevent overheating.

A–

Grn/Wht

A–

Grn/Wht n/c

White

A+

Green

6 lead motor

A+

White n/c

Green

6 lead motor

Red Black

B– n/c B+

Red/

Wht Red

B–

Black

B+ n/c

Red/

Wht

6 Leads Series Connected 6 Leads Center Tap Connected

RS-232 Comm Port:

(RJ11 6P4C)

– RX

– no connection

– TX

– GND

Chapter 4: SureStep™ Advanced Microstepping Drives

Connecting the Motor

Warning: When connecting a step motor to a Sure Step™ advanced 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.

A+

Red

4 lead motor

A–

White

Green

B+

4 Leads

B–

Black

All AutomationDirect Sure Step™ MTR and MTRL 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 30% less than rated current to prevent overheating.

A–

Grn/Wht

A–

Grn/Wht n/c

White

A+

Green

6 lead motor

A+

White n/c

Green

6 lead motor

Red Black

B– n/c B+

Red/

Wht Red

B–

Black

B+

Red/

Wht n/c

6 Leads Series Connected 6 Leads Center Tap Connected

Step motor wire lead colors vary from one manufacturer to another.

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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

30% above rated current. Care should be taken in either case to assure the motor does not overheat.

A+

Orange

Org/Wht

Blk/Wht

8 lead motor

Orange

A+

Blk/

Wht

Org/

Wht

8 lead motor

A–

Black

A–

Black

Red Red/

Wht

B+

Yel/

Wht

Yellow

B–

8 Leads Series Connected

Red Yellow

B+

Yel/

Wht

Red/

Wht B–

8 Leads Parallel Connected

Step motor wire lead colors vary from one manufacturer to another. The example above only pertains to STP-MTRAC-34075(x) and 34115(x) SureStep Motors. For

NEMA 42 wire colors, see “Connecting a STP-MTRAC(H)-42 Motor” in Chapter 7.

Connecting the Power Supply

An STP-PWR-xxxx power supply from AutomationDirect is the best choice to power the step motor drive. If you need information about choosing a different power supply, refer to the section entitled “Choosing a Power Supply” in Chapter

7: “SureStep System Power Supplies.”

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.

Fuse *

VDC

+

Step Motor

Power Supply

–

* External fuse not required when using an

STP-PWR-xxxx P/S; fuse is internal.

Further information about braking accessories and regeneration clamping can be found in Appendix A: “SureStep Accessories” and the STP-DRVA-RC-050(A)

REGENERATION CLAMP datasheet.

Warning: Connect the motor power supply “+” terminal to the drive “+ VDC” terminal, and connect the power supply “–” terminal to the drive “VDC–” 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.

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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).

STEP+

STEP–

330

220pF

Internal to the

STP-DRV-xxxx

The digital inputs are optically isolated to reduce electrical noise problems. There is no electrical 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

DIR+

DIR–

EN–

330

220pF

680 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.

EN+

For bidirectional rotation, supply a source of step pulses to the drive at the STEP+ and STEP– terminals, and a directional signal at the DIR+ and DIR– terminals.

Drive Digital Input Circuit

The ENABLE input allows the logic to turn off the current to the step motor by providing a signal to the EN+ and EN– terminals. The EN+ and EN– terminal can be left unconnected if the 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.

Connecting STEP and DIR to 5V TTL Logic

Connecting to an Indexer with Sinking Outputs

+5V OUT DIR+

Indexer with

Sinking

Outputs

DIR DIR–

STP-DRV-xxxx

Drive

STEP+ EN+

STEP STEP– EN–

N/C

N/C

Connecting to an Indexer with Sourcing Outputs

COM DIR–

Indexer with

Sourcing

Outputs

DIR DIR+

STP-DRV-xxxx

Drive

STEP–

STEP STEP+

EN+

EN–

N/C

N/C

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Connecting to an Indexer with Differential Outputs

Indexer with

Differential

Outputs

DIR+

DIR–

STEP+

DIR+

DIR–

STP-DRV-xxxx

Drive

STEP+ EN+

STEP– STEP– EN–

N/C

N/C

Many high speed indexers have differential outputs.

Wiring for Encoder Following

A+

Master

Encoder

A–

B+

B–

X1/STEP+

STP-DRV-xxxx

X1/STEP– Drive

X2/DIR+

X2/DIR–

EN+

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.

• For 12V logic, use 820 Ω , 1/4W resistors

• For 24V logic, use 2200 Ω , 1/4W resistors

Most PLCs can use 24 VDC Logic.

Warning: 5VDC is the maximum voltage that can be applied directly to a high speed input (STEP and DIR). If using a higher voltage power source, install resistors to reduce the voltage at the inputs. Do NOT apply an AC voltage to an input terminal.

Connecting to an Indexer with Sink or Source 12-24 VDC Outputs

Indexer with

Sinking

Outputs

ENABLE

+12-24V

DIR

STEP

R

R

DIR+

DIR–

STP-DRV-xxxx

Drive

STEP+

STEP–

EN+

EN–

R

(If enable function is used)

Indexer with

Sourcing

Outputs

ENABLE

COM

DIR

STEP

R

R

DIR–

DIR+

STP-DRV-xxxx

Drive

STEP–

STEP+

EN–

EN+

R

(If enable function is used)

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Chapter 4: SureStep™ Advanced Microstepping Drives

Connecting to a PLC with Sink or Source 12-24 VDC Outputs

COM

PLC with

Sinking

Outputs

+12-24V

DIR

ENABLE STEP

– +

12 - 24 VDC

R

R

DIR+

DIR–

STP-DRV-xxxx

Drive

STEP+

STEP–

EN+

EN–

R

(If enable function is used)

+12-24V

PLC with

Sourcing

Outputs

ENABLE

COM

DIR

STEP

+ –

12-24 VDC

R

R

DIR–

DIR+

STP-DRV-xxxx

Drive

STEP–

STEP+

EN–

EN+

R

(If enable function is used)

Connecting to Mechanical Switches at 24 VDC

+

+24VDC

Power

Supply

direction switch

2200 run/stop switch

(closed = run)

2200

DIR+

DIR-

STEP+

STP

-DRV

-xxxx

Drive

STEP-

Connections to the EN Input

The ENABLE input allows the user to turn off the current to the motor by providing a 5-12 VDC positive voltage between EN+ and EN-. The logic circuitry continues to operate, so the drive “remembers” the step position even when the amplifiers are disabled. However, the motor may move slightly when the current is removed depending on the exact motor and load characteristics.

Warning: 12VDC is the maximum voltage that can be applied directly to the standard speed EN input. If using a higher voltage power source, install resistors to reduce the voltage at the input. Do NOT apply an AC voltage to an input terminal.

Connecting ENABLE Input to Relay or Switch

+ EN+

5-12VDC

Power

Supply

switch or relay

(closed = logic low)

STP-DRV-xxxx

Drive

EN-

Connecting ENABLE Input to NPN Proximity Sensor

+ EN+

+ output

EN5-12VDC

Power

Supply

-

NPN

Proximity

Sensor

STP-DRV-xxxx

Drive

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Connecting ENABLE Input to PNP Proximity Sensor

+ + output EN+

5-12VDC

Power

Supply

-

-

PNP

Proximity

Sensor

STP-DRV-xxxx

Drive

EN-

Leave the ENABLE 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 AI to Analog Signal

0-5V signal AIN

+5V

AIN

GND

Internal to the

STP-DRV-xxxx

+5VDC, 10mA max

330

220pF

Drive Analog Input Circuit signal return

STP-DRV-xxxx

Drive

GND

Connecting AI to Potentiometer

+5V

1-10k potentiometer

AIN

GND

STP

-DRV

-xxxx

Drive

4–10

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 (DO) that has separate positive (+) and negative (-) terminals, and can be used to sink or source current.

OUT+

Internal to the

STP-DRV-xxxx

OUT–

Drive Digital Output Circuit

Connecting DO to Inductive Load

relay coil

(inductive load)

OUT+

STP-DRVxxxx Drive

OUT-

1N4935 diode

+

5-24 VDC

Power

Supply

-

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Connecting DO as Sinking Output

OUT+

STP-DRVxxxx Drive

OUT-

Load +

5-24 VDC

Power

Supply

-

Connecting DO as Sourcing Output

OUT+

STP-DRVxxxx Drive

OUTLoad

+

5-24 VDC

Power

Supply

-

Warning: Do NOT connect the digital output to a voltage greater than 30VDC.

The current through each DO terminal must not exceed 100mA.

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LED Display Codes

The LEDs on the Surestep advanced drives flash in the sequences shown in the table below to denote various alarm states.

STP-DRV-4850 and 80100 Alarm Codes

Alarm

Code

SG

LED Sequence

Solid green

Alarm Description

No alarm, motor disabled

FG

Fast green

Factory use

01

Flashing green

No alarm, motor enabled

10

Flashing red

Configuration or memory error1

11

1 red, 1 green

Motor stall (optional encoder only)4

12

1 red, 2 green

Move attempted while drive disabled

21

2 red, 1 green

CCW limit

22

2 red, 2 green

CW limit

31

3 red, 1 green

Drive overheating

32

3 red, 2 green

Internal voltage out of range2

33

3 red, 3 green

Factory use

41

4 red, 1 green

Power supply overvoltage2

42

4 red, 2 green

Power supply undervoltage

43

51

61

62

4 red, 3 green

5 red, 1 green

6 red, 1 green

6 red, 2 green

Flash memory backup error

Over current / short circuit2, 3

Open motor winding2

Bad encoder signal (optional encoder only)4

Serial communication error5 71

7 red, 1 green

72

7 red, 2 green

1 - Does not disable the motor.

The alarm will clear about 30 seconds after the fault is corrected.

2 - Disables the motor. Cannot be cleared until power is cycled.

Flash memory error

3 - 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.

4 - This alarm only occurs on STP-MTRD advanced integrated motor/drives

5 - This alarm does not occur on STP-DRV-6575 or standard integrated motor/drives

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01

10

11

12

21

22

31

32

Alarm Code Definitions

Alarm Code

SG

Error

No alarm, motor disabled

No alarm, motor enabled

Configuration or memory error

Motor stall

(optional encoder only)

Move attempted while drive disabled

CCW limit

Description

No faults active, Circuit is closed between EN+ and

EN-.

No faults active, Circuit is open between EN+ and EN-.

Memory error detected when trying to load config from flash on powerup.

Motor torque demand exceeded capability and the motor skipped steps. This is configured in SureMotion

Pro.

Drive is disabled and move attempted.

N/A

N/A

Corrective Action

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

Increase torque utilization if it’s not already maxed out, otherwise decrease the torque demand by modifying the move profile, or put in a larger motor.

Reset alarm, enable motor, and move again.

CW limit

Drive overheating

Internal voltage out of range

CCW limit is reached. The digital input that has been assigned CCW limit has been activated.

Unblock the CCW sensor (open the circuit) or redifine the input with

SureMotion Pro.

CW limit is reached. The digital input that has been assigned CW limit has been activated.

The drive’s internal temperature is too high.

Unblock the CCW sensor (open the circuit) or redefine the input with

SureMotion Pro.

Gate voltage, 5V rail, or 3V rail are out of spec.

If the drive is operating within its standard range (input voltage and output current are OK), more heat must be removed from the drive during operation. For Advanced drives (see “Mounting the Drive” on page 4-14), ensure the drive is mounted to a metal surface that can dissipate the drive’s heat.

For Integrated motor/drives, see

“Mounting” on page 5-13. For both types of drives: If the mounting surface cannot pull enough heat away from the drive, forced airflow (from a fan) may be required to cool the drive.

Ensure adequate supply voltage (in very rare cases, low input voltages combined with fast accelerations can draw down the gate voltage) and try again. If persistant, RMA is required.

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Alarm Code

41

42

43

51

61

62

71

72

Error

Power supply overvoltage

Power supply undervoltage

Flash memory backup error

Over current / short circuit

Open motor winding

Bad encoder signal (optional encoder only)

Serial communication error

Flash memory error

Description

The DC voltage feeding the drive is above the allowable level.

The DC voltage feeding the drive is below the allowable level.

Corrective Action

Decrease the input voltage.

Linear power supplies do not output a fixed voltage: the lighter the output current, the higher the output voltage will float. If a linear supply’s voltage floats above the drive’s max voltage, you can install a small power resistor across the linear power supply’s output to provide some load that will help pull down the floating voltage.

Consider using a switching power supply such as the Rhino PSB power supply series.

Overvoltage can also be fed back into a system by regeneration (when an overhauling load pushes energy back into the motor). In an application with regen problems, install an STP-DRVA-

RC-050 regen clamp to help dissipate the extra energy. (The regen clamp will not help with the floating linear power supply that floats too high, but it will help with excess voltage generated from an overhauling load.)

Correct the power supply. If this error occurs during operation, the power supply is most likely undersized. A sudden high current demand can cause an undersized power supply to dip in output voltage.

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

Check and fix motor wiring.

Memory error detected when trying to load config from flash on powerup.

Motor leads shorted - only checked on powerup.

Motor leads not connected - only checked on powerup.

Noisy or otherwise incorrectly formatted encoder signal (lack of A or

B, lack of differential signal).

Catch-all error for something wrong with serial communications. See CE command in HCR for details.

Memory error detected when trying to load config from flash on powerup.

Check and fix motor wiring.

Check encoder wiring, always use differential encoders (or use checkbox in SureMotion Pro to disable this error when using single ended).

If drive can communicate, CE can give a precise diagnosis. If not, refer to the Serial Communications part of the

HCR for troubleshooting.

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

4–14 SureStep

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Chapter 4: SureStep™ Advanced Microstepping Drives

Drive Configuration

You need to configure your drive for your particular application before using the drive for the first time. The SureStep advanced microstepping drives require

SureMotion Pro (part number SM-PRO, free download at Automationdirect.

com) drive configuration software for this purpose. Please refer to Chapter 8:

“SureMotion Pro Configuration Software” or the software’s help file for more detailed information on configuring the drive. 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

• I/O configuration

Anti-Resonance / Electronic Damping

Step motor systems have a tendency to resonate at certain speeds. SureStep advanced drives automatically calculate the system’s natural resonate frequency, and apply damping to the control algorithm. This greatly improves midrange stability, allows higher speeds and greater torque utilization, and improves settling times.

This feature is on by default, but it can be turned off using the “Motor...” icon of the SureMotion Pro software.

Idle Current Reduction

This feature reduces current consumption while the system is idle, and subsequently reduces drive and motor heating. However, reducing the idle current also reduces the holding torque.

The percent and delay time of the idle current reduction can be adjusted using the

“Motor...” icon of the SureMotion Pro software.

Microstep Resolution

The microstep resolution (steps/rev) can be selected using the “Motion & I/O...” icon of the SureMotion Pro software, and selecting “Pulse and Direction Mode”.

7th Ed. Rev D – 03/17/2022

SureStep

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Stepping Systems User Manual 4–15

Chapter 4: SureStep™ Advanced Microstepping Drives

Modes of Operation

Modes of operation are selectable via the SureMotion Pro software “Motion &

I/O...” icon.

• Pulse & Direction Mode

• Pulse & Direction

• CW & CCW Pulse

• A/B Quadrature

• Velocity (Oscillator) Mode

• Serial Command Language (SCL)

Phase Current Setting

Motor phase current settings are available through the SureMotion 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 & I/O...” icon of the SureMotion

Pro software, and selecting Serial Command Language.

Step Smoothing Filter (Command Signal Smoothing & Microstep Emulation)

The Step Smoothing Filter setting is effective only in the Step (Pulse) & Direction mode. It includes command signal smoothing and microstep emulation to soften the effect of immediate changes in velocity and direction, therefore making the motion of the motor less jerky. An added advantage is that it can reduce the wear on mechanical components.

This feature can be modified by using the “Motion & I/O...” icon of the

SureMotion 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 SureMotion Pro software. To set

Waveform Smoothing for custom motors, select “Define Custom Motor...” and the

“Waveform Smoothing” “Wizard...”.

CAUTION: Power down the SureStep drive before plugging a communication cable into the comm port of the drive. Failure to do so may result in damage to the drive comm port!

4–16 SureStep

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Chapter 4: SureStep™ Advanced Microstepping Drives

Mounting the Drive

You can mount your drive on the wide or the narrow side of the chassis using

#6 screws. Since the drive amplifiers generate heat, the drive should be securely fastened to a smooth, flat metal surface that will help conduct heat away from the chassis. If this is not possible, then forced airflow from a fan may be required to prevent the drive from overheating.

• Never use your drive in a space where there is no air flow or where the ambient temperature exceeds 40 °C (104 °F).

• When mouting multiple STP-DRV-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.

Drive Heating

For information on drive heating, please see Chapter 8: SureStep System Power

Supplies.

Dimensions and Mounting Slot Locations

0.61

[15.5]

1.98

[50.3]

SureStep

Microstepping

Drive

-

STP-DRV-4850

STP-DRV-80100

3.0

[76.2]

0.663

[16.8]

3.39 [86.1]

3.65 [92.7]

1.125

[28.6]

6X slot 0.16 [4.1] wide, full R

DIMENSIONS

= in [mm]

7th Ed. Rev D – 03/17/2022

SureStep

TM

Stepping Systems User Manual 4–17

Chapter 4: SureStep™ Advanced Microstepping Drives

BLANK

PAGE

4–18 SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

S ure

S

tep

tM

Stp-DRVAC-24025

M

iCRoStepping

D

RiVe

C hapter

5

In This Chapter...

Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–2

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–3

Mounting the Drive � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–4

Dimensions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–4

Wiring Connections and Configuration Switches � � � � � � � � �5–5

STP-DRVAC-24025 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–5

Connecting the Power Supply � � � � � � � � � � � � � � � � � � � � � � �5–6

Connecting the Motor � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–7

Selecting the Motor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–8

Torque-Speed Curves � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–8

Connecting the I/O � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–9

Step/Direction Mode and CW/CCW Mode Jumper � � � � � � � � � � �5–9

Connecting the Input Signals - Step and Direction � � � � � � � � � � �5–9

The Enable Input � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–10

Connecting the Fault Output Setting � � � � � � � � � � � � � � � � � � � �5–11

Drive Configuration � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–12

Microstepping � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–13

Setting Running Current � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–13

Idle Current Reduction � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–14

Step Noise Filter � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–14

Load Inertia � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–14

Smoothing Filter � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–14

Self Test � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–15

Alarm Codes � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �5–16

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Features

The STP-DRVAC-24025 AC input drive is based on advanced digital current control technology and provides high torque, low noise, and low vibration. Many of the operational parameters are switch selectable.

• Advanced digital current control provides excellent high speed torque

• Auto-setup probes the motor when power is applied and configures and fine tunes motor current control and anti-resonance gain settings

• Uses universal AC input 90 to 240 VAC, AC input voltage must be selected by switch

• Speed range - up to 50 rps

• Microstep resolution - switch selectable, 16 settings from 200 to 25600 steps/rev

• Running current - peak setting, switch selectable, 8 settings from 0.6 to 2.5 A

• Idle current -automatic reduction of running current 1 second after the motor stops, switch selectable, 2 settings, 50/90% of running current

• Anti resonance - raises the system-damping ratio to eleiminate midrange instability and allow stable operation throughout the speed range of the motor, switch selectable, 2 settings, low to high inertia loads

• Control modes - step/direction pulse input (default) or CW/CCW pulse input, internal jumper switch selectable

• Input signal filter - filters out unwanted noise that can cause extra steps, switch selectable, 150kHz or 2MHz

• Step smoothing filter (microstep emulation) - performs high resolution stepping by synthesizing coarse steps into fine micro-steps, switch selectable, ON or OFF

• Self test - performs a 2 rev 0.5 rps, forward and reverse move test, switch selectable, ON or OFF

• Motor selection - a 16-bit rotary switch is used to select the desired motor database which is pre-loaded at the factory

5–2 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Specifications

Sure Step™ Microstepping Drive Specifications

Part Number

Input Power

Output Current

Current Controller

STP-DRVAC-24025

90–240 VAC

0.6–2.5 A

MOSFET, dual H-bridge and 4-quadrant PWM at 20kHz

5 –24 VDC nominal (range: 4–28 VDC); optically isolated, differential. Maximum pulse frequency = 150kHz or 2MHz (user selectable).

Step

Minimum pulse width:

3 usec at 150 kHz setting SW9

1 usec at 2 MHz setting SW9

Function = Step or Step CW pulse.

5 –24 VDC nominal (range: 4–28 VDC); optically isolated, differential. Maximum pulse frequency = 150kHz or 2MHz (user selectable).

Input

Signals Direction

Step Pulse

Type

Minimum pulse width:

3 usec at 150 kHz setting SW9

1 usec at 2 MHz setting SW9

Function = Direction or Step CCW pulse.

5 –24 VDC nominal (range: 4–30 VDC); (5mA @ 4V; 15 mA @ 30V); Optically isolated, differential.

Output

Signal

Internal

Jumper

Selectable

Function

Enable

Fault

Max pulse frequency: 10kHz

Minimum pulse width: 500usec

Function = disable motor when closed.

30VDC max / 100mA max, optically isolated photodarlington, sinking or sourcing.

Function = closes on drive fault.

Step and Direction:

Step signal = step/pulse; Direction signal = direction.

Step CW & CCW:

Step signal = CW step; Direction signal = CCW step.

Step

Resolution

Running

Current

DIP Switch

Selectable

Functions

Idle Current

Reduction

Selectable from 200 steps/rev up to 25600 steps/rev using SW1-4.

The output current drive to the motor is set by the SW5, SW6, and SW7 switches and can be changed from 0.6 A to 2.5 A per phase.

Reduce power consumption and heat generation by limiting motor idle current to 90% or 50% of running current. (Holding torque is reduced by the same %.)

Step Noise

Filter

Selt Test

Select 150kHz or 2MHz using SW9.

Load Inertia Set the load inertia to 0-4x or 5-10x using SW10 (also referred to as anti-resonance)

Smoothing

Filter

Softens the effect of immediate changes in velocity and direction, making the motion of the motor less jerky. Can cause a small delay in following the control signal.

Automatically rotate the motor back and forth two turns in each direction in order to confirm that the motor is operational.

Drive Cooling Method Natural cooling or fan-forced cooling

Mounting Use (2) M4 screws to mount to metal surface

DEGSON:

Removable Connectors*

Weight

2EDGK-7.62-02P-14-00A(H), 2 pin power connector

2EDGK-5.08-04P-14-00A(H), 4 pin motor connector

15EDGK-3.81-08P-14-00A(H), 8 pin I/O connector

0.88 kg [1lb 15oz]

Operating Temperature 0– 85 °C [32–185 °F] (interior of electronics section)

Ambient Temperature 0– 40 °C [32–104 °F]

Humidity

Agency Approvals

Maximum 90% non-condensing

CE, cURus

*Replacement connectors are available in connector kit STP-CON-6

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Sure Step TM Stepping Systems User Manual 5–3

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Mounting the Drive

The STP-DRVAC-24025 drive can be mounted only on the narrow side of the chassis using (2) M4 screws in the holes at the back of the drive. Use forced air cooling such as a fan to operate the drive continuously at maximum power.

WARNING :

• Never mount the drive in a space where there is no air flow, or where other devices can heat the surrounding air to 40°C [104°F].

• Never put the drive where it can get wet, or where metal or other electricallyconductive particles can get on the circuitry.

• Always provide air flow around the drive. Minimum allowable spacing between multiple drives is 0.5 inches [13 mm].

Dimensions

Ø0.18

[Ø4.5]

0.18

[4.5]

0.41

[10.5]

0.24

[6.0]

0.18

[4.5]

5.15

[130.7]

Dimensions = in [mm]

4.32

109.8

1.87

47.5

5.56

141.2

5–4 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Wiring Connections and Configuration Switches

STP-DRVAC-24025

The following items are required to set up the STP-DRVAC-24025 drive:

• AC input of 90 to 240 VAC

• Pulse and direction signal

• A compatible step motor (STP-MTRAC-23 and -34 series recommended; the STP-

MTRAC(H)-42x series will not work with this drive. The motors can accept the high voltage, but the drive does not supply enough current for the NEMA 42 motors)

• AC input voltage must be selected by switch

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 5–5

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Connecting the Power Supply

DO NOT apply power until all connections to the drive have been made. Use a

4A fuse on the line connection for drive protection.

1. Select power input voltage. AC input voltage must be selected by switch.

Check input voltage to avoid damage before powering on.

Set 115VAC Set 230VAC (default)

Supply voltage is 90 to

135 VAC

Supply voltage is 135 to 240 VAC

2. Wire the drive to the AC power source. Use 16 AWG wire for Line (L) and

Neutral (N). Use 14 AWG for Earth Ground (G).

Neutral (White)

Line-hot (Black)

Earth Ground (Green)

The STP-DRVAC-24025 contains a non-replaceable internal 5A fast acting fuse.

Warning: When connecting a step motor to the SureStep™ STP-DRVAC-24025 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 cannot 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.

5–6 Sure Step TM Stepping Systems User Manual

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Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Connecting the Motor

Warning: When connecting a step motor to the Sure Step™ STP-DRVAC-24025 microstepping drive, be sure that the motor power supply is switched off. When using a motor not supplied by a utomation D irect , secure any unused motor leads so that they cannot 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.

Connect the drive to the motor. If using a non AutomationDirect motor, consult the motor specs for wiring information. It is very important to only use high bus voltage stepper motors with the STP-DRVAC-24025 as it outputs up to 340 volts to the motor. It is highly recommended that you use an AutomationDirect recommended motor that is equipped with a shielded cable. The NEMA23 and

NEMA34 STP-MTRAC-x motors are specifically made to be used with the STP-

DRVAC-24025 drive.

Always connect the motor’s cable drain wire to the two screws next to the A+ terminal. The connecting of this drain wire not only grounds the motor frame but also connects the cable shield to minimize electrical interference.

The recommended AutomationDirect step motors for the STP-DRVAC-24025 include shielded cables and should always be wired in the series configuration as shown below. The STP-DRVAC-24025 has an internal voltage doubler when connected to 115VAC so the series configuration is required in order to limit the current output of the drive. If you are using a different manufacturer’s drive that does not have a voltage doubler when connected to 110VAC then you should wire the STP-MTRAC-x motors in parallel to achieve the same phase current.

STP-MTRAC-23044(x), 23055(x),

23078(x), 34156(x)

A+

White

Orange

Brown

A–

8 lead motor

Green

Red

B+

Yellow

Blue

B–

Black

8 Leads Series Connected

(for use with 340VDC max output drives)

STP-MTRAC-34075(x), 34115(x)

A+ A+

White

Brown

Orange/White

8 lead motor

8 lead motor

A– A–

Black

Red

Red

B+

Red/

White

Yellow/

White

B–

B–

WARNING:

Always wire

STP-MTRAC motors in series when using the STP-

8 lead motor

Black

Red Yellow

B+

Yellow/

White

Red/

White

B–

8 Leads Parallel Connected

(for use with 170VDC max output drives)

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 5–7

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Selecting the Motor

Each position of the 16-bit rotary switch selects a different motor, automatically setting the configuration parameters in the drive. The STP-DRVAC-24025 drive comes programmed with up to 6 SureStep motors as factory defaults. The remaining options are either reserved for future or factory use.

Warning: Do NOT use standard low-voltage stepper motors with the AC-input drive.

Only use stepper motors rated for AC-input systems (such as the STP-MTRAC motors).

The high bus voltage on the STP-DRVAC drive will overheat and damage standard stepper motors that are wound for lower-voltage DC systems.

If the motor selection is changed, the drive power supply will need to be cycled.

NOTE: Motor current is limited by the lower value between rotary switch setting and the

Running Current dip switches. The default setting for the running current is 0.6 A for motor protection. Be sure to adjust this setting when selecting a motor .

For a custom motor, please select the closest comparable motor via the rotary switch, then use the DIP switches to configure motor current, anti-resonance, and other settings.

Rotary Switch

Position

0 – 6

7

A

B

8

9

C

D – F

STP-DRVAC-24025 Motor Selection

Motor

Rated Current

(A/phase RMS)

Reserved

STP-MTRAC-23044(D)

STP-MTRAC-23055(D)

STP-MTRAC-23078(D)

STP-MTRAC-34075(D)

STP-MTRAC-34115(D)

STP-MTRAC-34156(D)

0.71

0.71

0.71

2.15

2.05

2.55

Reserved

Wiring

Series

Series

Series

Series

Series

Series

5–8 Sure Step TM Stepping Systems User Manual

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Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Connecting the I/O

The SureStep STP-DRVAC-24025 drive includes two high-speed 5–24 VDC digital inputs (STEP & DIR, or CW/CCW) accepting single-ended or differential signals, up to 2MHz depending on DIP SW9 selection , one 5–24 VDC digital input (EN), and one digital output (Fault).

The digital inputs are optically isolated to reduce electrical noise problems. There is no electrical connection between the control and power circuits within the drive, and input signal communication between the two circuits is achieved by infrared light.

For bidirectional rotation, supply a source of step pulses to the drive at the STEP+ and STEP– terminals, and a directional 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.

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.

Step/Direction Mode and CW/CCW Mode Jumper

To adjust the STP-DRVAC-24025 drive to accept STEP CW and STEP CCW signals, remove the drive cover and move jumper J10 from the 1-2 position to the 2-3 position. Jumper J10 is located at the top of the main circuit board, just behind the white 4-pin connector. The CW signal should be connected to the

STEP input and the CCW signal should be connected to the DIR input.

Connecting the Input Signals - Step and Direction

Connecting Drive to Indexer with Sourcing Outputs

COM DIR–

Indexer with

Sourcing

Outputs

(5–24 VDC)

DIR

STEP

DIR+

STEP–

STEP+

Drive

Connecting Drive to Indexer with Sinking Outputs

(5–24 VDC) +V OUT DIR+

DIR DIR–

Indexer with

Sinking

Outputs

(5-24 VDC)

STEP

STEP+

STEP–

7th Ed. Rev D – 03/17/2022

Drive

Sure Step TM Stepping Systems User Manual 5–9

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Connecting Drive to Indexer with Differential Outputs

Indexer with

Differential

Outputs

DIR+

DIR–

DIR+

DIR–

STEP+

STEP–

STEP+

STEP–

Drive

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.

Connecting Drive EN to Switch or Relay

+

5-24 VDC

Power

Supply

switch or relay

(closed = logic low)

EN+

Drive

EN–

Connecting Drive EN to NPN

+

5-24 VDC

Power

Supply

-

+ output

-

NPN

Proximity

Sensor

EN+

EN–

Drive

5–10 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Connecting the Fault Output Setting

The Sure Step STP-DRVAC-24025 has one digital output that has separate positive

(+) and negative (-) terminals, and can be used to sink or source current. Do not connect more than 30VDC. Current must not exceed 80mA.

Connecting Drive’s Fault Output to Inductive Relay

FAULT+

Drive

FAULT–

+

5-24 VDC

Power

Supply

-

Connecting Fault Output as Sinking Output

FAULT+

Drive

FAULT–

Load +

5-24 VDC

Power

Supply

-

Connecting Fault Output as Sourcing Output

FAULT+

Drive

FAULT– Load

+

5-24 VDC

Supply

-

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 5–11

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Drive Configuration

You need to configure your drive for your particular application before using the drive for the first time. The SureStep STP-DRVAC-24025 microstepping drive offers several features and configuration settings, including:

Feature

Motor Phase Current

Mode of Operation

(Step Pulse Type)

Drive Configuration Settings

Description

Select motor based on part number.

Automatically sets drive to run the selected motor as optimally as possible.

Step and Direction (default): Step signal = step/pulse; Direction signal = direction.

Step CW & CCW: Step signal = CW step;

Direction signal = CCW step.

Configuration Method

Choose motor via rotary switch

Jumper J10

Step Pulse Noise Filter

Running Current

Idle Current Reduction

Load Inertia

Step Resolution

Self Test

Step Smoothing Filter

Select 150 kHz or 2MHz DIP switch SW9

The output current is set by the SW5, SW6 and SW7 switches.

NOTE: Drive’s running current will be limited by the lower value between motor selection rotary switch or the dip current switch

Reduce power consumption and heat generation by limiting motor idle current to

90% or 50% of running current. (Holding torque is reduced by the same %.)

Anti-resonance and damping feature improve motor performance.

Set motor and load inertia range to 0–4x or

5–10x.

For smoother motion and more precise speed, set the pulse per revolution value as needed.

Automatically rotates the motor back and forth 1/2 a revolution in each direction in order to confirm that the motor is operational.

Softens the effect of immediate changes in velocity and direction, making the motion of the motor less jerky. Can cause a small delay in following the control signal.

DIP switch SW5, SW6,

SW7

DIP switch SW8

DIP switch SW10

DIP switch SW1, SW2,

SW3, SW4

DIP switch SW12

DIP switch SW11

5–12 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Microstepping

The microstep resolution is set by the SW1, SW2, SW3, and SW4 switches. There are 16 settings.

Please refer to the table below and set the switches for the resolution you want.

STP-DRVAC-24025 Microstep Table

MicroStep

1000

2000

4000

5000

6000

8000

10000

20000

200

400

800

1600

3200

6400

12800

25600

Switch 1

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

Switch 2

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

ON

ON

OFF

OFF

Switch 3

ON

ON

ON

ON

OFF

OFF

OFF

OFF

ON

ON

ON

ON

OFF

OFF

OFF

OFF

Switch 4

OFF

OFF

OFF

OFF

OFF

OFF

OFF

OFF

ON

ON

ON

ON

ON

ON

ON

ON

Setting Running Current

Before you turn on the power supply the first time, you need to set the drive for the proper motor running current. The rated current is usually printed on the motor label. The SureStep drive current is easy to set using the table below:

STP-DRVAC-24025 Running Current Table

Peak A

1.6

1.8

2.0

2.5

0.6

0.8

1.0

1.2

Switch 5

ON

OFF

ON

OFF

ON

OFF

ON

OFF

Switch 6

ON

ON

OFF

OFF

ON

ON

OFF

OFF

Switch 7

ON

ON

ON

ON

OFF

OFF

OFF

OFF

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 5–13

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

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.

ON

Idle Current

Reduction

8

50%

8

90%

Idle current reduction is enabled by flipping switch SW8 toward the ON position, as shown in the sketch at right. Flipping the switch to the OFF position disables the reduction feature.

Step Noise Filter

Step Noise

Filter

Filters out unwanted noise that can cause extra steps. Set the switch SW9 to the ON position to set filter frequeny to

150kHz. Set the switch to the OFF position to set the filter frequency to 2MHz.

ON

9 9

150kHz 2MHz

Load Inertia

Step motor systems have a tendency to resonate at certain speeds. The load inertia setting applies damping to the control algorithm. This greatly improves midrange stability, allows higher speeds and greater torque utilization, and improves settling times.

Load inertia is set to the 0-4x setting by flipping switch

SW10 to the ON position, or 5-10x inertia by flipping the switch to the OFF position.

Load Inertia

ON 10 10

0-4x

Inertia

5-10x

Inertia

Smoothing Filter

The Step Smoothing Filter setting is effective only in the

Step (Pulse) & Direction mode. It includes command signal smoothing and microstep emulation to soften the effect of immediate changes in velocity and direction, therefore making the motion of the motor less jerky. An added advantage is that it can reduce the wear on mechanical components.

The smoothing filter is enabled when switch SW11 is in the

ON position, and disabled when the switch is in the OFF position.

Smoothing

Filter

ON 11 11

Enable Disable

NOTE: The power must be cycled each time the position of switch 9 or switch 11 is changed .

5–14 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

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.

Self

Test

To activate the self test, flip switch SW12 to the ON position. The drive will slowly rotate the motor, 1/2 revolution forward, then 1/2 rev backward. The pattern repeats until you flip the switch to the OFF position. The

ON

12 12

Enable Disable

SureStep drive always uses half step mode during the self test. The self test ignores the STEP and DIRECTION inputs while operating. The

ENABLE input continues to function normally.

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 5–15

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

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-DRVAC-xxxx Alarm Codes

Alarm

Code

SG

LED Sequence

Solid green

Alarm Description

No alarm, motor disabled

FG

Fast green

Factory use

01

Flashing green

No alarm, motor enabled

10

Flashing red

Configuration or memory error1

11

1 red, 1 green

Motor stall (optional encoder only)4

12

1 red, 2 green

Move attempted while drive disabled

21

2 red, 1 green

CCW limit

22

2 red, 2 green

CW limit

31

3 red, 1 green

Drive overheating

32

3 red, 2 green

Internal voltage out of range2

33

3 red, 3 green

Factory use

41

4 red, 1 green

Power supply overvoltage2

42

4 red, 2 green

Power supply undervoltage

43

51

52

4 red, 3 green

5 red, 1 green

5 red, 2 green

Flash memory backup error

Over current / short circuit2, 3

Excess regeneration

61

62

71

6 red, 1 green

6 red, 2 green

7 red, 1 green

Open motor winding2

Bad encoder signal (optional encoder only)4

Serial communication error5

72

7 red, 2 green

1 - Does not disable the motor.

The alarm will clear about 30 seconds after the fault is corrected.

Flash memory error

2 - Disables the motor. Cannot be cleared until power is cycled.

3 - 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.

4 - This alarm only occurs on STP-MTRD advanced integrated motor/drives

5 - This alarm only occurs on drives with serial communication.

5–16 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

01

10

11

12

21

22

31

32

Alarm Code Definitions

Alarm Code

SG

Error

No alarm, motor disabled

No alarm, motor enabled

Configuration or memory error

Motor stall

(optional encoder only)

Description

No faults active, Circuit is closed between EN+ and

EN-.

No faults active, Circuit is open between EN+ and EN-.

Memory error detected when trying to load config from flash on powerup.

Motor torque demand exceeded capability and the motor skipped steps. This is configured in SureMotion

Pro.

Drive is disabled and move attempted.

N/A

N/A

Corrective Action

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

Increase torque utilization if it’s not already maxed out, otherwise decrease the torque demand by modifying the move profile, or put in a larger motor.

Move attempted while drive disabled

CCW limit

Reset alarm, enable motor, and move again.

CW limit

Drive overheating

Internal voltage out of range

CCW limit is reached. The digital input that has been assigned CCW limit has been activated.

CW limit is reached. The digital input that has been assigned CW limit has been activated.

The drive’s internal temperature is too high.

Unblock the CCW sensor (open the circuit) or redifine the input with

SureMotion Pro.

Unblock the CCW sensor (open the circuit) or redefine the input with

SureMotion Pro.

Gate voltage, 5V rail, or 3V rail are out of spec.

If the drive is operating within its standard range (input voltage and output current are OK), more heat must be removed from the drive during operation. For Advanced drives (see

“Mounting the Drive” on page 4-14), ensure the drive is mounted to a metal surface that can dissipate the drive’s heat. For Integrated motor/drives, see

“Mounting” on page 5-13. For both types of drives: If the mounting surface cannot pull enough heat away from the drive, forced airflow (from a fan) may be required to cool the drive.

Ensure adequate supply voltage (in very rare cases, low input voltages combined with fast accelerations can draw down the gate voltage) and try again. If persistant, RMA is required.

7th Ed. Rev D – 03/17/2022

Sure Step TM Stepping Systems User Manual 5–17

Chapter 5: Sure Step TM STP-DRVAC-24025 Microstepping Drive

Alarm Code

41

42

43

51

52

61

62

71

72

Error

Power supply overvoltage

Power supply undervoltage

Flash memory backup error

Over current / short circuit

Excess regen

Open motor winding

Bad encoder signal (optional encoder only)

Serial communication error

Flash memory error

Description

The AC voltage feeding the drive is above the allowable level.

The AC voltage feeding the drive is below the allowable level.

Corrective Action

Limit the input voltage to the drive to

145VAC if the voltage switch is set for 115V. If the voltage switch is set for 230V, limit the input voltage to

295VAC.

Ensure the input voltage to the drive is at least 75VAC if the voltage switch is set for 115V. If the voltage switch is set for 230V, ensure the input voltage is at least 135VAC.

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

Check and fix motor wiring.

Memory error detected when trying to load config from flash on powerup.

Motor leads shorted - only checked on powerup.

Too much regenerative energy is being fed from the motor back into the drive.

Excess Regen typically occurs when a motor is being pushed by load

(overhauling load) or the motor is trying to decelerate the load too quickly.

Reduce the backdriving force, lengthen the deceleration ramp, or increase the size of the motor.

Check and fix motor wiring.

Motor leads not connected - only checked on powerup.

Noisy or otherwise incorrectly formatted encoder signal (lack of A or

B, lack of differential signal).

Catch-all error for something wrong with serial communications. See CE command in HCR for details.

Memory error detected when trying to load config from flash on powerup.

Check encoder wiring, always use differential encoders (or use checkbox in SureMotion Pro to disable this error when using single ended).

If drive can communicate, CE can give a precise diagnosis. If not, refer to the

Serial Communications part of the HCR for troubleshooting.

Restart device. No fix if restart doesn’t work. Return to manufacturer for correction.

5–18 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

S

ure

S

tep

™

I

ntegrated

M

otorS

/d

rIveS

C hapter

6

In This Chapter...

Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–3

General Features: � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–3

Standard Drive Features� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–3

Advanced Drive Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–3

Features Comparison � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–4

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–5

Getting Started � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–11

Installing Software � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–11

Mounting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–11

Additional Reading � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–12

Mating Connectors and Accessories � � � � � � � � � � � � � � � � � �6–12

Using a Regulated Power Supply � � � � � � � � � � � � � � � � � � � � � � � �6–17

LED Error Codes � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–18

STP-MTRD Inputs and Outputs � � � � � � � � � � � � � � � � � � � � � �6–22

Input/Output Functions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–25

The Step (STEP) and Direction (DIR) Inputs � � � � � � � � � � � � � � � �6–26

The Enable (EN/IN3) Digital Input � � � � � � � � � � � � � � � � � � � � � � �6–28

The Analog (AIN) Input � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–29

The Digital Output � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–30

Using the Optional Encoder � � � � � � � � � � � � � � � � � � � � � � � �6–31

Configuring the Standard STP-MTRD � � � � � � � � � � � � � � � � �6–32

Drive/Motor Heating � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–37

Torque Speed Graphs � � � � � � � � � � � � � � � � � � � � � � � � � � � � �6–40

Chapter 6: SureStep™ Integrated Motors/Drives

Dimensions and Mounting Slot Locations � � � � � � � � � � � � 6–43

6–2 SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 6: SureStep™ Integrated Motors/Drives

Features

General Features:

• NEMA 17, NEMA 23, and NEMA 24 frame sizes available

• DC power supply required: 12-48 VDC or

12-70 VDC

• Pulse/Direction or CW Pulse/CCW Pulse

• Digital input filtering

• Three optically isolated digital inputs, 5 to

24 volts

• One isolated digital input, 30V 100mA

• Step input signal smoothing (microstep emulation), performs high resolution stepping by synthesizing coarse steps into fine microsteps

• Dynamic smoothing, software configurable filtering for use in removing spectral components from command sequence, reduces jerk, limiting excitation of system resonance

• Anti-resonance (electronic damping): raises the system-damping ratio to eliminate midrange instability and allow stable operation throughout the speed range of the motor

• Idle current reduction range of 0-90% of running current after a delay selectable in milliseconds

• Configurable hardware digital noise filter, software noise filter

• Non-volatile storage, configurations are saved in FLASH memory on-board the DSP

• Dynamic current control, software configurable for running current, accel current, idle current, to make motion smoother and the motor run cooler

Standard Drive Features

• Optional, external encoder feedback

Note: Please see Appendix A for more encoder output options

• Configurable via DIP switches

• Available torque from 60 oz-in to 210 oz-in

Advanced Drive Features

• AB Quadrature/Encoder Following

• Velocity (Oscillator) and position mode

• Streaming SCL commands

• RS-485 communications

• Optional, internal encoder feedback. Internal only (not customer accessible)

• Four “Variable I/O” points, 5 to 24 volts (available on NEMA 24 only)

• 12-bit analog input for speed and position, 0 to 5 VDC

• Configurable via SureMotion Pro software

• Available torque from 68 oz-in to 340 oz-in

7th Ed. Rev D – 03/17/2022

SureStep

TM

Stepping Systems User Manual 6–3

Chapter 6: SureStep™ Integrated Motors/Drives

Features Comparison

Features Comparison – Integrated Motor/Drives

Motor/Drive Series

Motor/Drive Type

STP-MTRD-

17xxxxR(E)

STP-MTRD-

23xxxxR(E)

STP-MTRD-

24xxxxRV(E)

STP-MTRD-

17xxxx(E)

STP-MTRD-

23xxxx(E)

Advanced (w/RS-485 Serial/ASCII)

DC Power Supply 12-48 VDC 12-70 VDC 12-70 VDC

Pulse/Direction or

CW Pulse/CCW Pulse

AB Quadrature/

Encoder Following

Velocity (Oscillator) and Position Mode







Serial ASCII (SCL)

Commands

RS-485 ASCII

Communications

Optional, Internal

Encoder Feedback

(Position Verification)

Optional, External

Encoder Feedback

(Open Loop)

Available Torque







-

Up to 68 oz-in

 Digital Input Filtering

Three Optically

Isolated Digital

Inputs, 5-24 Volts

One Optically

Isolated Digital

Output, 30V 100mA

Four, 5-24 Volt digital

“Variable I/O” points

12-bit Analog Input

Step Input Signal

Smoothing

(Microstep

Emulation)

Anti-resonance

Electronic Damping

Idle Current

Reduction

Configuration

Method





-























-

Up to 210 oz-in







-











SureMotion Pro software













-

Up to 340 oz-in



-

-













Standard (Pulse/Direction only)

12-48 VDC 12-70 VDC



-

-

-

-

-



Up to 68 oz-in







-

-









Dip Switch



-

-

-

-

-



Up to 210 oz-in







-

-









6–4 SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 6: SureStep™ Integrated Motors/Drives

Specifications

General Specifications – All Integrated Motor/Drives

Drive Cooling Method Natural convection (mount to suitable heat sink)

Step Resolution

Step Angle

Full, Half, Microstepping, Microstep Emulation

Shaft Runout

Max Shaft Radial Play @

1lb load

Perpendicularity

Concentricity

1.8 degrees

NEMA 17: 0.03 mm

NEMA 23/24 : 0.05 mm

0.02 mm

0.08 mm

Maximum Radial Load

Maximum Axial (Thrust)

Load

Supply Output

Circuit Protection

Operating Temperature

Ambient Temperature

Over-temp Shutdown

Humidity

Insulation Class

Environmental Rating

Product Material

Agency Approvals

0.05 mm

NEMA 17: 6.7 lb.

NEMA 23/24: 13.9 lb.

NEMA 17: 34 lb.

NEMA 23/24: 63 lb.

+4.8 - 5 volts @ 50mA maximum

( Note: Not applicable to Pulse and Direction MTRD drives, only for advanced MTRD drives)

Short circuit, over-voltage, under-voltage, over-temp

0-85°C (32-185°F)

0-70°C (0-158°F) for NEMA 24 systems

0-40°C (32-104°F)

85°C (185°F)

90% max, non-condensing

Class B (130°C)

IP40

Aluminum/steel/plastic case, stainless steel shaft

CE*

*For NEMA 24 motors, an EMI filter (RES10F06) is needed on the power supply for CE compliance.

7th Ed. Rev D – 03/17/2022

SureStep

TM

Stepping Systems User Manual 6–5

Chapter 6: SureStep™ Integrated Motors/Drives

Sure

Step™ Standard Integrated Motor/Drive Specifications

Integrated Motor/

Drive

Frame Size

STP-MTRD-17038 /

STP-MTRD-17038E

NEMA 17

STP-MTRD-23042 /

STP-MTRD-23042E

NEMA 23

STP-MTRD-23065 /

STP-MTRD-23065E

Input Power

Current Controller

12-48 VDC (nominal)

(Range: 11-52 VDC)

(fuse at V+)

12-70 VDC (nominal)

(Range: 11-74 VDC)

(fuse at V+)

Digital MOSFET, PWM at 16kHz

Encoder Feedback “E” models only. External encoder must be wired to external feedback device.

Configuration Method Dip Switches

Input

Signals

Output

Signal

Step

Direction

Enable

Output

5-24 VDC nominal (range 4-30VDC); (5mA @ 4V; 15 mA @ 30V);

Optically isolated. Minimum pulse width = 3 µ s (at 2 MHz), 0.25

µ s (at 150kHZ)

Maximum pulse frequency = 150kHz or 2MHz (switch selectable)

Function = Step Input, Limit CW

5-24 VDC nominal (range 4-30VDC); (5mA @ 4V; 15 mA @ 30V);

Optically isolated. Minimum pulse width = 3 µ s (at 2 MHz), 0.25

µ s (at 150kHZ)

Maximum pulse frequency = 150kHz or 2MHz (switch selectable)

Function = Direction Input, Limit CCW

5-24 VDC nominal (range 4-30VDC); (5mA @ 4V; 15 mA @ 30V);

Optically isolated. Minimum pulse width = 3 µ s (at 2 MHz), 0.25

µ s (at 150kHZ)

Maximum pulse frequency = 150kHz or 2MHz (switch selectable)

Function = Enable Input

30 VDC / 100mA max, photodarlington, voltage drop = 1.2V max at 100mA

Function = Alarm Output

Step and Direction: Step signal = step/pulse; Direction signal = direction.

Step CW & CCW: Step signal = CW step; Direction signal = CCW step.

DIP Switch

Selectable

Functions

Step Pulse

Type

Step Pulse

Noise Filter

Current

Reduction

Idle

Current

Reduction

Load

Inertia

Step

Resolution

Self Test

Max Holding Torque

Selectable 150 kHz or 2MHz

This is the percentage of full current that the motor will use when the shaft is rotating. 100%, 90%, 70%, and 50% current selections.

Reduce power consumption and heat generation by limiting motor idle current to 90% or 50% of running current. (Holding torque is reduced by the same %.)

Anti-resonance and damping feature improves motor performance. Set motor and load inertia range to 0–4x or 5–10x.

200-25600 (dip switch selectable)

Automatically rotate the motor back and forth two turns in each direction in order to confirm that the motor is operational.

4.25 lb·in / 68 oz·in /

0.480189 N·m

7.8125 lb·in / 125 oz·in /

0.8827 N·m

13.125 lb·in / 210 oz·in /

1.482936 N·m

Mounting Four M3 screws Four #6 screws

Removable

Connector

Control Housing: Tyco 4-643498-1

Cover: Tyco 1-643075-1

Connector part number: Weidmuller 1610200000, included in STP-CON-3

Rotor Inertia

Status LEDs

Weight

Encoder Two 5 pin inserts (Molex# 14-60-0058), one housing Molex# 15-04-5104

0.448 oz-in 2 (0.082 kg-cm 2 )

1.420 oz-in 2 (0.260 kg-cm 2 )

2.515 oz-in 2 (0.460 kg-cm 2 )

1 red/green

14.7 oz 30 oz (850g) 42 oz (1200g)

6–6 SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Chapter 6: SureStep™ Integrated Motors/Drives

Sure

Step™ Advanced Integrated Motor/Drive Specifications

Integrated Motor/Drive

STP-MTRD-17030R /

STP-MTRD-17030RE

NEMA 17

STP-MTRD-17038R /

STP-MTRD-17038RE

Frame Size

Input Power

Current Controller

12-48 VDC (nominal) (Range: 11-52 VDC) (fuse at V+)

Encoder Feedback

Configuration Method

Dual H-Bridge, 4 Quadrant, 4 state PWM @ 16kHz

“E” models only. Encoder is internal and provides position verification and stall prevention control by default. Internal only (not customer accessible).

SureMotion Pro software (SM-PRO: Free download)

Step/Pulse

Direction

5-24 VDC nominal. Optically isolated. Minimum pulse width = 250 n s (at 3

MHz). Maximum pulse frequency = 3MHz, max current draw = 12mA

Function = Step Input, Jog CW, Limit CW, Start/Stop, General Purpose

5-24 VDC nominal. Optically isolated. Minimum pulse width = 250ns (at 3

MHz). Maximum pulse frequency = 3MHz, max current draw = 12mA

Function = Direction Input, Jog CCW, Limit CCW, General Purpose

Input

Signals

Enable

5-24 VDC nominal. Optically isolated. Minimum pulse width = 50 µ s, maximum pulse frequency = 10kHz, max current draw = 12mA

Function = Enable Input, Reset Input, Change Speed, General Purpose

Analog

0-5 VDC nominal (AIN referenced to GND). Input impedance: 30K ohms minimum, resolution = 12 bits

Function = analog control modes and general purpose analog usage; programmable for signal range, offset, dead band, and filtering

30VDC, 40mA maximum. Optically isoalted, open collector. Maximum pulse frequency 10kHz.

Output Signal

Communication Interface

Functions = Brake Output, Alarm Output, Motion Output, Tach Output,

General Purpose

RS-485 ASCII/SCL (2- or 4-wire network for PLC control; SureMotion Pro software requires 4-wire)

Non-volatile Memory Storage Configurations are saved in FLASH memory on-board the DSP

Current Reduction Selectable in SureMotion Pro software

Features

Idle Current

Reduction

Microstep

Resolution

Reduction range of 0–90% of running current after delay selectable in ms

Software selectable from 200 to 51200 steps/rev in increments of 2 steps/rev

Modes of Operation

Self Test

Pulse (step) & direction, CW/CCW, A/B quadrature, velocity (oscillator), SCL streaming commands via RS-485 ASCII/SCL (2- or 4-wire)

Checks internal and external power supply voltages, diagnoses open motor phases

Max Holding Torque

3.375 lb·in / 54 oz·in / 0.381326

N·m

4.25 lb·in / 68 oz·in / 0.480189

N·m

Mounting

Removable

Connector

(included in

STP-CON-3)

DC Power

Four M3 screws

2-position screw terminal: Dinkle 0225-1602L (new models) or Weidmuller

1615780000 (old models)

I/O 11-position spring cage: Phoenix 1881419

Comm 5-position spring cage: Phoenix 1881354

Rotor Inertia

Status LEDs

Weight

0.310 oz-in 2 (0.057 kg-cm 2 )

1 red, 1 green

12.7 oz (360g)

0.448 oz-in 2 (0.082 kg-cm 2 )

15.6 oz (441g)

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Stepping Systems User Manual 6–7

Chapter 6: SureStep™ Integrated Motors/Drives

Sure

Step™ Advanced Integrated Motor/Drive Specifications

Integrated Motor/Drive

STP-MTRD-23042R /

STP-MTRD-23042RE

STP-MTRD-23065R /

STP-MTRD-23065RE

Frame Size

Input Power

Current Controller

Encoder Feedback

NEMA 23

12-70 VDC (nominal) (Range: 11-74 VDC) (fuse at V+)

Dual H-Bridge, 4 Quadrant, 4 state PWM @ 20kHz

“E” models only. Encoder is internal and provides closed loop control by default. Internal only (not customer accessible).

SureMotion Pro software (SM-PRO: Free download) Configuration Method

Step/Pulse

Direction

5-24 VDC nominal. Optically isolated. Minimum pulse width = 250 n s (at 2

MHz). Maximum pulse frequency = 2MHz, max current draw = 12mA

Function = Step Input, Jog CW, Limit CW, Start/Stop, General Purpose

5-24 VDC nominal. Optically isolated. Minimum pulse width = 250 n s (at 2

MHz). Maximum pulse frequency = 2MHz, max current draw = 12mA

Function = Direction Input, Jog CCW, Limit CCW, General Purpose

Input

Signals

Enable

5-24 VDC nominal. Optically isolated. Minimum pulse width = 50 µ s, maximum pulse frequency = 10kHz, max current draw = 12mA

Function = Enable Input, Reset Input, Change Speed, General Purpose

Analog

0-5 VDC nominal (AIN referenced to GND). Input impedance: 30K ohms minimum, resolution = 12 bits

Function = analog control modes and general purpose analog usage; programmable for signal range, offset, dead band, and filtering

30VDC, 40mA maximum. Optically isolated, open collector. Maximum pulse frequency 10kHz.

Output Signal

Communication Interface

Functions = Brake Output, Alarm Output, Motion Output, Tach Output,

General Purpose

RS-485 ASCII/SCL (2- or 4-wire network for PLC control; SureMotion Pro software requires 4-wire)

Non-volatile Memory Storage Configurations are saved in FLASH memory on-board the DSP

Current Reduction Selectable in SureMotion Pro software

Features

Idle Current

Reduction

Reduction range of 0–90% of running current after delay selectable in ms

Microstep Resolution Software selectable from 200 to 51200 steps/rev in increments of 2 steps/rev

Modes of Operation

Self Test

Pulse (step) & direction, CW/CCW, A/B quadrature, velocity (oscillator), SCL streaming commands

Checks internal and external power supply voltages. Diagnoses open motor phases and motor resistance changes > 40%

Max Holding Torque

7.8125 lb·in / 125 oz·in / 0.8827

N·m

13.125 lb·in / 210 oz·in / 1.482936

N·m

Mounting Four #6 screws

DC Power 2-position screw terminal: Weidmuller 1615780000 Removable

Connector

(included in STP-

CON-3)

I/O 11-position spring cage: Phoenix 1881419

Comm 5-position spring cage: Phoenix 1881354

Rotor Inertia 1.420 oz-in 2 (0.260 kg-cm 2 ) 2.515 oz-in 2 (0.460 kg-cm 2 )

Status LEDs

Weight

1 red, 1 green

30 oz (850g) 42 oz (1191g)

6–8 SureStep

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Chapter 6: SureStep™ Integrated Motors/Drives

Sure

Step™ Advanced Integrated Motor/Drive Specifications

Integrated Motor/

Drive

Frame Size

Input Power

Current Controller

Encoder Feedback

Configuration Method

I/O 1 (Step/Pulse)

NEMA 24

STP-MTRD-24075RV / STP-MTRD-24075RVE

12-70* VDC (nominal) (Range: 11-74 VDC) (fuse at V+)

Dual H-Bridge, 4 Quadrant, 4 state PWM @ 20kHz

“E” models only. Encoder is internal and provides position verification and stall prevention control by default. Internal only (not customer accessible).

SureMotion Pro software (SM-PRO: free download)

INPUT: 5-24 VDC nominal. Optically isolated. Minimum pulse width = 250 n s (at

3MHz). Maximum pulse frequency = 3MHz, max current draw = 12mA,

Function = Step Input, Jog CW, Enable Input, Start/Stop, General Purpose

I/O 2 (Direction)

OUTPUT: 30VDC, 40mA maximum. Optically isolated, open collector. Maximum pulse frequency 10kHz. Functions = Brake Output, Fault Output, Motion Output,

Tach Output, General Purpose

INPUT: 5-24 VDC nominal. Optically isolated. Minimum pulse width = 250 n s (at

3MHz). Maximum pulse frequency = 3MHz, max current draw = 12mA,

Function = Direction Input, Jog CCW, Alarm Reset Input, General Purpose

I/O 3

OUTPUT: 30VDC, 40mA maximum. Optically isolated, open collector. Maximum pulse frequency 10kHz. Functions = Brake Output, Fault Output, Motion Output,

Tach Output, General Purpose

INPUT: 5-24 VDC nominal. Optically isolated. Minimum pulse width = 250 n s (at

3MHz). Maximum pulse frequency = 3MHz, max current draw = 12mA,

Function = Limit CW Input, Enable Input, Change Speed Input, General Purpose

I/O 4

Analog

Communication Interface

OUTPUT: 30VDC, 40mA maximum. Optically isolated, open collector. Maximum pulse frequency 10kHz. Functions = Brake Output, Fault Output, Motion Output,

Tach Output, General Purpose

INPUT: 5-24 VDC nominal. Optically isolated. Minimum pulse width = 250 n s (at 2

MHz). Maximum pulse frequency = 2MHz, max current draw = 12mA, Function

= Limit CCW Input, Alarm Reset Input, General Purpose

OUTPUT: 30VDC, 40mA maximum. Optically isolated, open collector. Maximum pulse frequency 10kHz. Functions = Brake Output, Fault Output, Motion Output,

Tach Output, General Purpose

0-5 VDC nominal (AIN referenced to GND). Input impedance: 30K ohms minimum, resolution = 12 bits, Function = analog control modes and general purpose analog usage; programmable for signal range, offset, dead band, and filtering

RS-485 ASCII/SCL (2- or 4-wire network for PLC control; SureMotion Pro software requires 4-wire)

Current Reduction Selectable in SureMotion Pro software

Idle Current Reduction Reduction range of 0–90% of running current after delay selectable in ms

Microstep Resolution Software selectable from 200 to 51200 steps/rev in increments of 2 steps/rev

Modes of Operation

Self Test

Pulse (step) & direction, CW/CCW, A/B quadrature, velocity (oscillator), SCL streaming commands

Checks internal and external power supply voltages. Diagnoses open motor phases and motor resistance changes > 40%.

* If using the STP-PWR-7005, the power supply (when unloaded) may float above the drive’s maximum alowable DC voltage if the power supply is fed with greater than 120VAC input. Either ensure that the incoming AC voltage is less than 120V or supply a burden resistor to pull the unloaded DC voltage level down.

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Chapter 6: SureStep™ Integrated Motors/Drives

Sure

Step™ Advanced Integrated Motor/Drive Specifications (continued)

Integrated Motor/

Drive

STP-MTRD-24075RV / STP-MTRD-24075RVE

Max Holding Torque 21.25 lb·in / 340 oz·in / 2.400944 N·m

Mounting Four #6 screws

DC Power 2-position screw terminal: Dinkle 0225-1602L (new models) or Weidmuller

1615780000 (old models)

I/O 11-position spring cage: Phoenix 1881419

Rotor Inertia

Status LEDs

Weight

Comm 5-position spring cage: Phoenix 1881354

4.900 oz-in 2 (0.897 kg-cm 2 )

1 red, 1 green

56 oz (1580g)

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Chapter 6: SureStep™ Integrated Motors/Drives

Getting Started

The following items are needed for the Standard and Advanced integrated motors/drives (STP-MTRD):

• DC power supply (see the Chapter 8, “Choosing a Power Supply”) for help in choosing one.

• A small, flat blade screwdriver for inserting wires into the connector.

• A source of step signals, such as a PLC or motion controller.

Additional items needed for Advanced integrated motors/drives (STP-MTRDxxxxR):

• A PC running Microsoft Windows software.

• A configuration cable and suitable USB to four wire RS-485 converter. ADC part numbers STP-USB485-4W and STP-485DB9-CLB-2 are recommended.

Installing Software

Before using the STP-MTRD-xxxxR Advanced integrated motor and SureMotion

Pro software in an application, the following steps are necessary:

• Install the SureMotion Pro software.

• Launch the software by clicking Programs -> AutomationDirect -> SureMotion Pro

• Connect the drive to the PC using the programming cable. STP-USB485-4W in 4-wire configuration is recommended (see “Chapter 9: Communications” for detailed info).

• Connect the drive to the power supply.

• Apply power to the drive. (When first powered-up, the drive sends out a “power-up packet” to identify itself. See the SCL Manual for more details.)

• The software will recognize the drive and display the model and firmware version. At this point, it is ready for use.

Mounting

As with any step motor, the STP-MTRD must be mounted so as to provide maximum heat sinking and airflow. Keep enough space around the unit to allow for airflow.

Never use the drive where there is no airflow or where other devices cause the surrounding air to be more than 40 ° C (104 ° F). Never put the drive where it can get wet. Never use the drive where metal or other electrically conductive particles can infiltrate the drive. Always provide airflow around the STP-MTRD.

Use the following to mount the motors:

• STP-MTRD-17 series: four M3 screws

• STP-MTRD-23 and -24 series: four #6 or #8 screws

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Chapter 6: SureStep™ Integrated Motors/Drives

Additional Reading

To learn more about SureMotion Pro™, please refer to the software’s built-in help.

To learn more about the SCL language, please read the Serial Command Language

User Manual.

Mating Connectors and Accessories

Advanced Drive Mating Connectors & Accessories

Mating Connector (Type) Part Number

Terminal

Tightening Torque

DC Power (new models) (2-position, spring cage)

Dinkle 0225-1602L N/A

Acceptable Wire

AWG

16-20 AWG, no ferrules allowed

DC Power (old models) (2-position, screw terminal)

Weidmuller 1615780000 0.25 Nm

16-20 AWG, ferrules allowed

I/O (11-position, spring cage) Phoenix 1881419

Comm (5-position, spring cage) Phoenix 1881354

N/A

20-22 AWG, no ferrules allowed

Note: ADC’s STP-CON-3 connector kit contains all three above parts.

Standard Drive Mating Connectors & Accessories

Mating Connector (Type) Part Number

Terminal

Tightening

Torque

NEMA 17: 11-pin insulation displacement style connector

Housing: Tyco 4-643498-1

Cover: Tyco 1643075-1

N/A

NEMA 23: 11-pin screw terminal connector

Weidmuller 1610200000 0.25 Nm

Acceptable Wire

AWG

22 AWG

18-20 AWG, ferrules allowed

Note: See STP-CON-3 connector kit and STP-CBL-CAxx for replacement options.

General Accessories

Part Part Number

USB to RS485 Adapter

Regeneration Clamp and/or breaking resistor for applications with high inertial loads

SureStep communication cable, 9-pin

STP-USB485-4W

STP-DRVA-RC-050

STP-DRVA-BR-100

STP-485DB9-CBL-2

Replacement SureStep incremental (quadrature) encoder for standard models

Note: Multiple replacement encoder options are available in Appendix A.

STP-MTRA-ENC1

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Chapter 6: SureStep™ Integrated Motors/Drives

Installation and Connections

STP-MTRD-17 Standard Series

STEP+

STEP-

DIR+

DIR-

EN+

EN-

OUT+

OUT-

N.C.

V -

V+ orange brown yellow green blue purple grey white white/green black red

1 ft cable included with motor

Steps/Rev DIP Switches

Setup DIP Switches

STEP+

STEP-

DIR+

DIR-

EN+

EN-

OUT+

OUT-

N.C.

V -

V+

STP-CBL-CAxx orange* brown yellow green blue tan** grey white pink black red

* grey/pink for Rev A

** red/blue for Rev A

Status LED Factory Use Only

Includes a 12 inch control cable for accessing the terminals. STP-CBL-CAxx cable can be purchased separately if longer cable lengths are needed.

STP-MTRD-23 Standard Series

Steps/Rev DIP Switches

Setup DIP Switches

STEP+

STEP-

DIR+

DIR-

EN+

EN-

OUT+

OUT-

V -

V+

Status LED

Factory Use Only

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Chapter 6: SureStep™ Integrated Motors/Drives

STP-MTRD-17 / STP-MTRD-23 Advanced Series

RS-485

Connection

Ground

TX-

TX+

RX-

RX+

Status LEDs

V-

V+

V+ V-

External Power

STEP+

STEP-

DIRECTION+

DIRECTION-

ENABLE+

ENABLE-

OUT+

OUT-

+5V

Analog Input

Ground

Note: Can be wired for 2-wire

or 4-wire networks

(see Appendix B for RS-485

wiring details)

STP-MTRD-24 Advanced Series

RS-485

Connection

Ground

TX-

TX+

RX-

RX+

Variable I/O 1+

Variable I/O 1-

Variable I/O 2+

Variable I/O 2-

Variable I/O 3+

Variable I/O 3-

Variable I/O 4+

Variable I/O 4-

+5V

Analog Input

Ground

Status LEDs

V-

V+

V+ V-

External Power*

* an EMI filter (RES10F03) is needed on the power supply for CE compliance

Note: Can be wired for 2-wire

or 4-wire networks

(see Appendix B for RS-485

wiring details)

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Chapter 6: SureStep™ Integrated Motors/Drives

Connecting a Power Supply to the Standard STP-MTRD-17

For information on choosing a power supply, please see the

“Choosing a Power Supply” section of Chapter 7, “SureStep

System Power Supplies.”

Connect the power supply “+” terminal to connector terminal

V+, then connect power supply

“-” to connector terminal V-.

Use 22 gauge stranded wire if supplying your own connector and cable.

V-

V+

The STP-MTRD-17 contains an internal fuse that connects to

V+ V-

External Power the power supply + terminal.

This fuse is not user replaceable. If you want to install a user serviceable fuse in your system, install a fast acting 2 amp fuse in line with the + power supply lead.

Be careful not to reverse the wires. Reverse connection will open the internal fuse on your drive and void your warranty. Fuse is not user-replaceable.

Connecting a Power Supply to the Standard STP-MTRD-23

For information on choosing a power supply, please see the “Choosing a

Power Supply” section of Chapter 7,

“SureStep System Power Supplies.”

Connect the power supply “+” terminal to the connector terminal labeled “V+”, then connect the power supply “-” to the connector terminal labeled “V-”. Use 14-20 gauge stranded wire.

The STP-MTRD-23 contains an internal fuse that connects to the power supply + terminal. This fuse is not user replaceable. If you want to install a user serviceable fuse in your system, install a fast acting 4 amp fuse in line with the + power supply lead.

V-

V+

V+ V-

External Power

Be careful not to reverse the wires. Reverse connection will open the internal fuse on your drive and void your warranty. Fuse is not user-replaceable.

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Chapter 6: SureStep™ Integrated Motors/Drives

Connecting a Power Supply to the Advanced STP-MTRD-xxxxxR

For information on choosing a power supply, please see the “Choosing a

Power Supply” section of Chapter 7,

“SureStep System Power Supplies.”

Connect the power supply “+” terminal to the drive “+” terminal and the power supply “-” terminal to the drive “-” terminal using 16 to 22 gauge wire. The STP-MTRD contains an internal fuse connected to the

“+” terminal. This fuse is not user replaceable. If a user serviceable fuse is desired, install a fast acting fuse in line with the “+” power supply lead.

Suitable fuses are:

• STP-MTRD-17 series: 2 amp

• STP-MTRD-23 series: 4 amp

V-

V+

• STP-MTRD-24 series: 5 amp

It is important that the motor frame be electrically connected to ground.

V+ V-

External Power

When the motor is mounted on an insulated surface, a ground wire is required. Also, in applications where multiple integrated motors are used on a machine, individual ground wires may reduce the overall electrical noise level.

Be careful not to reverse the wires. Reverse connection will open the internal fuse on your drive and void your warranty. Fuse is not user-replaceable.

To maintain CE compliance with the STP-MTRD-24, EMI filter RES10F06 must be wired in series with the V+ power supply to the motor/drive.

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Chapter 6: SureStep™ Integrated Motors/Drives

Using a Regulated Power Supply

If a regulated power supply is being used, there may be a problem with regeneration. When a load decelerates rapidly from a high speed, some of the kinetic energy of the load is transferred back to the power supply, possibly tripping the over-voltage protection of a regulated power supply, causing it to shut down. This problem can be solved with the use of an STP-DRVA-RC-050 regeneration clamp. It is recommended that an STP-DRVA-RC-050 initially be installed in an application. If the “regen” LED on the STP-DRVA-RC-050 never flashes, the clamp is not necessary. For additional regen clamping capacity,

STP-DRVA-BR-100 resistor can be added to the regen clamp. See Appendix A:

“SureStep Accessories.”

STP-DRVA-RC-050 Regen Clamp

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Chapter 6: SureStep™ Integrated Motors/Drives

LED Error Codes

STP-MTRD Alarm Codes

Alarm

Code

SG

LED Sequence

Solid green

Alarm Description

No alarm, motor disabled

FG

Fast green

Factory use

01

Flashing green

No alarm, motor enabled

10

Flashing red

Configuration or memory error1

11

1 red, 1 green

Motor stall (optional encoder only)4

12

1 red, 2 green

Move attempted while drive disabled

21

2 red, 1 green

CCW limit

22

2 red, 2 green

CW limit

31

3 red, 1 green

Drive overheating

32

3 red, 2 green

Internal voltage out of range2

33

3 red, 3 green

Factory use

41

4 red, 1 green

Power supply overvoltage2

42

4 red, 2 green

Power supply undervoltage

43

51

4 red, 3 green

5 red, 1 green

Flash memory backup error

Over current / short circuit2, 3

61

62

6 red, 1 green

6 red, 2 green

Open motor winding2

Bad encoder signal (optional encoder only)4

71

7 red, 1 green

72

7 red, 2 green

1 - Does not disable the motor.

The alarm will clear about 30 seconds after the fault is corrected.

2 - Disables the motor. Cannot be cleared until power is cycled.

Serial communication error5

Flash memory error

3 - 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.

4 - This alarm only occurs on STP-MTRD advanced integrated motor/drives

5 - This alarm does not occur on STP-DRV-6575 or standard integrated motor/drives

Alarm Code Definitions

Alarm

Code

SG

Error Description

No alarm, motor disabled

No faults active, Circuit is closed between EN+ and EN-.

N/A

Corrective Action

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Chapter 6: SureStep™ Integrated Motors/Drives

Alarm

Code

01

10

11

12

21

22

31

32

Error Description Corrective Action

No alarm, motor enabled

Configuration or memory error

Motor stall

(optional encoder only)

Move attempted while drive disabled

CCW limit

No faults active, Circuit is open between EN+ and EN-.

Memory error detected when trying to load config from flash on powerup.

Motor torque demand exceeded capability and the motor skipped steps. This is configured in SureMotion Pro.

Drive is disabled and move attempted.

CW limit

Drive overheating

CCW limit is reached. The digital input that has been assigned CCW limit has been activated.

CW limit is reached. The digital input that has been assigned CW limit has been activated.

The drive’s internal temperature is too high.

Internal voltage out of range

Gate voltage, 5V rail, or 3V rail are out of spec.

N/A

Restart device. No fix if restart doesn’t work.

Increase torque utilization if it’s not already maxed out, otherwise decrease the torque demand by modifying the move profile, or put in a larger motor.

Reset alarm, enable motor, and move again.

Unblock the CCW sensor (open the circuit) or redifine the input with

SureMotion Pro.

Unblock the CCW sensor (open the circuit) or redefine the input with

SureMotion Pro.

If the drive is operating within its standard range (input voltage and output current are OK), more heat must be removed from the drive during operation. For Advanced drives (see

“Mounting the Drive” on page 4-14), ensure the drive is mounted to a metal surface that can dissipate the drive’s heat. For Integrated motor/drives, see

“Mounting” on page 5-13. For both types of drives: If the mounting surface cannot pull enough heat away from the drive, forced airflow (from a fan) may be required to cool the drive.

Ensure adequate supply voltage (in very rare cases, low input voltages combined with fast accelerations can draw down the gate voltage) and try again. If persistant, RMA is required.

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Chapter 6: SureStep™ Integrated Motors/Drives

Alarm

Code

41

42

43

51

61

62

71

Error Description Corrective Action

Power supply overvoltage

Power supply undervoltage

Flash memory backup error

Over current / short circuit

Open motor winding

Bad encoder signal (optional encoder only)

Serial communication error

The DC voltage feeding the drive is above the allowable level.

The DC voltage feeding the drive is below the allowable level.

Memory error detected when trying to load config from flash on powerup.

Motor leads shorted - only checked on powerup.

Motor leads not connected - only checked on powerup.

Noisy or otherwise incorrectly formatted encoder signal (lack of A or B, lack of differential signal).

Catch-all error for something wrong with serial communications. See CE command in HCR for details.

Decrease the input voltage.

Linear power supplies do not output a fixed voltage: the lighter the output current, the higher the output voltage will float. If a linear supply’s voltage floats above the drive’s max voltage, you can install a small power resistor across the linear power supply’s output to provide some load that will help pull down the floating voltage.

Consider using a switching power supply such as the Rhino PSB power supply series.

Overvoltage can also be fed back into a system by regeneration (when an overhauling load pushes energy back into the motor). In an application with regen problems, install an STP-DRVA-

RC-050 regen clamp to help dissipate the extra energy. (The regen clamp will not help with the floating linear power supply that floats too high, but it will help with excess voltage generated from an overhauling load.)

Correct the power supply. If this error occurs during operation, the power supply is most likely undersized. A sudden high current demand can cause an undersized power supply to dip in output voltage.

Restart device. No fix if restart doesn’t work.

Check and fix motor wiring.

Check and fix motor wiring.

Check encoder wiring, always use differential encoders (or use checkbox in SureMotion Pro to disable this error when using single ended).

If drive can communicate, CE can give a precise diagnosis. If not, refer to the

Serial Communications part of the HCR for troubleshooting.

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Alarm

Code

72

Error

Flash memory error

Description Corrective Action

Memory error detected when trying to load config from flash on powerup.

Restart device. No fix if restart doesn’t work.

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Chapter 6: SureStep™ Integrated Motors/Drives

STP-MTRD Inputs and Outputs

The standard drives (STP-MTRD-xxxx) have three inputs:

• STEP: a high speed digital input for step pulse commands, 5-24 volt logic

• DIR: a high speed digital input for the direction signal, 5-24 volt logic

• EN: a 5-24 volt input for commanding the removal of power from the motor

NOTE: STEP and DIR inputs can be converted to STEP CW and STEP CCW by moving switch #8 to the ON position.

The standard drives have a single digital output labeled OUT. This output closes to signal a fault condition. The output can be used to drive LEDs, relays, and the inputs of other electronic devices like PLCs. The “+” (collector) and “-”

(emitter) terminals of the output are available at the connector - this allows you to configure the output for current sourcing or sinking. STP-MTRD-17038(E) includes a 12 inch control cable for accessing the terminals. STP-CBL-CAxx cable can be purchased separately if longer cable lengths are needed.

Connector Pin Diagrams Internal Circuit Diagram

STEP+

STEP-

DIR+

DIR-

EN+

EN-

OUT+

OUT-

N.C.

V-

V+

STP-MTRD-17 series

STP-MTRD-23 series

Control Cable STP-CBL-CAxx

(for STP-MTRD-17038/17038E)

(1)STEP+

(2)STEP-

(3)DIR+

(4)DIR-

(5)EN+

(6)EN-

(7)OUT+

(8)OUT-

(9)N.C.

(10)V-

(11)V+

STEP+

STEP-

DIR+

DIR-

EN+

EN-

OUT+

OUT-

V-

V+

ORANGE (Rev A - GRY/PINK)

BROWN

YELLOW

GREEN

BLUE

TAN (Rev A - RED/BLUE)

GREY

WHITE

PINK

BLACK

RED

1

STEP+

2

STEP-

3

DIR+

4

DIR-

5

EN+

6

EN-

7

OUT+

8

OUT-

220 pF

220 pF

220 pF

inside drive

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Chapter 6: SureStep™ Integrated Motors/Drives

The advanced STP-MTRD-17xxxxxR and -23xxxxxR drives include 3 digital inputs and 1 analog input:

• Two high speed digital inputs, 5-24 volt logic, labeled STEP (or IN1) and DIR

(or IN2), for commanding position. Pulse & direction, CW/CCW pulse, and A/B quadrature encoder signals can be used as position commands with these inputs.

The STEP/IN1 and DIR/IN2 inputs can also be connected to sensors, switches and other devices for use with streaming SCL commands such as Wait Input (WI),

Seek Home (SH), Feed to Sensor (FS), etc. When not being used for commanding position, these inputs can also be used for CW/CCW end-of-travel limits, CW/CCW jog inputs, or Run/stop & direction velocity-mode inputs.

NOTE: the available functionality of these inputs is determined by the STP-MTRD control option (R) as well as the motion control mode selected in SureMotion Pro.

• One digital input, 5-24 volt logic, labeled EN (or IN3), which can be used for motor enable/disable and/or alarm reset. It can also be connected to a sensor, switch or other device for use with streaming SCL commands such as Wait Input, Seek

Home, Feed to Sensor, etc.

• One analog input, 0-5 volt logic, labeled AIN, which can be used as an analog velocity or position command. It can also be used with streaming SCL commands such as Wait Input, Seek Home, Feed to Sensor, etc.

NOTE: On the advanced drives, the green 5 and 11 position spring clip terminal blocks do not accept ferrules, either use bare stranded copper or tinned leads.

Connector Pin Diagram

STEP+

STEP-

DIR+

DIR-

EN+

EN-

OUT+

OUT-

+5V

AIN

GND

STP-MTRD-xxxxR series

I/O Connector inside drive

STEP/IN1+

STEP/IN1-

DIR/IN2+

DIR/IN2-

EN/IN3+

EN/IN3-

OUT/IN4+

OUT/IN4-

+5V

AIN

GND

100ma Limit

Signal

Conditioning

RES

STP-MTRD-xxxxR series

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Chapter 6: SureStep™ Integrated Motors/Drives

The STP-MTRD-24 models have four “Variable I/O” points. Each can be configured as a digital input or a digital output. In addition, pre-defined functions such as motor enable or fault output can be assigned, providing the flexibility to handle a diverse range of applications.

SureMotion Pro™ is used to set each Variable I/O point as an input or output.

SureMotion Pro™ can also be used to assign functions to each I/O point, or functions can be assigned “on the fly” from SCL streaming commands.

Connector Pin Diagram

I/O 1+

I/O 1-

I/O 2+

I/O 2-

I/O 3+

I/O 3-

I/O 4+

I/O 4-

+5V

AIN

GND

STP-MTRD-24xxR series

I/O+

I/O-

Equivalent Circuit: Variable I/O Point Set as Input

I/O+

I/Oinside drive inside drive

Equivalent Circuit: Variable I/O Point Set as Output

+5V

AIN

GND inside drive

50 mA max

Signal

Conditioning

Equivalent Circuit: Analog Input

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Chapter 6: SureStep™ Integrated Motors/Drives

Input/Output Functions

Basic STP-MTRD-x I/O Functions (configure with dip switches)

Terminal STEP (5-24 Volts) DIR (5-24 Volts) EN (5-24 Volts) OUT (30V, 80mA)

Function

Step Input

Limit CW

Dir Input

Limit CCW

Enable Input

-

Alarm Output

-

Advanced STP-MTRD-17xR (23xR) I/O Functions (configure in software)

Terminal STEP (5-24 Volts) DIR (5-24 Volts) EN (5-24 Volts) OUT (30V, 80mA)

Step Input Dir Input Enable Input Brake Output

Jog CW Jog CCW Reset Input Alarm Output

Function Limit CW Limit CCW Change Speed Motion Output

Start/Stop General Purpose General Purpose Tach Output

General Purpose General Purpose

Advanced STP-MTRD-24xR I/O Functions (configure in software)

Terminal

Input

Function

I/O 1

Step/CW Pulse/AB

Quad Input

Jog CW Input

Enable Input

Start/Stop Input

I/O 2

DIR/CCW Pulse/AB

Quad Input

Jog CCW Input

Alarm Reset Input

General Purpose Input

I/O 3

Limit CW Input

Enable Input

Change Speed Input

General Purpose

Input

I/O 4

Limit CCW Input

Alarm Reset Input

General Purpose

Input

-

Output

Function

General Purpose

Input

Brake Output

Fault Output

Motion Output

Tach Output

General Purpose Output

-

Brake Output

Fault Output

Motion Output

Tach Output

-

-

Brake Output

Fault Output

Motion Output

Tach Output

General Purpose

Output

-

Brake Output

Fault Output

Motion Output

Tach Output

General Purpose

Output

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Chapter 6: SureStep™ Integrated Motors/Drives

The Step (STEP) and Direction (DIR) Inputs

The STP-MTRD motor/drives include two high-speed inputs called STEP (or IN1) and DIR (or IN2). They accept 5 to 24 volt single-ended or differential signals, up to 2 MHz. Typically these inputs connect to an external controller that provides step and direction command signals. With the Advanced models you can also connect a master encoder to the high-speed inputs for “encoder following” applications. Or you can use these inputs with Wait Input, If Input, Feed to

Sensor, Seek Home, and other SCL commands.

If the 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.

Example connection diagrams:

Indexer or PLC with Sinking

Outputs

5-24 VDC

DIR

STEP

DIR+

DIR-

STEP+

STEP-

All

STP-MTRD

Connecting to indexer with Sinking Outputs

Indexer or PLC with Sourcing

Outputs

0 VDC

DIR

STEP

DIR-

DIR+

STEP-

STEP+

All

STP-MTRD

Connecting to indexer with Sourcing Outputs

Indexer or PLC with

Differential

Outputs

DIR+

DIR-

STEP+

STEP-

DIR+

DIR-

STEP+

STEP-

All

STP-MTRD

Connecting to indexer with Differential Outputs

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Chapter 6: SureStep™ Integrated Motors/Drives

5 to 24

VDC

Power

Supply

+

direction switch run/stop switch

(closed=run)

DIR+

DIR-

STEP+

STEP-

All

STP-MTRD

-

Using Mechanical Switches

(The switches can also be placed on the + line)

Master

Encoder

A+

A-

B+

B-

STEP+

STEP-

DIR+

DIR-

Wiring for Encoder Following

Advanced

STP-MTRD

Only

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Chapter 6: SureStep™ Integrated Motors/Drives

The Enable (EN/IN3) Digital Input

As mentioned in the previous section, the high-speed STEP and DIR inputs are designed for high speed operation. The Enable digital input is designed for low speed digital input operation between 5 and 24 volts DC.

If the current is flowing into or out of an input, the logic state of that input is low or closed (active). If no current is flowing, or the input is not connected, the logic state is high or open. Using a switch (see the first image below) to activate the “Enable” circuit will actually disable the drive. The switch in the image below could be considered a “Disable” switch.

Example connection diagrams:

5-24

VDC

Power

Supply

+

Switch or Relay

(closed = logic Low)

EN+

All

STP-MTRD

EN-

Connecting the Input to a Switch or Relay

5-24

VDC

Power

Supply

+

-

+

NPN

Proximity output

EN+

EN-

All

STP-MTRD

Connecting an NPN Type Proximity Sensor to an input

(When proximity sensor activates, input goes low).

6–28

5-24

VDC

Power

Supply

+

-

+

PNP

Proximity output

EN+

EN-

All

STP-MTRD

Connecting an PNP Type Proximity Sensor to an input

(When prox sensor activates, input goes low).

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Chapter 6: SureStep™ Integrated Motors/Drives

The Analog (AIN) Input

The Advanced STP-MTRD drives feature an analog input. The input can accept a signal range of 0 to 5 VDC. The drive can be configured to operate at a speed or position that is proportional to the analog signal. Use the SureMotion Pro software to set the signal range, offset, dead-band and filter frequency. For some

SCL commands the analog input can be used as an emulated digital input by just using the full analog scale as the on/off condition. The Advanced STP-MTRD also provides a +5VDC 50mA output that can be used to power external devices such as potentiometers. It is not the most accurate supply for reference; for more precise readings use an external supply that can provide the desired accuracy.

Example connection diagram:

inside drive

50mA Limit

+5V

AIN

Signal

Conditioning

GND

Connecting a Potentiometer to the Analog Input

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Chapter 6: SureStep™ Integrated Motors/Drives

The Digital Output

The STP-MTRD drives feature one configurable optically isolated digital output.

In the units with RS-485 communication this output can be set to automatically control a motor brake, to signal a fault condition, to indicate when the motor is moving, or to provide an output frequency proportional to motor speed (tach signal). The output can also be turned on and off by program instructions like

Set Output. The output can be used to drive LEDs, relays, and the inputs of other electronic devices like PLCs and counters. The “OUT+” (collector) and “OUT-”

(emitter) terminals of the transistor are available at the connector. This allows you to configure the output for current sourcing or sinking. The STP-MTRD-24 has four variable I/O points. Each one can be either an output or an input.

If current is flowing into or out of an output, the logic state of that output is low or closed (active). If no current is flowing, or the output is not connected, the logic state is high or open.

Do not connect the output to more than 30VDC.

The current through the output terminal must not exceed 40mA.

Example connection diagrams:

5-24 VDC

Power Supply

+ –

Load

STP-MTRD

OUT+

OUT-

Connecting as a Sinking Output

5-24 VDC

Power Supply

+ –

OUT+

STP-MTRD

OUTLoad

Connecting as a Sourcing Output

6–30 relay

OUT+

STP-MTRD

OUT-

1N4935 (or equivalent) suppression diode

Driving a Relay

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5-24 VDC

Power Supply

+ –

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Chapter 6: SureStep™ Integrated Motors/Drives

Using the Optional Encoder

(STP-MTRD-17038E, 23042E, 23065E)

The optional encoder that is included with the standard E models is a differential line driver 1000 ppr incremental encoder assembled to the rear shaft of the unit. This is replacement part number STP-MTRA-ENC1. The A, B, and Index (Z) channel signals of this encoder can be connected back to the external controller for position verification and enhanced performance, depending on the features of the controller. To facilitate connecting the encoder signals to your external controller you should purchase cable part number STP-CBL-EAx.

For more information on the encoder, please see the Accessories appendix.

Replacement encoder part number is STP-MTRA-ENC1.

Incremental encoder specifications:

• 10-pin connector provides the following signals (pin assignments): Ground (1,2),

Index- (3), Index+ (4), A- (5), A+ (6), +5VDC power (7,8), B- (9) and B+ (10).

• Power supply requirements: 5 VDC at 56mA typical, 59 mA max.

• The encoder’s internal differential line driver can source and sink 20mA at TTL levels.

• Maximum noise immunity is achieved when the differential receiver is terminated with a 110-ohm resistor in series with a .0047 microfarad capacitor placed across each differential pair. The capacitor simply conserves power; otherwise power consumption would increase by approximately 20mA per pair, or 60mA for three pairs.

• If making your own cable to connect the encoder signals to your controller, we recommend using a shielded cable with four or five twisted pairs for improved noise immunity.

• Max encoder frequency is 100,000 pulses per second.

Other encoder configurations are available. Please see Appendix A for the full line of encoders compatible with the standard E series STP-MTRD integrated motor/ drives.

Connection Table for STP-EA-EAx

PIN 1

Note: Pin 1 and Pin 2 are internally connected. Pin 7 and Pin 8 are internally connected inside the encoder.

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PIN 2

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Configuring the Standard STP-MTRD

Step 1: Setting the Current

To achieve maximum torque, you should set the current to 100%. But under some conditions you may want to reduce the current to save power or lower motor temperature. This is important if the motor is not mounted to a surface that will help it dissipate heat or if the ambient temperature is expected to be high.

Step motors produce torque in direct proportion to current, but the amount of heat generated is roughly proportional to the square of the current. If you operate the motor at 90% of rated current, you’ll get 90% of the rated torque. But the motor will produce approximately 81% as much heat. At 70% current, the torque is reduced to 70% and the heating to about 50%.

Two of the small switches on the front of the STP-MTRD are used to set the percent of rated current that will be applied to the motor: SW1 and SW2. Please set them according to the illustration below.

1 2 1 2 1 2 1 2

100% 90% 70% 50%

Step 2: Setting Idle Current

Motor heating and power consumption can also be reduced by lowering the motor current when it is not moving. The STP-MTRD will automatically lower the motor current when it is idle to either 50% or 90% of the running current. The

50% idle current setting will lower the holding torque to 50%, which is enough to prevent the load from moving in most applications. This reduces motor heating by 75%. In some applications, such as those supporting a vertical load, it is necessary to provide a high holding torque. In such cases, the idle current can be set to 90% as shown.

3 3

6–32

50% 90%

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Step 3: Load Inertia

The Standard STP-MTRD includes anti-resonance and electronic damping features which greatly improve motor performance. To perform optimally, the drive must understand the electromechanical characteristics of the motor and load. Most of this is done automatically when the motor and drive are assembled at the factory. To further enhance performance, you must set a switch to indicate the approximate inertia ratio of the load and motor. The ranges are 0 to 4X and 5 to

10X. Please divide your load inertia by the STP-MTRD rotor inertia (82 g-cm2) to determine the ratio, then set switch 7 accordingly, as shown.

7 7

5-10X 0-4X

Step 4: Step Size

The Standard STP-MTRD requires a source of step pulses to command motion.

This may be a PLC, an indexer, a motion controller or another type of device.

The only requirement is that the device be able to produce step pulses whose frequency is in proportion to the desired motor speed, and be able to smoothly ramp the step speed up and down to produce smooth motor acceleration and deceleration.

Smaller step sizes result in smoother motion and more precise speed, but also require a higher step pulse frequency to achieve maximum speed. The smallest step size is 1/25,600th of a motor turn. To command a motor speed of 50 revolutions per second (3000 rpm) the step pulses frequency must be 50 x 25,600

= 1.28 MHz. Many motion devices, especially PLCs cannot provide step pulses at such a high speed. If so, the drive must be set for a lower number of steps per revolution. Sixteen different settings are provided, as shown in the diagrams on the next page.

Please choose the one that best matches the capability of your system.

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Chapter 6: SureStep™ Integrated Motors/Drives

1 2 3 4

200

1 2 3 4

400

1 2 3 4

800

1 2 3 4

1600

1 2 3 4

3200

1 2 3 4

6400

1 2 3 4

12800

1 2 3 4

25600

1 2 3 4

1000

1 2 3 4

2000

1 2 3 4

4000

1 2 3 4

5000

1 2 3 4

8000

1 2 3 4

10000

1 2 3 4

20000

1 2 3 4

25000

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At lower step resolutions such as 200 steps/rev (full step) and 400 steps/rev (half step), motors run a little rough and produce more audible noise than when they are microstepped. The STP-MTRD includes a feature called “microstep emulation”, also called

“step smoothing”, that can provide smooth motion from coarse command signals. If you set switch 6 to the ON position, this feature is automatically employed to provide the smoothest possible motion from a less than ideal signal source.

6 6

Because a command filter is used as part of the step smoothing process, there will be a slight delay, or “lag”, in the motion. The graph below shows an example of the delay that can occur from using the step smoothing filter.

ON OFF

SMOOTHING

Step 5: Step Pulse Type

Most indexers and motion controllers provide motion commands in the “Step and Direction” format. The step signal pulses once for each motor step and the direction signal commands direction. However, a few PLCs use a different type of command signal: one signal pulses once for each desired step in the clockwise direction (called STEP CW), while a second signal pulses for counterclockwise motion (STEP CCW). The Standard STP-MTRD can accept this type of signal if you adjust switch 8 as shown in the diagram on the next page.

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Chapter 6: SureStep™ Integrated Motors/Drives

In STEP CW/STEP CCW mode, the CW signal should be connected to the STEP input and the CCW signal to the DIR input.

8 8

STEP CW/

STEP CCW

STEP/

DIR

Step 6: Step Pulse Noise Filter

Electrical noise can affect the STEP signal in a negative way, causing the drive to think that one step pulse is two or more pulses. This results in extra motion and inaccurate motor and load positioning. To combat this problem, the Standard STP-MTRD includes a digital noise filter on the STEP and DIR inputs. The default factory setting of this filter is 150 kHz, which works well for most applications. This is set by moving switch 5 to the ON position.

5 5

However, as discussed in Step 4, if you are operating the

STP-MTRD at a high number of steps/rev and at high motor speeds, you will be commanding the drive at step rates above 150 kHz. In such cases, you should set switch 5 to the OFF position as shown.

150

KHZ

2.0

MHZ

Your maximum pulse rate will be the highest motor speed times the steps/rev. For example, 40 revs/second at 20,000 steps/rev is 40 x

20,000 = 800 kHz. Please consider this when deciding if you must increase the filter frequency.

Self Test

If you are having trouble getting your motor to turn, you may want to try the builtin self-test. Any time switch 4 is moved to the ON position, the drive will automatically rotate the motor back and forth, two and a half turns each direction. This feature can be used to confirm that the motor is correctly wired and otherwise operational.

4 4

ON OFF

SELF TEST

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Drive/Motor Heating

Step motors convert electrical power from the driver into mechanical power to move a load. Because step motors are not perfectly efficient, some of the electrical power turns into heat on its way through the motor. This heating is not dependent on the load being driven but rather the motor speed and power supply voltage. There are certain combinations of speed and voltage at which a motor cannot be continously operated without damage.

Provided below are curves showing the maximum duty cycle versus speed for each size at commonly used power supply voltages. Please refer to these curves when planning your application.

Also keep in mind that a step motor typically reaches maximum temperature after

30 to 45 minutes of operation. If you run the motor for one minute then let it sit idle for one minute, that is a 50% duty cycle. Five minutes on and five minutes off is also a 50% duty. However, one hour on and one hour off has the effect of

100% duty because during the first hour the motor will reach full (and possibly excessive) temperature.

The actual temperature of the motor depends on how much heat is conducted, convected, or radiated out of it. The measurements below were made in a 40°C

(104°F) environment with the motor mounted to an aluminum plate sized to provide a surface area consistent with the motor power dissipation. Your results may vary.

Please use the motor body temperature curves below to determine the maximum duty cycle of the drive/motor under various conditions.

100

STP-MTRD-17030 Max Duty Cycle vs Speed

1.8 Amps @ Ambient of 40°C

80 x 80x 6(mm) Aluminum Plate

80

60

40

20

12V Duty Cycle

24V Duty Cycle

48V Duty Cycle

Note: This graph does not represent maximum speed of the motor. Refer to the

Speed/Torque curves for nominal speed limitations.

0

0 10 20 30

Speed (RPS)

40 50

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Chapter 6: SureStep™ Integrated Motors/Drives

100

STP-MTRD-17038 Max Duty Cycle vs Speed

1.8 Amps @ Ambient of 40°C

80 x 80x 6(mm) Aluminum Plate

80

60

12V Duty Cycle

24V Duty Cycle

48V Duty Cycle

Note: This graph does not represent maximum speed of the motor. Refer to the

Speed/Torque curves for nominal speed limitations.

40

20

0

0 10 20 30

Speed (RPS)

40 50

STP-MTRD-23042 Max Duty cycle vs Speed

5 Amps @Ambient of 40°C

Mounted to a 6.4" x 6.4" x .25" Aluminum Plate

100

40

20

80

60

0

0 10 30 40

12V Duty Cy c le

24V Duty Cy c le

48V Duty Cy c le

65V Duty Cy c le

Note: This graph does not represent maximum speed of the motor. Refer to the

Speed/Torque curves for nominal speed limitations.

50

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STP-MTRD-23065 Max Duty cycle vs Speed

5 Amps @Ambient of 40°C

Mounted to a 6.4" x 6.4" x .25" Aluminum Plate

100

80

60

40

20

0

0 10 20 30

Speed (RPS)

12V Duty Cy c le

24V Duty Cy c le

48V Duty Cy c le

65V Duty Cy c le

Note: This graph does not represent maximum speed of the motor. Refer to the

Speed/Torque curves for nominal speed limitations.

40 50

STP-MTRD-24075

Max Duty Cycle vs Speed

6A/phase, 40°C Ambient

Mounted on a 162 x 162 x 6 (mm)

Aluminum Plate

100

80

60

40

20

12V Duty Cy c l

24V Duty Cy c l

48V Duty Cy c l

65V Duty Cy c l

Note: This graph does not represent maximum speed of the motor. Refer to the

Speed/Torque curves for nominal speed limitations.

0

0 10 20 30

Speed (RPS)

40 50

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Chapter 6: SureStep™ Integrated Motors/Drives

Torque Speed Graphs

STP-MTRD-17030 Torque vs Speed (1.8° step motor; 1/2 stepping)

48V Power Supply

100

0

12V Power Supply

600

24V Power Supply

Speed (rpm)

1200 1800 2400 3000

80

80

60

40

20

60

40

20

0

0 4000 8000 12000

Speed (pps) [1 pulse = 0.9°]

16000 20000

100

0

STP-MTRD-17038 Torque vs Speed (1.8° step motor; 1/2 stepping)

12V Power Supply

600

24V Power Supply

Speed (rpm)

1200 1800

48V Power Supply

2400 3000

6–40

0

0 4000 8000 12000

Speed (pps) [1 pulse = 0.9°]

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Chapter 6: SureStep™ Integrated Motors/Drives

90

60

30

0

0

STP-MTRD-23042 Torque vs Speed (1.8° step motor; 1/2 stepping)

12V Power Supply

600

24V Power Supply 48V Power Supply

Speed (rpm)

1200 1800

150

0

70V Power Supply

2400 3000

120

4000 8000 12000

Speed (pps) [1 pulse = 0.9°]

16000 20000

150

100

50

0

0

STP-MTRD-23065 Torque vs Speed (1.8° step motor; 1/2 stepping)

12V Power Supply

600

24V Power Supply 48V Power Supply

Speed (rpm)

1200 1800

250

0

70V Power Supply

2400 3000

200

4000 8000 12000

Speed (pps) [1 pulse = 0.9°]

16000 20000

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Chapter 6: SureStep™ Integrated Motors/Drives

STP-MTRD-24075 Torque vs Speed (1.8° step motor; 1/2 stepping)

12V Power Supply

600

24V Power Supply 48V Power Supply

Speed (rpm)

1200 1800

375

0

70V Power Supply

2400 3000

300

225

150

75

0

0 4000 8000 12000

Speed (pps) [1 pulse = 0.9°]

16000 20000

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Dimensions and Mounting Slot Locations

Dimensions = inches [mm]

STP-MTRD-17030R / STP-MTRD-17030RE

STP-MTRD-17038

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STP-MTRD-17038E

STP-MTRD-17038R / STP-MTRD-17038RE

6–44

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STP-MTRD-23042

Chapter 6: SureStep™ Integrated Motors/Drives

STP-MTRD-23042E

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Stepping Systems User Manual 6–45

Chapter 6: SureStep™ Integrated Motors/Drives

STP-MTRD-23042R / STP-MTRD-23042RE

STP-MTRD-23065

6–46

For complete drawings, please visit www.automationdirect.com

SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

STP-MTRD-23065E

Chapter 6: SureStep™ Integrated Motors/Drives

STP-MTRD-23065R / STP-MTRD-23065RE

7th Ed. Rev D – 03/17/2022

SureStep

TM

Stepping Systems User Manual 6–47

Chapter 6: SureStep™ Integrated Motors/Drives

STP-MTRD-24075RV / STP-MTRD-24075RVE

For complete drawings, please visit www.automationdirect.com

6–48 SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

S ure

S

tep

tM

S

tepping

M

otorS

C hapter

7

In This Chapter...

Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �7–2

Design and Installation Tips � � � � � � � � � � � � � � � � � � � � � � � � �7–3

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �7–4

Power Supply and Step Motor Drive� � � � � � � � � � � � � � � � � � �7–7

Mounting the Motor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �7–7

Connecting the Motor � � � � � � � � � � � � � � � � � � � � � � � � � � � � �7–7

Extension Cable Wiring Diagrams � � � � � � � � � � � � � � � � � � � � � � � �7–8

Connecting a STP-MTRAC Motor � � � � � � � � � � � � � � � � � � � � � � � �7–8

Motor Dimensions and Cabling � � � � � � � � � � � � � � � � � � � � �7–10

Typical Dimension & Cable Diagrams � � � � � � � � � � � � � � � � � � � �7–10

Typical Dimension & Cable Diagram for STP-MTRH � � � � � � � � �7–13

Typical Dimension & Cable Diagram for STP-MTRAC � � � � � � � �7–16

Torque vs� Speed Charts � � � � � � � � � � � � � � � � � � � � � � � � � � �7–18

Chapter 7: Sure Step TM Stepping Motors

Features

• Step motors available in NEMA 14, NEMA 17, NEMA 23, NEMA 34, and NEMA

42 frame sizes.

• Square frame style produces high torque and achieves best torque to volume ratio.

• Holding torque ranges from 8 to 4532 oz·in.

• Available in single-shaft, dual-shaft (encoder ready), encoder mounted, IP65

(wash-down), and high bus voltage configurations.

• 12-inch long connectorized cables attached to motors, with extension cables available in 6, 10, and 20 foot lengths. NEMA 23 and NEMA 34 high-bus voltage models (MTRAC-23 and MTRAC-34) have 10’ long non-connectorized 8-lead cables.

• All NEMA 14, NEMA 17, NEMA 23, NEMA 34, and NEMA 42 dual-shaft motors come with pretapped holes ready for a modular encoder to be mounted.

• All “E” models include a premounted line driver encoder AMT112Q-V (replaces

STP-MTRA-ENC9). The AMT112Q-V is a configurable encoder that comes preconfigured with 400ppr when shipped attached to a motor. Other ppr and output types are available for purchase. See Appendix A for more information on encoder options and configuration utility.

• All “W” model motors and extension cables include an IP65 connector attached to the cable.

NEMA 14 NEMA 17

NEMA 23

Note: Small holes are often drilled into the end of the rotor shaft. This is for manufacturing tooling purposes.

These holes do not have a dimensional tolerance and cannot be guaranteed to be present on subsequent orders.

NEMA 42

Encoder Versions Available

NEMA 34

Dual-shaft Versions Available

IP65 Versions Available

7–2 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

Design and Installation Tips

Allow sufficient time to accelerate the load and size the step motor with a 100% torque safety factor (i.e. design the system using a maximum of 50% of the motor’s torque). DO NOT disassemble step motors, as 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 and radial loading on bearings from minor misalignment.

In general, the higher the current into a step motor the higher the torque, especially at lower speeds. The higher the voltage to the step motor, the higher the torque at higher speeds. Losses come in to play here, too. The higher you run the current on the motors, the higher your losses are going to be, and the hotter your motors are going to get. For this reason, AutomationDirect specs current for motors at the RMS value. This is the value on the motor’s label and specification table. This guarantees a very long life for the motor. Multiplying the motor’s RMS phase current by 1.2 gives a good balance of torque vs loss. This value should then be used to set the drive’s peak phase current. Note that the whole speed torque curve won’t be shifted up, only the low speed flat part before the torque starts dropping. The curve can drop for many reasons, but typically it’s due to not having enough voltage to push the desired current into the windings, so increasing the voltage is what gives you a boost there, not making more current available.

For STP-MTRAC(H)-x motors or other high bus voltage motors ensure the drain wire or ground wire from the motor is properly grounded to the motor and drive’s grounding lug. Also ensure the drive’s grounding point is properly grounded to the panel ground.

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–3

Chapter 7: Sure Step TM Stepping Motors

Specifications

Sure

Step™ Series Specifications – Connectorized Bipolar Stepping Motors

Bipolar

Stepping Motors

NEMA Frame Size

Optional Encoder

* Max

Holding

Torque

(lb·in)

(oz·in)

(N·m)

Rotor

Inertia

(oz·in 2

(kg·cm

)

2 )

Rated RMS Current

(A/phase)

Resistance

( Ω /phase)

Inductance

(mH/phase)

Insulation Class

Basic Step Angle

Shaft Runout

Max Shaft Radial

Play @ 1lb load

Perpendicularity

Concentricity

*Max Radial Load

(lb [kg])

* Max Axial (Thrust)

Load (lb [kg])

Storage

Temperature

Operating

Temperature

Operating

Humidity

Product Material

Low Torque Motors

STP-MTR L -

14026x

14

STP-MTR

14034x

14

L -

Y

0.5

8

0.06

0.06

0.0003

0.35

8.5

5.77

Y

1.25

20

0.14

0.08

0.00035

0.8

7.66

6.92

STP-MTR-

17040x

17

Y

3.81

61

0.43

0.28

0.05

1.7

1.6

3.0

High Torque Motors

STP-MTR-

17048x

17

Y

5.19

83

0.59

0.37

0.07

2.0

1.4

2.7

STP-MTR-

130°C [266°F] Class B; 300V rms

1.8°

0.002 in [0.051 mm]

0.001 in [0.025 mm]

0.003 in [0.076 mm]

0.003 in [0.076 mm]

6.0

[2.7]

6.0

[2.7]

-20°C to 100°C [-4°F to 212°F]

17060x

17

Y

7.19

115

0.81

0.56

0.10

2.0

2.0

3.3

-20°C to 50°C [-4°F to 122°F]

(motor case temperature should be kept below 80°C [176°F])

55% to 85% non-condensing steel motor case; stainless steel (SUS 303) shaft(s)

STP-MTR-

23055x

23

Y

10.37

166

1.17

1.46

0.27

2.8

0.75

2.4

15.0

[6.8]

13.0

[5.9]

Environmental

Rating

Weight (lb [kg])

(E models)

Agency Approval

0.25 [0.11]

(0.3 [0.1])

IP40

0.35 [0.15]

(0.4 [0.2])

0.6 [0.3]

(0.7 [0.3])

CE

IP40

IP65 (W motors only)

0.7 [0.3]

(0.8 [0.4])

0.9 [0.4]

(0.9 [0.4])

1.5 [0.7]

(1.5 [0.7])

Accessory

Extension Cable

STP-EXT L -006, 010, 020

STP-EXT-006, 010, 020

STP-EXTW-006, 010, 020 (W motors only)

* 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.

7–4 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

Specifications (continued)

Table continued from previous page

Sure

Step™ Series Specifications – Connectorized Bipolar Stepping Motors

Bipolar

Stepping Motors

High Torque Motors

STP-MTR-

23079x

STP-MTR-

34066x

STP-MTR H -

23079x

Higher Torque Motors

STP-MTR H -

34066x

STP-MTR H -

34097x

STP-MTR H -

34127x

NEMA Frame Size

Optional Encoder

Max

Holding

Torque

(lb·in)

(oz·in)

(N·m)

23

17.25

276

1.95

34

27.12

434

3.06

23

17.87

286

2.02

Yes

34

27.12

434

3.06

34

50.00

800

5.65

34

80.50

1288

9.10

Rotor

Inertia

(oz·in 2 )

(kg·cm 2 )

Rated RMS

Current

(A/phase)

Resistance

( Ω /phase)

Inductance

(mH/phase)

Insulation Class

Basic Step Angle

Shaft Runout

Max Shaft Radial

Play @ 1lb load

Perpendicularity

2.60

0.48

2.8

1.1

3.8

7.66

1.40

2.8

1.11

6.6

2.60

0.48

5.6

0.4

1.2

1.8°

7.66

1.40

6.3

0.25

1.5

130°C [266°F] Class B; 300V rms

0.002 in [0.051 mm]

0.001 in [0.025 mm]

0.003 in [0.076 mm]

14.80

2.71

6.3

0.3

2.1

21.90

4.01

6.3

0.49

4.1

Concentricity

Maximum Radial

Load (lb [kg])

Max Axial (Thrust)

Load (lb [kg])

Storage Temp.

Operating

Temperature

Operating

Humidity

Product Material

Environmental

Rating

Weight (lb [kg])

(E models)

Agency Approval

Accessory

Extension Cable

15.0

[6.8]

13.0

[5.9]

2.2 [1.0]

(2.4 [1.1])

39.0

[17.7]

25.0

[11.3]

0.003 in [0.076 mm]

15.0 [6.8]

13.0 [5.9]

-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 80°C [176°F])

55% to 85% non-condensing steel motor case; stainless steel (SUS 303) shaft(s)

3.9 [1.7]

STP-EXT-006, 010, 020

STP-EXTW-006, 010, 020

(W motors only)

IP40

IP65 (W motors only)

2.4 [1.1]

(2.4 [1.1])

3.9 [1.7]

CE

39.0 [17.7]

25.0 [11.3]

5.9 [2.7] 8.4 [3.8]

STP-EXT H -006, 010, 020

STP-EXTW H -006, 010, 020 (W motors only)

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–5

Chapter 7: Sure Step TM Stepping Motors

Specifications (continued)

Table continued from previous page

Sure

Step™ Series Specifications – Non-connectorized Bipolar Stepping Motors

Bipolar

Stepping Motors

NEMA Frame Size

Optional Encoder 1

Max

Holding

Torque

Rotor

Inertia

STP-

MTRAC-

23044(x)

23

Y

(lb·in) 4.69

(oz·in) 75

(N·m)

(oz·in 2 ) 0.66

(g·cm 2 )

0.53

120

Rated RMS

Current

(A/phase)

Series

Parallel

0.71

1.41

Resistance

( Ω /phase)

Series

Parallel

12.4

3.1

23

High Bus Voltage Motors

STP-

MTRAC-

23055(x)

STP-

MTRAC-

23078(x)

23

STP-

MTRAC-

34075(x)

34

STP-

MTRAC-

34115(x)

34

Y

9.31

149

1.05

1.64

300

Y

14.19

227

1.6

2.62

480

Y

51.31

821

5.8

7.38

1350

Y

69.38

1110

7.84

14.74

2700

0.71

1.41

14.4

3.6

0.71

1.41

18

4.5

2.15

4.3

4

1.0

2.05

4.1

4.8

1.2

2.55

5.1

4.8

1.375

STP-

MTRAC-

34156(x)

34

Y

115.06

1841

13

24.06

4400

Inductance

(mH/phase)

Series

Parallel

Insulation Class

Steps per Revolution

Basic Step Angle

Shaft Runout

Max Shaft Radial Play

@ 1lb load

Max End Play @ 2.2-lb

Axial Load

Connectors

Temperature Rise

Storage Temp.

Operating Temperature

30.4

7.6

51.2

12.8

0.02 in

0.08 in

60.8

32

15.2

B

200

1.8°

0.05 mm

8.0

0.025 in

0.075 in

8 leads, 24AWG 8 leads, 22AWG

80°C max

-40°C to 70°C [-40°F to 158°F]

-20°C to 50°C [-4°F to 122°F]

43.2

10.8

44.8

11.2

0.02 in

0.08 in

Operating Humidity

Product Material

Environmental Rating

Weight (lb [kg])

Steel motor case, stainless steel shaft(s)

1.03 [0.47] 1.54 [0.7]

5% to 95% non-condensing

2.2 [1.0]

Agency Approval None

1 - Only Dual-shaft motors (suffix = “D”) are encoder ready.

IP40

4.2 [1.9] 8.4 [3.8] 11.464 [5.2] c

UR us

7–6 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

Specifications (continued)

Sure

Step™ Series Specifications – Connectorized Stepping Motors

Stepping Motors

NEMA Frame Size

Optional Encoder 1

Unipolar Series Max Holding

Torque

(N·m)

Bipolar Series

Bipolar Parallel

Rotor Inertia (g·cm 2 )

Unipolar Series Rated RMS

Current

(A/phase)

Bipolar Series

Bipolar Parallel

Resistance

( Ω /phase)

Unipolar Series

Bipolar Series

Bipolar Parallel

Inductance

(mH/phase)

Unipolar Series

Bipolar Series

Bipolar Parallel

Insulation Class

Steps per Revolution

Basic Step Angle

Shaft Runout

Max Shaft Radial Play

@ 1lb load

Connectors

Temperature Rise

Storage Temp.

STP-

MTRAC-

42100x

42

Y

9.7

8.4

0.6

1.19

0.3

5

19.8

5

12.2

12.2

5500

6

4.2

Higher Bus Voltage Motors

STP-

MTRAC-

42151x

42

STP-

MTRAC-

42202x

42

STP-

MTRACH-

42100x

42

STP-

MTRACH-

42151x

42

Y Y Y Y

STP-

MTRACH-

42202x

42

Y

19.0

26.0

9.7

17.5

26.0

12

0.34

0.68

0.17

3.6

14.5

3.6

22.0

22.0

10900

9.4

6

31.0

31.0

16200

9

6

12

0.46

0.91

0.23

5.5

22

2.5

10.1

5.5

B

200

1.8°

0.05 mm

2.5

12.3

12.3

5500

8.5

6

12

0.32

0.64

0.159

1.1 in

8 leads, 18AWG

80°C max

-30°C to 70°C [-22°F to 158°F]

22.0

22.0

10900

11.3

8

16

0.215

0.43

0.108

1.9

7.6

1.9

32.0

32.0

16200

11.5

8

16

0.29

0.58

0.144

3.2

13

3.2

Operating Temperature -20°C to 40°C [-4°F to 104°F]

Operating Humidity

Product Material

Environmental Rating

Weight (lb [kg]) 10.6 [4.8]

5% to 95% non-condensing

Steel motor case, stainless steel shaft(s)

IP40

17.6 [8] 25.6 [11.6] 10.6 [4.8] 17.6 [8] 25.6 [11.6]

Agency Approval c

UR us

1 - Only Dual Shaft motors (suffix = “D”) are Encoder Ready. NEMA 42 motors require an STP-MTRA-

42ENC adapter plate for encoder mounting (holes pre-drilled and tapped for CUI Devices AMT31/AMT33 or

US Digital E6).

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–7

Chapter 7: Sure Step TM Stepping Motors

Power Supply and Step Motor Drive

An STP-PWR-xxxx linear power supply from AutomationDirect is the best choice to power AutomationDirect and other DC-input stepper drives. These power supplies were designed to work with the AutomationDirect SureStep™ STP-

DRV-xxxx series bipolar DC microstepping motor drives. PSBxx switching power supplies are also available from AutomationDirect.

SureStep STP-MTR AC series motors (NEMA23 and NEMA34 only) and STP-DRV AC drives are designed for high bus voltages (120VAC, 240VAC drive input). Higher DC power supply voltages and AC-input stepper drives generate very high bus voltages and will result in excessive losses (heat) in the motors unless they are designed for it

(see STP-MTRAC motors and STP-DRVAC drives). Do not use low-voltage motors in a high bus voltage system.

Always check the motor specs and speed-torque curves to determine allowable drive input voltage. To minimize heat loss in the motor, always choose the lowest input voltage that satisfies the application’s speed-torque requirements.

Mounting the Motor

We recommend mounting the motor to a metallic surface to help dissipate heat generated by the motor.

Connecting the Motor

W arning

: 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 STP-MTR series motors have connectorized cables which connect directly to available SureStep extension cables. Due to the different current ranges of the three motor torque classes, three different ampacity rated cables are available in three different lengths. The MTR L motors use EXT L cables, the MTR motors use EXT cables, and the MTR H motors use EXT H 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. The NEMA 23 and NEMA 34 high bus voltage MTRAC motors have

8-lead, 10-foot cables (no in-line connectors or extension cables). NEMA 42 STP-

MTRAC(H)-42x motors have a connectorized cable that will mate with the STP-

EXT42(H) extension cables.

7–8 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

Extension Cable Wiring Diagrams

STP-EXTx-xxx Cables

EXT & EXTH CABLES

PIN# COLOR PHASE

1 RED A+

2 WHITE A-

3 GREEN B+

4 BLACK B-

1.0" ref

EXTL CABLES

PIN# COLOR PHASE

1 RED A+

2 WHITE A-

3 GREEN B+

4 BLACK B-

PIN #4

PIN #2

PIN #1

PIN #3

PIN #1

CONNECTORS:

EXT: Molex #43020-0401

EXTH: Molex #39-01-2041

EXTL: TE #103653-3

L

STP-EXTxW-xxx Cables

(

1.8

[46.35]

)

(

0.50

[12.70]

)

L ±0.50

[L ±12.70]

1.00±0.25

[25.40±6.35]

3

4

1

2

5

6

PIN #

PIN OUT CONNECTION

COLOR

RED

WHITE

GREEN

BLACK

GROUND

N/A

PHASE

A+

A-

B+

B-

GROUND

N/A

(

Ø0.77

[Ø19.60]

)

PIN # 5

PIN # 1

PIN # 2

LABEL:

STP-EXTW-0XX or

STP-EXTHW-0XX PIN # 6

PIN # 4 PIN # 3

STP-EXT42-006

STP-EXT42-010

STP-EXT42-020

TABLE INFORMATION

CABLE LENGTH L

6 Feet

10 Feet

20 Feet

18AWG SHIELDED CABLE:

BELDEN # 9418

(OR EQUIVALENT)

STP-EXT42(H)-xxx Cables

HEAT SHRINK

LABEL UL2517 18AWG 8C HEAT SHRINK

2.00"

1.00"

HEAT SHRINK UNSHIELDED CABLE:

24AWG = EXTL cables

20AWG = EXT cables

18AWG = EXTH cables

7th Ed. Rev D –03/17/2022

26±2

80±3

STP-EXT42- XXX

Automation Direct

YYDDD

75±3

L

Pin

8

7

9

6

5

4

3

2

1

Wire Description

A - White

A - Orange

C - Green

C - Brown

B - Red

B - Yellow

D - Black

D - Blue

GND - Drain wire

For stepper drive connections (A+, A-, B+,

B-), see wiring diagrams on page 7–11.

Sure Step TM Stepping Systems User Manual 7–9

Chapter 7: Sure Step TM Stepping Motors

Connecting a STP-MTRAC-23x or STP-MTRAC-34x Motor

The NEMA 23 and NEMA 34 STP-MTRAC series high bus voltage motors have eight leads and should be wired using the diagrams below:

STP-MTRAC-230xx(x), 34156(x)

A+

Orange

Brown

A–

White

8 lead motor

Green

Red

B+

Yellow

Blue

B–

Black

8 Leads Series Connected

(for use with 340VDC max output drives)

Use the series winding diagram with

STP-DRVAC-24025 drives (115 or

230 VAC)

A+

Brown

White

8 lead motor

Orange

A–

Green

Red Black

B+

Blue Yellow

B–

8 Leads Parallel Connected

(for use with 170VDC max output drives)

Warning!!

Do NOT use this parallel winding diagram with STP-DRVAC-24025 drives

STP-MTRAC-34075(x), 34115(x)

A+

Orange

Orange/White

Black/White

A–

Black

Red

B+

Red/

White

8 lead motor

Yellow/

White

Yellow

B–

8 Leads Series Connected

(for use with 340VDC max output drives)

Use the series winding diagram with

STP-DRVAC-24025 drives (115 or

230 VAC)

Black/

White

Orange/

White

A+

A–

Orange

Black

Red

8 lead motor

Yellow

B+

Yellow/

White

Red/

White

B–

8 Leads Parallel Connected

(for use with 170VDC max output drives)

Warning!!

Do NOT use this parallel winding diagram with STP-DRVAC-24025 drives

7–10 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

Connecting a STP-MTRAC(H)-42 Motor

The STP-MTRAC(H)-42 series higher bus voltage motors have eight leads and should be wired using the diagrams below:

A+ O A- B+ M BA+ A- B+ B-

A+ AB+ B-

NOTE: Bipolar Series will be the most common application. The larger Bipolar Parallel motors require 12A and 16A current from a stepper drive.

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–11

Chapter 7: Sure Step TM Stepping Motors

Motor Dimensions and Cabling

Typical Dimension & Cable Diagrams

STP-MTR-xxxxx

STP-MTR-xxxxxW

NOTE: MTRH and MTRAC information is on later pages

7–12 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

3.39

[86.1]

2.74

[69.6]

STP-MTR-34xxx

2.88 [73.0]

A**

D**

1.46

[37.1]

C**

4X 0.26 [6.6] through

UNSHIELDED CABLE:

4 CONDUCTORS

B

12 [305]

PIN # 1

CONNECTOR:

VIEW FROM WIRE ENTRANCE

C**

PIN #

1

2

3

4

EXTL MOTORS

COLOR

RED

YELLOW

GREEN

BLACK

PHASE

A+

A-

B+

B-

CONNECTOR:

MOLEX #

PIN # 1

PIN # 3

PIN # 2

PIN # 4

CONNECTOR:

VIEW FROM WIRE ENTRANCE

D**

NEMA # 34 (front shaft): TWO FLATS 90° APART

**

**

***

Dimension A is the same for both front and rear shafts of dual-shaft motors.

Dimensions C & D do NOT apply to rear shafts of dual-shaft motors

Dimension applies only to dual-shaft (D) motors.

(all rear shafts are round style).

1.13 [28.7]***

1.22

[31.0]

1.812

[46.0]

1.22

[31.0]

EXT & EXTH MOTORS

PIN #

3

1

2

4

COLOR

RED

WHITE

GREEN

BLACK

PHASE

A+

A-

B+

B-

2X M3 x 0.5 thread

on 1.73 in.

bolt circle

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–13

Chapter 7: Sure Step TM Stepping Motors

Dimensions

(in [mm])*

A

B

C

D**

E

SureStep™ Series Dimensions & Cabling – STP-MTR-x*** Step Motors

Low Torque Motors

STP-MTRL

-14026x

STP-MTRL

-14034x

1.39 [35.3]

High Torque Motors STP-MTR-x

STP-MTR

-17040x

STP-MTR

-17048x

1.67 [42.3]

STP-MTR

-17060x

STP-MTR

-23055x

STP-MTR

-23079x

2.25 [57.2]

1.02 [25.9]

4-40 thread

0.15 [3.8] min depth

1.22 [31.0]

Ø 0.87 [22.1]

Ø 0.20 [5.0]

M3 x 0.5 thread

0.15 [3.8] min depth

1.86 [47.2]

Ø 1.50 [38.1]

Ø 0.25 [6.4]

Ø 0.20 [5.1] through

STP-MTR

-34066x

3.39 [86.1]

2.74 [69.6]

Ø 2.88 [73.0]

Ø 0.50 [12.7]

Ø 0.26 [6.6] through

E

E

2

3

M2.5 X 0.45 thread

M2 x 0.4 thread

4-40

M2.5 x 0.45 thread n/a

M3 x 0.5 thread on a

1.73 in. bolt circle

1.02 [25.9] 1.34 [34.0] 1.58 [40.1] 1.89 [48.0] 2.34 [59.5] 2.22 [56.4] 3.10 [78.7] 2.64 [67.1] F

1

**

F

2

G

**

1 n/a 1.90 [48.3] 2.24 [56.9] 2.67 [67.8] 2.33 [59.1] 3.19 [81.0] 2.64 [67.1]

0.375 [9.5]

0.75 [19.1]

0.411

[10.4] n/a

0.906 [23]

1.812 [46] n/a

G 2

G 3

H

1

H

2

**

H

3**

J**

K**

0.60 [15.2]

0.51 [13.0] n/a n/a n/a

0.94 [24.0]

0.51 [13]

0.40 [10.1]

0.81 [20.6]

0.51 [13]

0.59 [15.0]

0.23 [5.8]

1.22 [31]

1.46 [37.1]

1.13 [28.7] n/a

0.98 [25.0]

0.45 [11.4]

L 12 [305]

Conductor

Connector

(4) #26 AWG

TE # 103653-3

Pin

TE # 1-104505-3

(LOOSE)

* mm dimensions are for reference purposes only.

(4) #20 AWG

(5) #18 AWG (for W motors)

Molex # 43025-0400

PXP4010/06S/6065 (for W motors)

Molex # 43030-0007

Socket: SA3347 (for W motors)

** Dimension D (shaft diameter) is the same for both front and rear shafts of dual-shaft and encoder motors. Dimension H

2

applies only to dual-shaft (D) and encoder (E) motors. Dimensions J & K do

NOT apply to rear shafts of dual-shaft or encoder motors (all rear shafts are round style). Dimension H3 applies only to “E” models with the encoder pre-mounted. Dimension F2 applies to “W” models only.

*** Higher Torque STP-MTRH and high bus voltage STP-MTRAC motors are shown in a separate table.

7–14 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

Typical Dimension & Cable Diagram for STP-MTRH

STP-MTRH-23079x

STP-MTRH-xxxxxW

NOTE: NEMA 34 motor on the next page.

NOTE: STP-MTRAC information is on later pages

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–15

Chapter 7: Sure Step TM Stepping Motors

3.39

[86.1]

2.74

[69.6]

STP-MTRH-34xxx

2.88 [73.0]

D**

1.46

[37.1]

A**

C**

4X 0.26 [6.6] through

UNSHIELDED CABLE:

4 CONDUCTORS

B

12 [305]

PIN # 1

CONNECTOR:

VIEW FROM WIRE ENTRANCE

C**

PIN #

1

2

3

4

EXTL MOTORS

COLOR

RED

YELLOW

GREEN

BLACK

PHASE

A+

A-

B+

B-

CONNECTOR:

MOLEX #

PIN # 1

PIN # 3

PIN # 2

PIN # 4

CONNECTOR:

VIEW FROM WIRE ENTRANCE

D**

NEMA # 34 (front shaft): TWO FLATS 90° APART

**

**

***

Dimension A is the same for both front and rear shafts of dual-shaft motors.

Dimensions C & D do NOT apply to rear shafts of dual-shaft motors

Dimension applies only to dual-shaft (D) motors.

(all rear shafts are round style).

1.13 [28.7]***

1.22

[31.0]

1.812

[46.0]

1.22

[31.0]

EXT & EXTH MOTORS

PIN #

1

2

3

4

COLOR

RED

WHITE

GREEN

BLACK

PHASE

A+

A-

B+

B-

2X M3 x 0.5 thread

on 1.73 in.

bolt circle

7–16 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

SureStep™ Series Dimensions & Cabling – STP-MTR

H

-x*** Step Motors

Dimensions

(in [mm])*

STP-MTR H -

23079x

2.25 [57.2]

Higher Torque Motors STP-MTR H -x

STP-MTR H -

34066x

STP-MTR

34097x

H -

3.39 [86.1]

STP-MTR H -

34127x

A

B

C

D**

E

E

2

E 3

F

1

F

2

**

**

G 1

G 2

G 3

H

1

H

2

**

1.86 [47.2]

Ø 1.50 [38.1]

Ø 0.25 [6.4]

Ø 0.20 [5.1] through

4-40 n/a

3.10 [78.7]

3.19 [81.0]

0.906 [23] n/a

0.81 [20.6]

0.51 [13]

2.64 [67.1]

2.74 [67.1]

1.812 [46]

2.74 [69.6]

Ø 2.88 [73.0]

Ø 0.50 [12.7]

Ø 0.26 [6.6] through

M2.5 x 0.45 thread

M3 x 0.5 thread on a 1.73 in. bolt circle

3.82 [97.1]

3.82 [97.1] n/a

1.22 [31]

1.46 [37.1]

1.13 [28.7]

5.00 [127.0]

5.00 [127.0]

H

3

**

J**

K**

0.40 [10.2]

0.59 [15.0]

0.23 [5.8] n/a

0.98 [25.0]

0.45 [11.4]

L 12 [305]

Conductor

Connector

Pin

(4) #18 AWG

(5) #18 AWG (for W motors)

Molex # 39-01-3042

PXP4010/06S/6065 (for W motors)

Molex # 39-00-0039

Socket: SA3347 (for W motors)

* mm dimensions are for reference purposes only.

** Dimension D (shaft diameter) is the same for both front and rear shafts of dual-shaft and encoder motors. Dimension H

2

applies only to dual-shaft (D) and encoder (E) motors. Dimensions J & K do

NOT apply to rear shafts of dual-shaft and encoder motors (all rear shafts are round style). Dimension

H3 applies only to “E” models with the encoder pre-mounted. Dimension F2 applies to “W” models only.

*** High bus voltage STP-MTRAC motors are shown in a separate table.

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–17

Chapter 7: Sure Step TM Stepping Motors

Typical Dimension & Cable Diagram for STP-MTRAC

STP-MTRAC-23xxx

H

1 A

B

J**

F H

2

J**

øC

øD**

4X øE

SHIELDED CABLE:

8 CONDUCTORS

STRIPPED

0.60-0.80"

L

Rear of Motor

2X E

2

* on ø1.28 BC

D**

2X E

3

* on ø1.81 BC

2X E

4

* on ø0.75 BC

NEMA # 23: ONE FLAT of DIMENSION J LENGTH

**

**

Dimension H2 applies only to dual-shaft (D).

Dimension D is the same for both front and rear shafts of dual-shaft.

MODEL #

STP-MTRAC-23044

STP-MTRAC-23055

STP-MTRAC-23078

STP-MTRAC-23044D

STP-MTRAC-23055D

STP-MTRAC-23078D

A

2.25

2.25

2.25

2.25

2.25

2.25

STP-MTRAC-34xxx

B

1.86

1.86

1.86

1.86

1.86

1.86

ĂC

1.50

1.50

1.50

1.50

1.50

1.50

ĂD**

0.25

0.25

0.25

0.25

0.25

0.25

A

B

ĂE

0.2

0.2

0.2

0.2

0.2

0.2

E

2

N/A

N/A

N/A

56-UNC 0.2 DEEP

56-UNC 0.2 DEEP

56-UNC 0.2 DEEP

ø

ø D**

C

J**

H

1

DIMENSIONS IN INCHES

E

3

N/A

N/A

N/A

56-UNC TAP THRU

56-UNC TAP THRU

56-UNC TAP THRU

K**

F

E

4

N/A

N/A

N/A

4-40 UNC TAP 0.2 DEEP

4-40 UNC TAP 0.2 DEEP

4-40 UNC TAP 0.2 DEEP

4X ø E

STRIPPED

0.60-0.80" L

SHIELDED CABLE:

8 CONDUCTORS

H

2

F

1.71

2.16

3.05

1.71

2.16

3.05

G

1

N/A

N/A

N/A

0.375

0.375

0.375

G

2

N/A

N/A

N/A

0.64

0.64

0.64

Rear of Motor Rear Shaft ø 0.375

2X E

2

* on ø 1.28 BC

2X E

3

* on ø 1.81BC

D** K**

NEMA # -34075x and -34155x (front shaft): KEYED,

Key Dimensions 0.125 X 0.125 X 0.875

NEMA # -34156x (front shaft): KEYED,

Key Dimensions 0.1875 X 0.1875 X 0.875

**

**

Dimension H2 applies only to dual-shaft (D) motors.

Dimensions J & K do NOT apply to rear shafts of dual-shaft motors (all rear shafts are round style).

H

1

0.81

0.81

0.81

0.81

0.81

0.81

H

2

N/A

N/A

N/A

0.63

0.63

0.63

J

0.60

0.60

0.60

0.60

0.60

0.60

L

120

120

120

120

120

120

7–18 Sure Step TM Stepping Systems User Manual

DIMENSIONS IN INCHES

MODEL #

STP-MTRAC-34075

STP-MTRAC-34115

STP-MTRAC-34156

STP-MTRAC-34075D

STP-MTRAC-34115D

STP-MTRAC-34156D

A

3.39

3.39

3.39

3.39

3.39

3.39

B

2.74

2.74

2.74

2.74

2.74

2.74

ø C

2.87

2.87

2.87

2.87

2.87

2.87

ø D**

0.5

0.5

0.5

0.5

0.5

0.5

ø E

0.25

0.25

0.25

0.25

0.25

0.25

E

2

N/A

N/A

N/A

4-40 UNC TAP 0.2 DEEP

4-40 UNC TAP 0.2 DEEP

4-40 UNC TAP 0.2 DEEP

E

3

N/A

N/A

N/A

4-40 UNC TAP 0.2 DEEP

4-40 UNC TAP 0.2 DEEP

4-40 UNC TAP 0.2 DEEP

7th Ed. Rev D –03/17/2022

F

2.95

4.52

6.14

2.95

4.52

6.14

G

1

N/A

N/A

N/A

0.64

0.64

0.64

G

2

N/A

N/A

N/A

0.905

0.905

0.905

H

1

1.25

1.25

1.25

1.25

1.25

1.25

H

2

N/A

N/A

N/A

1.12

1.12

1.12

J

0.87

0.87

0.87

0.87

0.87

0.87

L

120

120

120

120

120

120

Chapter 7: Sure Step TM Stepping Motors

SureStep™ Series Dimensions & Cabling – STP-MTRAC-x Step Motors

Dimensions

(in [mm])*

STP-MTRAC

-23044x

STP-MTRAC

-23055x

High Bus Voltage Motors

STP-MTRAC

-23078x

STP-MTRAC

-34075x

STP-MTRAC

-34115x

STP-MTRAC

-34156x

A

B

2.25 [57.15]

1.86 [47.24]

2.25 [57.15]

1.86 [47.24]

2.25 [57.15]

1.86 [47.24]

3.39 [86.1]

2.74 [69.6]

3.39 [86.1]

2.74 [69.6]

3.39 [86.1]

2.74 [69.6]

C

D**

1.50 [38.1]

0.25 [6.35]

1.50 [38.1]

0.25 [6.35]

1.50 [38.1]

0.25 [6.35]

2.87 [72.9]

0.5 [12.7]

2.87 [72.9]

0.5 [12.7]

2.87 [72.9]

0.625 [15.9]

E 0.2 [5.08] 0.2 [5.08] 0.2 [5.08] 0.22 [5.59] 0.26 [6.6] 0.22 [5.59]

E

E

2

3

***

***

E

4

***

F

H

1

H

2

***

J

L

2-56 thru 2-56 thru 2-56 thru

4-40 UNC x 0.2

Deep

2-56 UNC Tap

0.2 Deep

1.71 [43.43]

4-40 UNC x 0.2 4-40 UNC x 0.2

Deep

2-56 UNC Tap

0.2 Deep

Deep

2-56 UNC Tap

0.2 Deep

2.16 [54.86] 3.05 [77.47]

2-56 UNC

Tap 0.2 Deep

4-40 UNC Tap

0.2 Deep

–

2.95 [74.93]

0.81 [20.57] 0.81 [20.57] 0.81 [20.57] 1.25 [31.75]

2-56 UNC

Tap 0.2 Deep

4-40 UNC Tap

0.2 Deep

–

4.52 [114.81]

1.25 [31.75]

2-56 UNC Tap

0.2 Deep

4-40 UNC Tap

0.2 Deep

–

6.14 [155.96]

1.25 [31.75]

0.63 [16.0]

0.60 [15.24]

120 [3048]

0.63 [16.0]

0.60 [15.24]

120 [3048]

0.63 [16.0]

0.60 [15.24]

120 [3048]

1.12 [28.45]

0.87 [22.1]

120 [3048]

1.12 [28.45]

0.87 [22.1]

120 [3048]

1.12 [28.45]

0.87 [22.1]

120 [3048]

* mm dimensions are for reference purposes only.

** Dimension D (shaft diameter) is the same for both front and rear shafts of NEMA 23 dual-shaft motors.

See diagrams for NEMA 34.

*** Dimension applies only to dual-shaft (D) motors.

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–19

Chapter 7: Sure Step TM Stepping Motors

Typical Dimension & Cable Diagram for STP-MTRAC(H)-42x

o A o B

H

1

F

ØC

J***

Rear Shaft Ø0.50

ĂD*

4X E

2

* on Ø3.00 BC

K***

4X ØE

Housing: MOLEX 39-01-2100

Terminal: MOLEX 39-00-0038

L

SHIELDED CABLE:

8 CONDUCTORS

D* K***

NEMA # 42 (front shaft): KEYED, Key Dimensions 0.188 X 0.188 X 1.377

**

*

***

Dimension D applies only to the front shaft.

Dimension H2 applies only to dual-shaft (D) motors.

Dimensions J & Key do NOT apply to rear shafts of dual-shaft motors (all rear shafts are round style).

SureStep™ Series Dimensions & Cabling – STP-MTRAC(H)-42x Step Motors

Dimensions

MODEL #

STP-MTRAC-42100

STP-MTRAC-42151

STP-MTRAC-42202

STP-MTRACH-42100

STP-MTRACH-42151

STP-MTRACH-42202

STP-MTRAC-42100D

STP-MTRAC-42151D

STP-MTRAC-42202D

STP-MTRACH-42100D

STP-MTRACH-42151D

STP-MTRACH-42202D

(in [mm])*

4.33

4.33

A

4.33

4.33

4.33

B

4.33

C

4.33

3.50

3.50

3.50

3.50

3.50

3.50

3.50

B

3.50

3.50

3.50

3.50

3.50

D**

ĂC

2.19

2.19

2.19

2.19

2.19

2.19

2.19

2.19

2.19

2.19

2.19

2.19

STP-

MTRAC(H)-

42100

4.33 [110]

0.75

0.327

3.50 [88.9]

0.75 [19.05]

E 0.327 [8.31]

N/A

N/A

N/A

STP-

MTRAC(H)-

42151

4.33 [110]

N/A

3.50 [88.9]

0.75 [19.05]

0.327 [8.31]

3

STP-

MTRAC(H)-

42202

4.33 [110]

N/A

3.50 [88.9]

N/A

N/A

2.19 [55.6]

N/A

0.75 [19.05]

0.327 [8.31]

STP-

MTRAC(H)-

42100D

4.33 [110]

7.91

3.50 [88.9]

7.91

3.88

5.94

7.91

N/A

N/A

N/A

N/A

2.19 [55.6]

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

G

2

N/A

N/A

N/A

0.75 [19.05]

STP-

MTRAC(H)-

42151D

2.19

2.19

N/A

N/A

N/A

4.33 [110]

2.19

2.19

3.50 [88.9]

2.19

2.19

2.19

N/A

1.12

1.12

1.12

0.75 [19.05]

J

1.37

1.37

1.37

1.37

1.37

1.37

1.37

1.37

1.37

1.37

1.37

1.37

STP-

MTRAC(H)-

42202D

4.33 [110]

120

3.50 [88.9]

120

120

120

120

0.75 [19.05]

0.327 [8.31] 0.327 [8.31] 0.327 [8.31]

E

2 n/a n/a n/a

4-40 UNC

Tap 0.2 Deep

4-40 UNC

Tap 0.2 Deep

4-40 UNC

Tap 0.2 Deep

F

H

1

H

2

3.88

2.19 [55.6] n/a

5.94

2.19 [55.6] n/a

7.91

2.19 [55.6] n/a

3.88***

2.19 [55.6]

1.12 [28.4]

5.94***

2.19 [55.6]

1.12 [28.4]

7.91***

2.19 [55.6]

1.12 [28.4]

J** 1.37 [34.8] 1.37 [34.8] 1.37 [34.8] 1.37 [34.8] 1.37 [34.8] 1.37 [34.8]

L 12 [305]

* mm dimensions are for reference purposes only.

** Dimension D (shaft diameter), J, and Key do not apply to rear shafts of dual-shaft motors.

*** For encoder mounting the required STP-MTRA-42ENC will add 0.13 inches [3.2 mm] to the length of the motor.

7–20 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

Torque vs. Speed Charts

STP-MTR-14xxx(D) NEMA 14 Step Motors

STP-MTR-14026(x) Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

8

0 300

48V Power Supply 24V Power Supply

Speed (rpm)

600 900 1200 1500 1800 2100

6

12

8

4

0

0

4

2

0

0 2000 4000 6000 8000 10000

Speed (pps) [1 pulse = 0.9°]

12000 14000

STP-MTR-14034(x) Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

300

48V Power Supply 24V Power Supply

Speed (rpm)

600 900 1200 1500 1800 2100

16

0

2000 4000 6000 8000 10000

Speed (pps) [1 pulse = 0.9°]

12000 14000

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–21

Chapter 7: Sure Step TM Stepping Motors

90

80

70

60

50

40

30

0

20

10

0

0

STP-MTR-17xxx(D) NEMA 17 Step Motors

Note: “W” series motors have 5% less running torque than other models.

STP-MTR-17040x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

70V Power Supply

300 600 900

48V Power Supply

Speed (rpm)

32V Power Supply

1200 1500 1800 2100 2400 2700

2000 4000 6000 8000 10000 12000 14000 16000 18000

Speed (pps) [1 pulse = 0.9 degree]

STP-MTR-17048x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

70V Power Supply

300 600 900

48V Power Supply

Speed (rpm)

32V Power Supply

1200 1500 1800 2100 2400 2700

90

0

80

70

60

50

40

30

20

10

0

0 2000 4000 6000 8000 10000 12000 14000 16000 18000

Speed (pps) [1 pulse = 0.9 degree]

7–22 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

90

0

80

70

60

50

40

30

20

10

0

0

Torque vs. Speed Charts (continued)

Note: “W” series motors have 5% less running torque than other models.

STP-MTR-17xxx(D) NEMA 17 Step Motors (continued)

STP-MTR-17060x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

70V Power Supply

300 600 900

48V Power Supply

Speed (rpm)

1200 1500

32V Power Supply

1800 2100 2400 2700

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-23055x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

32V Power Supply

200

0

70V Power Supply

450 900

48V Power Supply

Speed (rpm)

1350 1800 2250

150

100

50

0

0 2000 4000 6000 8000 10000 12000 14000

Speed (pps) [1 pulse = 0.9°]

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–23

Chapter 7: Sure Step TM Stepping Motors

Torque vs. Speed Charts (continued)

Note: “W” series motors have 5% less running torque than other models.

STP-MTR(H)-23xxx(D) NEMA 23 Step Motors (continued)

STP-MTR-23079x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

200

0

70V Power Supply

450 900

48V Power Supply

Speed (rpm)

1350

32V Power Supply

1800 2250

150

100

50

0

0 2000 4000 6000 8000 10000 12000 14000

Speed (pps) [1 pulse = 0.9°]

STP-MTR H -23079x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

32V Power Supply

200

0

70V Power Supply

450 900

48V Power Supply

Speed (rpm)

1350 1800 2250

150

100

50

0

0 2000 4000 6000 8000 10000

Speed (pps) [1 pulse = 0.9°]

12000 14000

7–24 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

800

600

400

200

0

0

Torque vs. Speed Charts (continued)

Note: “W” series motors have 5% less running torque than other models.

STP-MTR(H)-34xxx(D) NEMA 34 Step Motors

STP-MTR-34066x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

32V Power Supply

1000

0

70V Power Supply

450 900

48V Power Supply

Speed (rpm)

1350 1800 2250

800

600

400

200

0

0 2000 4000 6000 8000 10000

Speed (pps) [1 pulse = 0.9°]

12000 14000

STP-MTR H -34066x Torque vs Speed (1.8° motor; 1/2 stepping, RMS phase current)

70V Power Supply 32V Power Supply

450 900

48V Power Supply

Speed (rpm)

1350 1800 2250

1000

0

2000 4000 6000 8000 10000 12000 14000

Speed (pps) [1 pulse = 0.9°]

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–25

Chapter 7: Sure Step TM Stepping Motors

Torque vs. Speed Charts (continued)

Note: “W” series motors have 5% less running torque than other models.

STP-MTR(H)-34xxx(D) NEMA 34 Step Motors (continued)

STP-MTR H -34097x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

70V Power Supply 32V Power Supply

1000

0 450 900

48V Power Supply

Speed (rpm)

1350 1800 2250

800

600

400

200

0

0 2000 4000 6000 8000 10000

Speed (pps) [1 pulse = 0.9°]

12000 14000

STP-MTR H -34127x Torque vs Speed (1.8° step motor; 1/2 stepping, RMS phase current)

70V Power Supply

450 900

48V Power Supply

Speed (rpm)

1350

32V Power Supply

1800 2250

1000

0

800

600

400

200

0

0 2000 4000 6000 8000 10000

Speed (pps) [1 pulse = 0.9°]

12000 14000

7–26 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 7: Sure Step TM Stepping Motors

Torque vs. Speed Charts (continued)

STP-MTRAC-23xxxx Torque vs Speed @ 340VDC bus

(1.8° step motor; 1/2 stepping)

250

200

150

100

50

0

0 10

STP-MTRAC-23044

20 30

(rps)

40

STP-MTRAC-23055

50 60

STP-MTRAC-23078

70

STP-MTRAC-34xxxx Torque vs Speed @ 340VDC bus

(1.8° step motor; 1/2 stepping)

1600

1400

1200

1000

800

600

400

200

0

0 10

STP-MTRAC-34075

20 30 40

Revoluons per second (rps)

STP-MTRAC-34115

50 60

STP-MTRAC-34156

70

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–27

1600

0

1400

1200

1000

800

600

400

200

0

0

Chapter 7: Sure Step TM Stepping Motors

1600

0

Torque vs. Speed Charts (continued)

STP-MTRAC-42100x 24/48 VDC

S 4.2 A, 24vDC S 4.2 A, 48vDC

250 500 750

P 8.4 A, 24vDC

Speed (RPM)

1000 1250 1500

For NEMA 42 charts:

“S” = Bipolar Series

“P” = Bipolar Parallel

P 8.4 A, 48vDC

1750 2000

1400

1200

1000

800

600

400

200

0

0 1667 3333 5000 6667 8333

Speed (pps) [1 pulse = 0.9 degree]

10000 11667 13333

500

S 4.2 A, 72vDC

1000

STP-MTRAC-42100x 72/160VDC

P 8.4 A, 72vDC S 4.2 A, 160vDC

Speed (RPM)

1500 2000 2500

P 8.4 A, 160vDC

3000 3500

3333 6667 10000 13333

Speed (pps) [1 pulse = 0.9 degree]

16667 20000 23333

7–28 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

2500

2000

1500

1000

500

0

0

3000

0

Chapter 7: Sure Step TM Stepping Motors

Torque vs. Speed Charts (continued)

S 6.0 A, 24vDC

STP-MTRAC-42151x 24/48 VDC

P 12.0 A, 24vDC S 6.0 A, 48vDC

For NEMA 42 charts:

“S” = Bipolar Series

“P” = Bipolar Parallel

P 12.0 A, 48vDC

250 500 750 1000 1250 1500 1750 2000

1667 3333 5000 6667 8333 10000 11667 13333

500

S 6.0 A, 72vDC

1000

STP-MTRAC-42151x 72/160VDC

P 12.0 A, 72vDC S 6.0 A, 160vDC

Speed (RPM)

1500 2000 2500

P 12.0 A, 160vDC

3000 3500

3000

0

2500

2000

1500

1000

500

0

0 3333

7th Ed. Rev D –03/17/2022

6667 10000 13333

Speed (pps) [1 pulse = 0.9 degree]

16667 20000

Sure Step TM Stepping Systems User Manual

23333

7–29

4000

0

3500

3000

2500

2000

1500

1000

500

0

0

Chapter 7: Sure Step TM Stepping Motors

3500

3000

2500

2000

1500

1000

500

0

0

4000

0

Torque vs. Speed Charts (continued)

STP-MTRAC-42202x 24/48 VDC

S 6.0 A, 24vDC P 12.0 A, 24vDC S 6.0 A, 48vDC

250 500 750

Speed (RPM)

1000 1250

1667 3333 5000 6667 8333

Speed (pps) [1 pulse = 0.9 degree]

1500

10000

For NEMA 42 charts:

“S” = Bipolar Series

“P” = Bipolar Parallel

P 12.0 A, 48vDC

1750

11667

2000

13333

500

S 6.0 A, 72vDC

1000

STP-MTRAC-42202x 72/160VDC

P 12.0 A, 72vDC S 6.0 A, 160vDC

Speed (RPM)

1500 2000 2500

P 12.0 A, 160vDC

3000 3500

3333 6667 10000 13333

Speed (pps) [1 pulse = 0.9 degree]

16667 20000 23333

7–30 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

1600

0

1400

1200

1000

800

600

400

200

0

0

1400

1200

1000

800

600

400

200

0

0

1600

0

Chapter 7: Sure Step TM Stepping Motors

Torque vs. Speed Charts (continued)

STP-MTRACH-42100x 24/48 VDC

S 6.0 A, 24vDC P 12.0 A, 24vDC S 6.0 A, 48vDC

250 500 750

Speed (RPM)

1000 1250 1500

For NEMA 42 charts:

“S” = Bipolar Series

“P” = Bipolar Parallel

P 12.0 A, 48vDC

1750 2000

1667 3333 5000 6667 8333

Speed (pps) [1 pulse = 0.9 degree]

10000 11667 13333

S 6.0 A, 72vDC

500 1000

STP-MTRACH-42100x 72/160VDC

P 12.0 A, 72vDC S 6.0 A, 160vDC

Speed (RPM)

1500 2000 2500

P 12.0 A, 160vDC

3000 3500

3333 6667 10000 13333

Speed (pps) [1 pulse = 0.9 degree]

16667 20000 23333

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–31

2000

1500

1000

500

0

0

Chapter 7: Sure Step TM Stepping Motors

3000

0

Torque vs. Speed Charts (continued)

STP-MTRACH-42151x 24/48 VDC

S 8.0 A, 24vDC P 16.0 A , 24vDC S 8.0 A, 48vDC

250 500 750 1000 1250

For NEMA 42 charts:

“S” = Bipolar Series

“P” = Bipolar Parallel

P 16.0 A , 48vDC

1500 1750 2000

2500

1667 3333 5000 6667 8333 10000 11667 13333

500

S 8.0 A, 72vDC

1000

STP-MTRACH-42151x 72/160VDC

P 16.0 A , 72vDC S 8.0 A, 160vDC

Speed (RPM)

1500 2000 2500

P 16.0 A , 160vDC

3000 3500

3000

0

2500

2000

1500

1000

500

0

0 3333 6667 10000 13333

Speed (pps) [1 pulse = 0.9 degree]

16667

7–32 Sure Step TM Stepping Systems User Manual

20000 23333

7th Ed. Rev D –03/17/2022

4000

0

3500

3000

2500

2000

1500

1000

500

0

0

3500

3000

2500

2000

1500

1000

500

0

0

4000

0

Chapter 7: Sure Step TM Stepping Motors

Torque vs. Speed Charts (continued)

STP-MTRACH-42202x 24/48 VDC

250

S 8.0 A, 24vDC

500

P 16.0 A, 24vDC

750

Speed (RPM)

1000

S 8.0 A, 48vDC

1250

For NEMA 42 charts:

“S” = Bipolar Series

“P” = Bipolar Parallel

P 16.0 A, 48vDC

1500 1750 2000

1667 3333 5000 6667 8333

Speed (pps) [1 pulse = 0.9 degree]

10000 11667 13333

500

S 8.0 A, 72vDC

1000

STP-MTRACH-42202x 72/160VDC

P 16.0 A, 72vDC S 8.0 A, 160vDC

Speed (RPM)

1500 2000 2500

P 16.0 A, 160vDC

3000 3500

3333 6667 10000 13333

Speed (pps) [1 pulse = 0.9 degree]

16667 20000 23333

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 7–33

Chapter 7: Sure Step TM Stepping Motors

BLANK

PAGE

7–34 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

S ure

S

tep

tM

L

inear

a

ctuatorS

C hapter

8

In This Chapter...

Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �8–2

Design and Installation Tips � � � � � � � � � � � � � � � � � � � � � � � � �8–3

Model Number Explanation � � � � � � � � � � � � � � � � � � � � � � � � �8–3

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �8–4

Power Supply and Step Motor Drive� � � � � � � � � � � � � � � � � � �8–8

Mounting the Motor � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �8–8

Journal Mounting � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �8–8

Connecting the Motor � � � � � � � � � � � � � � � � � � � � � � � � � � � �8–10

Extension Cable Wiring Diagrams � � � � � � � � � � � � � � � � � � � � � � �8–10

Motor Dimensions and Cabling � � � � � � � � � � � � � � � � � � � � �8–12

Thrust vs� Speed Charts � � � � � � � � � � � � � � � � � � � � � � � � � � �8–16

Chapter 8: Sure Step TM Linear Actuators

Features

• Stepper Linear Actuators available in NEMA 17 and NEMA 23 motor frame sizes.

• Square frame style produces high torque and achieves best torque to volume ratio.

• Linear forces up to 193lbs

• Linear speeds up to 19 in/sec

• Available in single-shaft and dual-shaft configurations.

• Lead Screws are cold-finished stainless steel (SUS303Cu).

• Nuts are PTFE-infused polymer (TECFORM AD AF) and require no lubrication.

• Dual shaft models are encoder ready (pretapped holes ready for modular encoder mounting).

• Dual shaft models have machined journals and grooves for bearing and retaining ring mounting.

• Three lead screw lengths of 6, 9, and 12 inches

• Nine different lead pitches from 1.25 mm/rev to 1 inch/rev

• Optional 6, 10, or 20 foot extension cable with locking connector available.

• Replacement triangular nuts and round nuts available.

NEMA 17

NEMA 23

8–2 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 8: Sure Step TM Linear Actuators

Design and Installation Tips

Allow sufficient time to accelerate the load and size the step motor with a

100% torque safety factor (i.e.: design the system using a maximum of 50% of the motor’s torque). DO NOT disassemble lead screw step motors, as 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). There can be slight backlash when mounting in a horizontal application. Most vertical applications will not be subjected to any noticeable backlash. In horizontal applications do not apply any appreciable overhung load to the screw. If the load causes more than 0.0025” of deflection per inch of lead screw, support the end of the screw with a sleeve, bushing or bearing. In vertical applications securing the end of the screw may not be needed. Mount it to a surface with good thermal conductivity, such as steel or aluminum, to allow heat dissipation.

In general, the higher the current into a step motor the higher the torque, especially at lower speeds. The higher the voltage to the step motor, the higher the torque at higher speeds. Losses come in to play here, too. The higher you run the current on the motors, the higher your losses are going to be, and the hotter your motors are going to get. For this reason, Automation Direct specs current for motors at the RMS value. This is the value on the motor’s label and specification table. This guarantees a very long life for the motor. Multiplying the motor’s RMS phase current by 1.2 gives a good balance of rotary torque (linear thrust of the actuator) vs loss. This value should then be used to set the drive’s peak phase current. Note that the whole speed thrust curve won’t be shifted up, only the low speed flat part before the torque starts dropping. The curve can drop for many reasons, but typically it’s due to not having enough voltage to push the desired current into the windings, so increasing the voltage is what gives you a boost there, not making more current available.

Model Number Explanation

STP- L E x x - x x xx xxx

Screw Configuration

ANN: Triangular nut, no encoder, no machining

ADJ: Triangular nut, dual shaft, encoder ready,

journal w/groove

Screw Length

06: 6 inches

09: 9 inches

12: 12 inches

Screw Code

A, B, C, D, E, F, G, H, or K.

Motor Stacks

1: Single stack

2: Double stack

3: Triple stack

Component Type

LE17: NEMA 17 linear actuator

LE23: NEMA 23 linear actuator

Sure Step Series Designation: STP

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 8–3

Chapter 8: Sure Step TM Linear Actuators

STP-LE17-2A06ANN

STP-LE17-2A09ANN

STP-LE17-2A12ANN

STP-LE17-2A06ADJ

STP-LE17-2A09ADJ

STP-LE17-2A12ADJ

STP-LE17-3A06ANN

STP-LE17-3A09ANN

STP-LE17-3A12ANN

STP-LE17-3A06ADJ

STP-LE17-3A09ADJ

STP-LE17-3A12ADJ

STP-LE17-3B06ANN

STP-LE17-3B09ANN

STP-LE17-3B12ANN

STP-LE17-3B06ADJ

STP-LE17-3B09ADJ

STP-LE17-3B12ADJ

STP-LE17-2C06ANN

STP-LE17-2C09ANN

STP-LE17-2C12ANN

STP-LE17-2C06ADJ

STP-LE17-2C09ADJ

STP-LE17-2C12ADJ

STP-LE17-2D06ANN

STP-LE17-2D09ANN

STP-LE17-2D12ANN

STP-LE17-2D06ADJ

STP-LE17-2D09ADJ

STP-LE17-2D12ADJ

Specifications

The tables below reference the specifications for all the SureStep Linear Actuators sold by AutomationDirect. Click the location link to go directly to the spec table.

Model Number

Lead

(per rev)

0.25”

0.25”

0.5”

3mm

1.25 mm

Nominal Thrust

(@150RPM)

45lbs

69lbs

38lbs

73lbs

87lbs

Motor Weight

(lbs)

1.1

1.3

0.9

1.1

1.3

0.9

1.1

1.3

0.9

0.7

0.8

0.9

0.7

0.8

0.9

0.9

1.1

1.3

0.7

0.8

0.9

0.7

0.8

1.0

0.8

0.9

1.0

0.9

0.8

0.9

Specifications

Location

Table 1, STP-LE17-2Axxyyy

Table 1, STP-LE17-3Axxyyy

Table 1, STP-LE17-3Bxxyyy

Table 1, STP-LE17-2Cxxyyy

Table 1, STP-LE17-2Dxxyyy

8–4 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 8: Sure Step TM Linear Actuators

Model Number

STP-LE23-1H09ANN

STP-LE23-1H12ANN

STP-LE23-1H06ADJ

STP-LE23-1H09ADJ

STP-LE23-1H12ADJ

STP-LE23-3H06ANN

STP-LE23-3H09ANN

STP-LE23-3H12ANN

STP-LE23-3H06ADJ

STP-LE23-3H09ADJ

STP-LE23-3H12ADJ

STP-LE23-3K06ANN

STP-LE23-3K09ANN

STP-LE23-3K12ANN

STP-LE23-3K06ADJ

STP-LE23-3K09ADJ

STP-LE23-3K12ADJ

STP-LE17-3E06ANN

STP-LE17-3E09ANN

STP-LE17-3E12ANN

STP-LE17-3E06ADJ

STP-LE17-3E09ADJ

STP-LE17-3E12ADJ

STP-LE23-1F06ANN

STP-LE23-1F09ANN

STP-LE23-1F12ANN

STP-LE23-1F06ADJ

STP-LE23-1F09ADJ

STP-LE23-1F12ADJ

STP-LE23-1G06ANN

STP-LE23-1G09ANN

STP-LE23-1G12ANN

STP-LE23-1G06ADJ

STP-LE23-1G09ADJ

STP-LE23-1G12ADJ

STP-LE23-1H06ANN

Lead

(per rev)

Nominal Thrust

(@150RPM)

8mm

10.5 mm

2mm

6mm

6mm

1”

55lbs

63lbs

137lbs

87lbs

193lbs

62lbs

Motor Weight

(lbs)

1.0

1.7

2.0

2.7

3.0

3.3

2.7

1.7

2.0

1.4

1.4

1.7

2.0

1.4

1.7

2.0

1.4

1.2

1.4

1.0

1.2

1.4

1.4

1.6

1.8

1.4

1.6

1.8

3.0

3.3

2.7

3.0

3.3

2.7

3.0

3.3

Specifications

Location

Table 1, STP-LE17-3Exxyyy

Table 2, STP-LE23-1Fxxyyy

Table 2. STP-LE23-1Gxxyyy

Table 2, STP-LE23-1Hxxyyy

Table 2, STP-LE23-3Hxxyyy

Table 2, STP-LE23-3KxxAyy

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 8–5

Chapter 8: Sure Step TM Linear Actuators

Table 1: NEMA 17 Linear Actuator Specifications

Sure

Step™ Series Specifications – Linear Actuator Stepping Motors

Linear Actuator

Motors

NEMA

Phases

Rated Current

Phase Resistance

STP-LE17-

2Axxyyy

STP-LE17-

2Cxxyyy

STP-LE17-

2Dxxyyy

17

2

2A

STP-LE17-

3Axxyyy

8mm

B (130 ° C)

0.25”

STP-LE17-

3Bxxyyy

STP-LE17-

3Exxyyy

Phase Inductance

Radial Deflection

(Max) 3

1.04 Ω ± 10% (@20 ° C)

2.5 mH ± 20%

(1kHz 1V rms)

57 g · cm 2

1.25 Ω ± 15% (@20 ° C)

2.8 mH ± 20%

(1kHz 1V rms)

82 g · cm 2 Rotor Inertia

Rotational Shaft

Holding Torque

No. of Motor

Stacks

Motor Length

Screw Material

Nut Material

Lead

Linear Travel/Step

(1.8

° )

Linear Speed 1

(@150rpm)

Thrust

(@150rpm)

Load Limit (lbs) 2

0.46 N · m (65.14 oz-in)

0.25”/rev

0.00125 in/step

2

0.63 N · m (89.21 oz-in)

3

39.8 mm 48.3 mm

SUS303Cu (cold-finished stainless steel)

TECAFORM AD AF (PTFE-infused polymer)

3mm/rev

0.015 mm/ step

0.6250 in/sec 7.5 mm/sec

45lbs

75

73lbs

75

1.25 mm/ rev

0.00625 mm/step

3.125 mm/sec

87lbs

0.25”/rev

0.00125 in/step

0.625 in/sec

69lbs

0.5”/rev

0.0025 in/ step

1.25 in/sec

38lbs

75

8mm/rev

0.04 mm/step

20 mm/sec

55lbs

80 80 75

6” lead screw: 0.015”

9” lead screw: 0.0225”

12” lead screw: 0.03”

Ambient

Operating

Temperature

Insulation Class

Screw Diameter 0.25” 6.5 mm

-20-50 ° C

0.25” 8mm

Agency Approvals CE

1 To determine your linear speed as it relates to RPM use the following formula:

Linear Speed = RPM x (Lead/60 sec)

2 The load limit indicates max load before the nut lifespan is negatively impacted, not what the linear actuator can move.

3 Calculated deflection is the deflection value measured at the end of the lead screw.

Note: For dual-shaft motors (STP-LExx-xxxxADJ series) 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.

8–6 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 8: Sure Step TM Linear Actuators

Table 2: NEMA 23 Linear Actuator Specifications

Sure

Step™ Series Specifications – Connectorized Bipolar Stepping Motors

Linear Actuator

Motors

STP-LE23-

1Fxxyyy

STP-LE23-

1Hxxyyy

STP-LE23-

1Gxxyyy

STP-LE23-

3Kxxyyy

STP-LE23-

3Hxxyyy

NEMA

Phases

Rated Current

Phase Resistance

Phase Inductance

2.1 A

1.6 Ω ± 10% (@20 ° C)

3.9 mH ± 20%

(1kHz 1V rms)

180 g · cm 2

23

2

3A

1.1 Ω ± 10% (@20 ° C)

5.0 mH ± 20%

(1kHz 1V rms)

460 g · cm 2 Rotor Inertia

Rotational Shaft

Holding Torque

No. of Motor

Stacks

Motor Length

Screw Material

Nut Material

0.9 N · m (127.45 oz-in)

1

45mm

2.3 N · m (325.70 oz-in)

SUS303Cu (cold-finished stainless steel)

TECAFORM AD AF (PTFE-infused polymer)

Lead

Linear Travel/Step

(1.8

° )

Linear Speed 1

(@150rpm) 2

Thrust

(@150rpm) 2

Load Limit (lbs) 3

10.5 mm/rev

0.0525 mm/step 0.03 mm/step

26.25 mm/sec

63lbs

100

6mm/rev

15 mm/sec

87lbs

175

Radial Deflection

(Max) 4

2mm/rev

0.01 mm/step

5 mm/sec

137lbs

175

6” lead screw: 0.015”

9” lead screw: 0.0225”

12” lead screw: 0.03”

1”/rev

0.005 in/step

2.5 in/sec

62lbs

175

Ambient

Operating

Temperature

Insulation Class

-20-50 ° C

B (130 ° C)

3

79mm

6mm/rev

0.03 mm/step

15 mm/sec

193lbs

175

Screw Diameter 10mm 12mm 12mm

Agency Approvals CE

1 To determine your linear speed as it relates to RPM use the following formula:

Linear Speed = RPM x (Lead/60 sec)

0.5” 12mm

2 For STP-LE23-3KxxAyy and STP-LE23-3HxxAyy series motors, nominal speed and thrust values are provided for operation at 120rpm rather than 150rpm.

3 The load limit indicates max load before the nut lifespan is negatively impacted, not what the linear actuator can move.

4 Calculated deflection is the deflection value measured at the end of the lead screw.

Note: For dual-shaft motors (STP-LExx-xxxxADJ series) 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.

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 8–7

Chapter 8: Sure Step TM Linear Actuators

Power Supply and Step Motor Drive

An STP-PWR-xxxx linear power supply from AutomationDirect is the best choice to power AutomationDirect and other DC-input stepper drives. These power supplies were designed to work with the AutomationDirect SureStep™ STP-

DRV-xxxx series bipolar DC microstepping motor drives. PSBxx switching power supplies are also available from AutomationDirect.

Always check the motor specs and speed-torque curves to determine allowable drive input voltage. To minimize heat loss in the motor, always choose the lowest input voltage that satisfies the application’s speed-torque requirements.

Mounting the Motor

We recommend mounting the motor to a metallic surface to help dissipate heat generated by the motor.

Journal Mounting

Below is a list of mounting components that are compatible with the NEMA17 and NEMA23 journal machined end (ADJ) motors. These are not sold by

Automaton Direct but McMasterCarr part numbers have been given as an example. This list is not a suggested solution for your application as it may not be suitable. These are for securing the end of the lead screw so it does not move in the radial plane and to provide radial support of the lead screw and load.

The bearings in the motor are designed to handle the axial loads not the bearing securing the journal end. The axial load forces should not exceed the force determined by the Speed Force curve for each model.

NOTE: Some of the smaller NEMA 17 lead screws have journals and rear shafts with threads still visible in the machined area. This occurs on screw codes A, B, and C. This is done to maintain minimum shaft diameter. Bearings, bushings, and motor-mounted encoders will still work correctly on the grooved journals. The journal ends do still have a groove for a retaining clip, but may be hard to see.

Journal end with visible threads Standard journal end

8–8 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 8: Sure Step TM Linear Actuators

NEMA Rating

17

23

Part Number

98541A113

6153K69

92161A025

98089A331

90967A120

6661K820

90134A030

98089A136

STP-LE17-xxxxADJ Journal Mounting

98541A113

EXTERNAL

RETAINING

RING

92161A025

WAVE WASHER

6153K690

BEARING

92161A025

WAVE WASHER

98089A331

ROUND

SHIM

NEMA 17

SHAFT JOURNAL

Description

Retainer for 5mm shaft

5mm ID bearing

5mm ID wave washer

5mm ID x 0.5 mm thick shim

Retainer for 8mm shaft

8mm ID bearing

5/16” ID wave washer

8mm ID x 0.5 mm thick shim

ASSEMBLED

Quantity

1

1

1

2

1

1

1

1

STP-LE23-xxxxADJ Journal Mounting

90967A120

EXTERNAL

RETAINING

RING

6661K820

BEARING

98089A136

ROUND

SHIM

90134A030

WAVE WASHER

NEMA 23

SHAFT JOURNAL ASSEMBLED

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 8–9

Chapter 8: Sure Step TM Linear Actuators

Connecting the Motor

W arning

: 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 STP-MTR series motors have connectorized cables which connect directly to available SureStep extension cables. STP-LA-EXT17-x cables fit the NEMA17 lead screw motors and the STP-LA-EXT23-x cables fit the NEMA

23 lead screw motors.

Extension Cable Wiring Diagrams

ECN

46416

REV

A0

DATE

7/1/19

REVISION HISTORY

DESCRIPTION

ORIGINAL

STP-LA-EXT17-0xx Dimensions (mm [in])

L (IN)  13

[ L (mm)  0.5

]

INIT.

BJR

CONNECTOR

JST #

PHR-6

PIN

JST #

SPH-002T-P0.5

PIN 1

VIEW FROM

WIRE ENTRANCE

PIN #

1

2

3

4

5

6

PINOUT CHART

COLOR

RED

N/A

YELLOW

GREEN

N/A

BLACK

WIRE

A+

A-

B+

B-

AUTOMATION DIRECT

STP-LA-EXT17-XXX

CABLE

ALHPAWIRE # 1604

(24AWG/4C)

OR EQUIVALENT

CABLE PART #

STP-LA-EXT17-006

STP-LA-EXT17-010

STP-LA-EXT17-020

CABLES

LENGTH L (IN)

72

120

240

LENGTH L (mm)

1828

3048

6096

8–10 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 8: Sure Step TM Linear Actuators

ECN

46416

REV

A0

DATE

7/1/19

REVISION HISTORY

DESCRIPTION

ORIGINAL

STP-LA-EXT23-0xx Dimensions (mm [in])

INIT.

BJR

[

L (IN)

L (mm)

 13

 0.5

]

CONNECTOR

JST #

XHP-6

PIN

JST #

SXH-001T-P0.6

PIN 1

PIN #

1

2

3

4

5

6

PINOUT CHART

COLOR

RED

N/A

WHITE

GREEN

N/A

BLACK

WIRE

A+

A-

B+

B-

VIEW FROM

WIRE ENTRANCE

AUTOMATION DIRECT

STP-LA-EXT23-XXX

CABLE

BELDEN # 8444

(22AWG/4C)

OR EQUIVALENT

CABLE PART #

STP-LA-EXT23-006

STP-LA-EXT23-010

STP-LA-EXT23-020

CABLES

LENGTH L (IN)

72

120

240

LENGTH L (mm)

1828

3048

6096

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 8–11

Chapter 8: Sure Step TM Linear Actuators

Motor Dimensions and Cabling

STP-LE17-xxANN

S1

Ø 19.1

0.75

BC

3X

Ø 3.5

0.14

Ø 22.0

0.87

31.0

1.22

42.2

1.66

Ø 25.4

1.00

2X M2.5

DEPTH

19.1

0.75

L1

L3

7.7

0.30

L2

2.0

0.08

8–12

Part #

STP-LE17-2A06ANN

STP-LE17-2A09ANN

STP-LE17-2A12ANN

STP-LE17-2C06ANN

STP-LE17-2C09ANN

STP-LE17-2C12ANN

STP-LE17-2D06ANN

STP-LE17-2D09ANN

STP-LE17-2D12ANN

STP-LE17-3A06ANN

STP-LE17-3A09ANN

STP-LE17-3A12ANN

STP-LE17-3B06ANN

STP-LE17-3B09ANN

STP-LE17-3B12ANN

STP-LE17-3E06ANN

STP-LE17-3E09ANN

STP-LE17-3E12ANN

STP-LE17-xxANN Dimensions (mm [in])

L1 L2 L3

152.4 [6.00] 39.3 [1.55] 191.7 [7.55]

228.6 [9.00]

304.8 [12.00]

152.4 [6.00]

228.6 [9.00]

304.8 [12.00]

152.4 [6.00]

228.6 [9.00]

304.8 [12.00]

152.4 [6.00]

228.6 [9.00]

304.8 [12.00]

152.4 [6.00]

228.6 [9.00]

304.8 [12.00]

152.4 [6.00]

228.6 [9.00]

304.8 [12.00]

47.8 [1.88]

47.8 [1.88]

47.8 [1.88]

47.8 [1.88]

47.8 [1.88]

47.8 [1.88]

47.8 [1.88]

47.8 [1.88]

47.8 [1.88]

39.3 [1.55]

39.3 [1.55]

39.3 [1.55]

39.3 [1.55]

39.3 [1.55]

39.3 [1.55]

39.3 [1.55]

39.3 [1.55]

267.9 [10.55]

344.1 [13.55]

191.7 [7.55]

267.9 [10.55]

344.1 [13.55]

191.7 [7.55]

267.9 [10.55]

344.1 [13.55]

200.2 [7.88]

276.4 [10.88]

352.6 [13.88]

200.2 [7.88]

276.4 [10.88]

352.6 [13.88]

200.2 [7.88]

276.4 [10.88]

352.6 [13.88]

S1

6.4 [0.25] 0.25” Lead

6.4 [0.25] 0.25” Lead

6.4 [0.25] 0.25” Lead

6.5 [0.47] 3.0 mm Lead

6.5 [0.47] 3.0 mm Lead

6.5 [0.47] 3.0 mm Lead

8.0 [0.31] 1.25 mm Lead

8.0 [0.31] 1.25 mm Lead

8.0 [0.31] 1.25 mm Lead

6.4 [0.25] 0.25” Lead

6.4 [0.25] 0.25” Lead

6.4 [0.25] 0.25” Lead

6.4 [0.25] 0.5” Lead

6.4 [0.25] 0.5” Lead

6.4 [0.25] 0.5” Lead

8.0 [0.31] 8.0 mm Lead

8.0 [0.31] 8.0 mm Lead

8.0 [0.31] 8.0 mm Lead

Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 8: Sure Step TM Linear Actuators

STP-LE17-xxADJ

S1

Ø 19.1

0.75

BC

3X

Ø 3.5

0.14

9.7

0.38

L1

L3

L2

7.7

0.30

11.9

0.47

Ø 22.0

0.87

4X M3

4.5mm DEPTH

Ø 25.4

1.00

Ø 4.9

0.19

31.0

1.22

42.2

1.66

0.7

0.03

6.3

0.25

2.0

0.08

2X M2.5

2.5mm

DEPTH

19.1

0.75

REAR SHAFT

Ø4.8

[Ø0.19]

Part # L1

STP-LE17-xxADJ Dimensions (mm [in])

L2 L3 NA NB S1

STP-LE17-2A06ADJ

STP-LE17-2A09ADJ

152.4 [6.00] 39.3 [1.55] 203.6 [8.02] 19.0 [0.75] 10.0 [0.39]

228.6 [9.00] 39.3 [1.55] 279.8 [11.02] 19.0 [0.75] 10.0 [0.39]

STP-LE17-2A12ADJ 304.8 [12.00] 39.3 [1.55] 356.0 [14.02] 19.0 [0.75] 10.0 [0.39]

STP-LE17-2C06ADJ 152.4 [6.00] 39.3 [1.55] 203.6 [8.02] 19.0 [0.75] 10.0 [0.39]

6.4 [0.25] 0.25” Lead

6.4 [0.25] 0.25” Lead

6.4 [0.25] 0.25” Lead

6.5 [0.47] 3.0 mm Lead

STP-LE17-2C09ADJ 228.6 [9.00] 39.3 [1.55] 279.8 [11.02] 19.0 [0.75] 10.0 [0.39]

STP-LE17-2C12ADJ 304.8 [12.00] 39.3 [1.55] 356.0 [14.02] 19.0 [0.75] 10.0 [0.39]

6.5 [0.47] 3.0 mm Lead

6.5 [0.47] 3.0 mm Lead

STP-LE17-2D06ADJ 152.4 [6.00] 39.3 [1.55] 203.6 [8.02] 19.0 [0.75] 12.7 [0.50] 8.0 [0.31] 1.25 mm Lead

STP-LE17-2D09ADJ 228.6 [9.00] 39.3 [1.55] 279.8 [11.02] 19.0 [0.75] 12.7 [0.50] 8.0 [0.31] 1.25 mm Lead

STP-LE17-2D12ADJ 304.8 [12.00] 39.3 [1.55] 356.0 [14.02] 19.0 [0.75] 12.7 [0.50] 8.0 [0.31] 1.25 mm Lead

STP-LE17-3A06ADJ 152.4 [6.00] 47.8 [1.88] 212.1 [8.35] 19.0 [0.75] 10.0 [0.39] 6.4 [0.25] 0.25” Lead

STP-LE17-3A09ADJ 228.6 [9.00] 47.8 [1.88] 288.3 [11.35] 19.0 [0.75] 10.0 [0.39]

STP-LE17-3A12ADJ 304.8 [12.00] 47.8 [1.88] 364.5 [15.35] 19.0 [0.75] 10.0 [0.39]

6.4 [0.25] 0.25” Lead

6.4 [0.25] 0.25” Lead

STP-LE17-3B06ADJ

STP-LE17-3B09ADJ

152.4 [6.00] 47.8 [1.88] 212.1 [8.35] 19.0 [0.75] 10.0 [0.39]

228.6 [9.00] 47.8 [1.88] 288.3 [11.35] 19.0 [0.75] 10.0 [0.39]

STP-LE17-3B12ADJ 304.8 [12.00] 47.8 [1.88] 364.5 [15.35] 19.0 [0.75] 10.0 [0.39]

STP-LE17-3E06ADJ 152.4 [6.00] 47.8 [1.88] 212.1 [8.35] 19.0 [0.75] 12.7 [0.50]

STP-LE17-3E09ADJ 228.6 [9.00] 47.8 [1.88] 288.3 [11.35] 19.0 [0.75] 12.7 [0.50]

STP-LE17-3E12ADJ 304.8 [12.00] 47.8 [1.88] 364.5 [15.35] 19.0 [0.75] 12.7 [0.50]

6.4 [0.25] 0.5” Lead

6.4 [0.25] 0.5” Lead

6.4 [0.25] 0.5” Lead

8.0 [0.31] 8.0 mm Lead

8.0 [0.31] 8.0 mm Lead

8.0 [0.31] 8.0 mm Lead

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 8–13

Chapter 8: Sure Step TM Linear Actuators

S1

STP-LE23-xxANN

D1

D2

D3

Ø 38.1

1.50

4X

Ø 5.1

0.20

47.1

1.86

o 56.2

[2.21] 2X M2.5

2.5mm

DEPTH

19.1

0.75

L1

L3

4.8

0.19

L2

1.6

0.06

Part #

STP-LE23-1F06ANN

STP-LE23-1F09ANN

STP-LE23-1F12ANN

STP-LE23-1G06ANN

STP-LE23-1G09ANN

STP-LE23-1G12ANN

STP-LE23-1H06ANN

STP-LE23-1H09ANN

STP-LE23-1H12ANN

STP-LE23-3H06ANN

STP-LE23-3H09ANN

STP-LE23-3H12ANN

STP-LE23-3K06ANN

STP-LE23-3K09ANN

STP-LE23-3K12ANN

STP-LE23-xxANN Dimensions (mm [in])

L1

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

L2

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

78.5

[3.09]

78.5

[3.09]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

78.5

[3.09]

78.5

[3.09]

78.5

[3.09]

78.5

[3.09]

L3

196.9

[7.75]

273.1

[10.75]

349.3

[13.75]

196.9

[7.75]

273.1

[10.75]

349.3

[13.75]

196.9

[7.75]

273.1

[10.75]

349.3

[13.75]

230.9

[9.09]

307.1

[12.09]

383.3

[15.09]

230.9

[9.09]

307.1

[12.09]

383.3

[15.09]

D1

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 22.2

[0.87] BC

Ø 22.2

[0.87] BC

Ø 22.2

[0.87] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

D2

3x Ø3.56

[0.14]

3x Ø3.56

[0.14]

3x Ø3.56

[0.14]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

D3

Ø29.5

[1.16]

Ø29.5

[1.16]

Ø29.5

[1.16]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

S1

10.0 [0.39]

10.5 mm Lead

10.0 [0.39]

10.5 mm Lead

10.0 [0.39]

10.5 mm Lead

12.0 [0.47]

2.0 mm Lead

12.0 [0.47]

2.0 mm Lead

12.0 [0.47]

2.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.5 [0.50]

1in Lead

12.5 [0.50]

1in Lead

12.5 [0.50]

1in Lead

8–14 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 8: Sure Step TM Linear Actuators

S1

STP-LE23-xxADJ

D1

D2

11.5

0.45

L1

L3

4.8

0.19

L2

Ø 38.1

1.50

Ø 5.1

0.20

D3

47.1

1.86

56.2

2.21

2X M2.5

DEPTH

REAR SHAFT

Ø6.4

[Ø0.25]

19.1

0.75

Ø 8.0

0.31

0.9

0.04

7.9

0.31

1.6

0.06

Part #

STP-LE23-1F06ADJ

STP-LE23-1F09ADJ

STP-LE23-1F12ADJ

STP-LE23-1G06ADJ

STP-LE23-1G09ADJ

STP-LE23-1G12ADJ

STP-LE23-1H06ADJ

STP-LE23-1H09ADJ

STP-LE23-1H12ADJ

STP-LE23-3H06ADJ

STP-LE23-3H09ADJ

STP-LE23-3H12ADJ

STP-LE23-3K06ADJ

STP-LE23-3K09ADJ

STP-LE23-3K12ADJ

L1

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

152.4

[6.00]

228.6

[9.00]

304.8

[12.00]

L2

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

44.5

[1.75]

78.5

[3.09]

78.5

[3.09]

78.5

[3.09]

78.5

[3.09]

78.5

[3.09]

78.5

[3.09]

L3

208.9

[8.22]

285.1

[11.22]

361.3

[14.22]

208.9

[8.22]

285.1

[11.22]

361.3

[14.22]

208.9

[8.22]

285.1

[11.22]

361.3

[14.22]

242.9

[9.06]

319.1

[12.56]

395.3

[15.56]

242.9

[9.06]

319.1

[12.56]

395.3

[15.56]

STP-LE23-xxADJ Dimensions (mm [in])

D1

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 22.2

[0.87] BC

Ø 22.2

[0.87] BC

Ø 22.2

[0.87] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

Ø 28.58

[1.13] BC

D2

3x Ø3.56

[0.14]

3x Ø3.56

[0.14]

3x Ø3.56

[0.14]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

3x Ø5.2

[0.20]

D3

Ø29.5

[1.16]

Ø29.5

[1.16]

Ø29.5

[1.16]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

Ø38.1

[1.50]

S1

10.0 [0.39]

10.5 mm Lead

10.0 [0.39]

10.5 mm Lead

10.0 [0.39]

10.5 mm Lead

12.0 [0.47]

2.0 mm Lead

12.0 [0.47]

2.0 mm Lead

12.0 [0.47]

2.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.0 [0.47]

6.0 mm Lead

12.5 [0.50]

1in Lead

12.5 [0.50]

1in Lead

12.5 [0.50]

1in Lead

12.0

0.47

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 8–15

Chapter 8: Sure Step TM Linear Actuators

Thrust vs. Speed Charts

The dashed horizontal lines indicate the maximum thrust allowed by the nut.

Note that some motors and leads can result in thrust above the nut’s limit. Ensure that the system does not apply too much force to the nut (example: limit the motor current, or monitor position feedback to determine a stall). Allow sufficient time to accelerate the load and size the step motor with a 100% thrust safety factor (i.e.: design the system using a maximum of 50% of the motor’s thrust).

50

40

70

60

100

90

80

30

20

10

Power Supply: 24V

Rated Current: 2.0 A/Phase

Ø1/4” x 1/4” (2Axxx)

Ø1/4” x 1/4” Nut Load Limit

Ø6.5 mm x 3mm (2Cxxx)

Ø6.5 mm x 3mm Nut Load Limit

Ø8mm x 1.25 mm (2Dxxx)

Ø8mm x 1.25 mm Nut Load Limit

2 4 6

Linear Speed (in/sec)

8 10 12

8–16 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 8: Sure Step TM Linear Actuators

40

30

60

50

100

90

80

70

20

10

Power Supply: 24V

Rated Current: 2.0 A/Phase

Ø8mm x 8mm (3Exxx)

Ø8mm x 8mm Nut Load Limit

Ø1/4” x 1/4” (3Axxx)

Ø1/4” x 1/4” Nut Load Limit

Ø1/4” x 1/2” (3Bxxx)

Ø1/4” x 1/2” Nut Load Limit

2 4 6 8 10

Linear Speed (in/sec)

12 14 16 18

150

100

250

200

50

Ø10mm x 10.5 mm (1Fxxx)

Ø10mm x 10.5 mm Nut Load Limit

Ø12mm x 6mm (1Hxxx)

Ø12mm x 6mm Nut Load Limit

Ø12mm x 2mm (1Gxxx)

Ø12mm x 2mm Nut Load Limit

Power Supply: 24V

Rated Current: 2.1 A/Phase

1 2 3 4

Linear Speed (in/sec)

5 6

7th Ed. Rev D –03/17/2022

Sure Step TM Stepping Systems User Manual 8–17

Chapter 8: Sure Step TM Linear Actuators

100

50

250

200

150

2 4

Linear Speed (in/sec)

6

Power Supply: 24V

Rated Current: 3.0 A/Phase

Ø1/2” x 1” (3Kxxx)

Ø1/2” x 1” Nut Load Limit

Ø12mm x 6mm (3Hxxx)

Ø12mm x 6mm Nut Load Limit

8 10

8–18 Sure Step TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

S

ure

S

tep

tM

S

ySteM

p

ower

S

upplieS

C hapter

9

In This Chapter...

Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �9–2

Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �9–3

Drive Heating � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �9–4

Choosing a Power Supply � � � � � � � � � � � � � � � � � � � � � � � � � � �9–5

Power Supply Terminal & Component Layout � � � � � � � � � � �9–7

Mounting the Power Supply � � � � � � � � � � � � � � � � � � � � � � � � �9–8

Dimensions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �9–9

Dimensions (continued) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �9–10

Chapter 9: SureStep TM System Power Supplies

Features

• Linear models available with 32V@4A, 48V@5A, 48V@10A, & 70V@5A DC unregulated step motor power

• 5VDC ±5% at 500 mA regulated logic power (electronic overload)

• Screw terminal AC input and DC output connectors

• 120 or 240 VAC, 50/60 Hz power input, switch selectable

• Power ON LEDs

• Integrated input and output fusing

• Matched to SureStep drives for maximum voltage

• Switching models also available. Series PSBxx-xxxS is recommended.

Linear Power

Supplies

Switching Power Supplies

The stepping system power supplies can supply power for multiple Sure Step STP-

DRV-xxxx microstepping motor drives, depending on step motor size and application requirements. To select a power supply for multiple drives, use the following formula:

I(ps) ≥ 0.66 x (I_motor1 + I_motor2 + I_motor3 + . . . )

Further information about braking accessories and regeneration clamping can be found in Appendix A and the STP-DRVA-RC-050 REGENERATION CLAMP datasheet.

9–2 SureStep TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 9: SureStep TM System Power Supplies

Specifications

Sure

Step™ Linear Power Supply Specifications

Part Number STP-PWR-3204 STP-PWR-4805 STP-PWR-4810 STP-PWR-7005

Input Power

(fuse protected)1)

Input Voltage

Inrush Current

1-phase,

120/240 VAC,

50/60 Hz, 150 VA

Fuse1): 3A

1-phase,

120/240 VAC,

50/60 Hz, 350 VA

Fuse1): 5A

1-phase,

120/240 VAC,

50/60 Hz, 650 VA

Fuse1): 8A

1-phase,

120/240 VAC,

50/60 Hz, 500 VA

Fuse1): 7A

120/240 VAC ±10% (3)

(switch selectable; voltage range switch is set to 240 VAC from factory)

120 VAC < 12A

240 VAC < 14A

120 VAC < 20A

240 VAC < 24A

120 VAC < 40A

240 VAC < 50A

Motor Supply

Output

(linear unregulated, fuse protected1), power on LED indicator)

32 VDC @ 4A

(full load)

35 VDC @ 1A load

41 VDC @ no load

Fuse1): 6A

46.5 VDC @ 5A

(full load)

52 VDC @ 1A load

57.5 VDC @ no load

Fuse1): 8A

46.5 VDC @ 10A

(full load)

50 VDC @ 1A load

57.5 VDC @ no load

Fuse1): 15A

70 VDC @ 5A

(full load)

79 VDC @ 1A load

86.5 VDC @ no load (3)

Fuse1): 8A

SureStep Drive

Compatibility 2)

Logic Supply

Output

Watt Loss

Storage

Temperature

Operating

Temperature

Humidity

Cooling Method

Dimensions

(in [mm])

Mounting

Weight (lb [kg])

STP-DRV-4035

(STP-DRV-4850)

(STP-DRV-80100)

STP-DRV-4850

(STP-DRV-80100)

STP-DRV-80100

5VDC ±5% @ 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

Natural convection (mount power supply to metal surface if possible)

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, tightening torque of 4.5 in·lbs

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.

3) An unloaded STP-PWR-7005 can float above the allowable input voltages of some drives if it is fed with a high AC input voltage (greater than 120VAC). Either ensure that the incoming AC supply is less than

120V, or supply a burden resistor to pull the unloaded linear DC voltage level down.

4) For switching power supply specifications, please refer to that part number's data sheet or manual.

7th Ed. Rev D –03/17/2022

SureStep TM Stepping Systems User Manual 9–3

Chapter 9: SureStep TM System Power Supplies

Drive Heating

Note: The following information applies to STP-DRV-6575, STP-DRV-4850, and

STP-DRV-80100 models only.

While STP drives efficiently transmit power between the power supply and motor, they do generate some heat in the process. This will cause the temperature of the drive to rise above the surrounding air temperature and may also require that the drive be mounted to a heat conducting metal surface.

For those who wish to calculate the power dissipation and temperature rise, the following information is provided:

1. Drive power dissipation Pd versus motor current and power supply voltage (see chart).

2. Drive thermal constant R

Q

The final drive case temperature is given by:

Tc=Ta+R Q *Pd drive should not be allowed to exceed 70°C or the life of the product could be reduced.

Drive Thermal Constant

• Narrow side of drive mounted on a 13.5" x 13.5" steel plate, 0.70" thick:

R Q =1.0

° C/W

• Narrow side of drive mounted on a non-heat conducting surface: R Q =2.1

° C/W

Drive Watt Loss

9–4 SureStep TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 9: SureStep TM System Power Supplies

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. Due to the inductances in the windings which rely on current to produce torque, the voltage should be much greater to allow fast changes in winding current (stepping). 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. SureStep Drives are designed to work well with SureStep motors so choosing the proper voltage of the supply is made easy when using all AutomationDirect products. A compatibility chart for

AutomationDirect power supplies and drives is located below.

SureStep™ Power Supply Compatibility

Drive

STP-DRV-4035

STP-DRV-4830

STP-DRV-4845

STP-DRV-4850

STP-DRV-6575

STP-DRV-80100

STP-MTRD-17

STP-MTRD-23,-24

STP-

PWR-3024

















Linear Power Supply

STP-

PWR-4805

No



STP-

PWR-4810

No



























Switching Power Supply

STP-

PWR-7005*

No

No

No

No

No



No



Drive

PSB12-xxxS PSB24-xxxS PSB48-xxxS

STP-DRV-4035

STP-DRV-4830

STP-DRV-4845

STP-DRV-4850

STP-DRV-6575

STP-DRV-80100

STP-MTRD-17

STP-MTRD-23,-24







No

No

No

















No











 it is fed with a high AC input voltage (greater than 120VAC). Either ensure that the incoming

AC supply is less than 120V, or supply a burden resistor to pull the unloaded liner DC voltage level down.

  

*An unloaded STP-PWR-7005 can float above the allowable input voltages of some drives if

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. With voltage, there is a trade-off between higher voltage and increased heating.

Voltage determines max speed. A higher voltage power supply equals higher top-end motor speed. But higher voltages also mean higher temperatures (drive and motor), so the lowest voltage that will satisfy your required speed should be used.

7th Ed. Rev D –03/17/2022

SureStep TM Stepping Systems User Manual 9–5

Chapter 9: SureStep TM System Power Supplies

Linear (Unregulated) vs Switching (Regulated) Power Supplies

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 25% greater than the voltage listed on the power supply label. Some applications may have regeneration (the motor tries to decelerate a large load quickly and becomes a generator). The motor tries to dump the excess energy back into the drive (and supply). This can sometimes boost the DC voltage up higher than the regulated supply would normally output which can turn into an overvoltage situation, causing the power supply to shut down. Regeneration clamp STP-DRVA-RC-050 can help in these situations. It is installed between the power supply and drive, where it monitors incoming power supply voltage and the voltage on the drive side. If the drive side goes higher than the incoming (the motor is regenerating power), the clamp “dumps” energy out to its resistor. Linear supplies don’t care (they will just float higher), but regulated supplies might trip. STP-DRVA-BR-100 allows the regeneration clamp to

"dump" even more energy from the system.

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 small number of drives, choose a power supply using the following formula:

I(ps) ≥ 0.66 x (I_motor1 + I_motor2 + I_motor3 + . . . )

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 or switching 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.

9–6 SureStep TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 9: SureStep TM System Power Supplies

Power Supply Terminal & Component Layout

STP-PWR-3204

Voltage Selection

Switch *

* Voltage range switch is factory set to 240 VAC.

AC input fuse **

STP-PWR-3204

F1

GND

L2

L1

240V 120V

Transformer

F2

–

+

–

+

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-PWR-4805, STP-PWR-4810, STP-PWR-7005

DC output fuse **

** Fuses to be replaced by qualified service personnel only.

** Fuses are listed in power supply specifications table.

Circuit Board

+

–

STP-PWR-48xx

STP-PWR-70xx

5 VDC

Power LED

Linear DC

Power LED +

–

F2

Transformer

L1

L2

GND

120V 240V

F1

AC input fuse **

* Voltage range switch is factory set to 240 VAC.

Voltage Selection Switch *

7th Ed. Rev D –03/17/2022

SureStep TM Stepping Systems User Manual 9–7

Chapter 9: SureStep TM System Power Supplies

Mounting the Power Supply

STP-PWR-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-PWR-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 fastened to a smooth, flat metal surface that will dissipate heat.

Wide Side Mount Narrow Side Mount sheet metal mounting screws 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.

9–8 SureStep TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Dimensions

STP-PWR-3204

Dimensions = [in] mm

3.25 82.6

Chapter 9: SureStep TM System Power Supplies

4.00 101.6

0.25 6.4

0.25 6.4

0.70 17.8

2.53 64.3

3.30 83.8

0.77 19.6

7.00 177.8

6.50 165.1

6.50 165.1

0.25 6.4

8X 0.21

7th Ed. Rev D –03/17/2022

0.25 6.4

SureStep TM Stepping Systems User Manual 9–9

Chapter 9: SureStep TM System Power Supplies

Dimensions (continued)

STP-PWR-4805, -4810, -7005

3.89 98.7

4.99 126.8

0.35 8.9

0.35 8.9

2.66 67.6

0.88 22.3

0.95 24.1

0.32 8.2

3.80 96.5

0.87 22.1

0.35 8.9

8.10 205.7

8.10 205.7

0.25 6.4

9–10

0.25 6.4

SureStep™ Series – 48V & 70V Power Supplies

STP-PWR-4805 STP-PWR-4810 STP-PWR-7005

Mtg Screw #10 1/4

SureStep TM Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

S

ure

M

otion

P

ro

C

onfiguration

S

oftware

C hapter

10

In This Chapter...

Sure Motion™ Pro Software � � � � � � � � � � � � � � � � � � � � � � � �10–2

Communication � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �10–2

Motor Configuration � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �10–2

Motion and I/O � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �10–3

Drive Pull-down Menu � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �10–4

Chapter 10: SureMotion Pro Configuration Software

Sure

Motion™ Pro Software

The Sure Step advanced drives STP-DRV-4850 & -80100 and advanced integrated motor/drives (STP-MTRD-17R, -23R, and -24R) are configured using Sure Motion

Pro™ configuration software, which is available for download from the

Automationdirect.com website.

Note: SureMotion Pro is the successor to SureStep Pro. Anything that could be done with SureStep Pro can still be done with SureMotion Pro.

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.

Complete software instructions are included in the “Help” files within the software.

10–2

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.

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

SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Chapter 10: SureMotion Pro Configuration Software be left at 1. The idle current is default at 50%. Idle current should be used unless the application will require a constant high holding torque

Motion and I/O

Selecting this tab will allow you to set the drive’s mode of operation.

• Pu lse and Direction:

Used with high-speed pulse inputs (CW/CCW,

Pulse/Direction, Quadrature) generated from a PLC, encoder, etc.

• Ve locity (Oscillator):

Allows the drive to be speed controlled by an analog signal. The input is 0 – 5V and can be scaled to the desired maximum speed. Bidirectional motion can be attained by changing the Offset

(under “Advanced Analog Settings”) to a nonzero value. EX: Setting this value to 2500mV will command the drive to be at zero speed when 2.5V are present.

• Se rial Command Language (SCL):

Causes the drive to respond to serial commands.

A PLC or PC can issue a variety of commands to enable simple motion, gearing/following, turn on the output, wait for an input, etc. See the “SCL Manual” under the Sure Motion Pro Help menu. Serial commands can be tested by selecting the “Drive” pull-down menu from the menu bar, and then selecting “SCL Terminal”.

7th Ed. Rev D –03/17/2022

SureStep

TM

Stepping Systems User Manual 10–3

Chapter 10: SureMotion Pro Configuration Software

Drive Pull-down Menu

This software menu gives you several features to monitor and test the drive.

• Self-Test – Rotates the motor clockwise and counterclockwise.

(Tests motor and cabling)

• Status Monitor – Shows the current Drive and I/O 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.)

• 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.

• Set Quick Decel Rate – Used when the drive encounters faults or overtravel limits.

If using SCL mode, and if testing is done with SCL terminal, make sure to disconnect software and turn power off to the drive for at least 10 seconds to clear the drive’s communication buffer.

SCL terminal can be used to test SCL strings before programming your PLC. However,

PLC communications will fail after using SCL Terminal unless the drive is powered down for at least 10 seconds before attempting PLC-to-drive communication.

10–4 SureStep

TM

Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

S

ure

S

tep

tM

C

oMMuniCationS

C hapter

11

In This Chapter...

Connecting to a Host Using RS-485 � � � � � � � � � � � � � � � � � �11–2

Four-Wire Configuration � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �11–2

Two-Wire Configuration � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �11–3

Assigning RS-485 Addresses � � � � � � � � � � � � � � � � � � � � � � � � � � �11–3

Connecting to an STP-MTRD-xxxxR using the STP-USB485-4W

Adapter � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �11–4

Connecting to a drive using RJ12 � � � � � � � � � � � � � � � � � � � � � � �11–5

Chapter 11: SureStep TM Communications

Connecting to a Host Using RS-485

The Advanced integrated motor/drives (STP-MTRD-xxxxxR) support RS-485 ASCII/

SCL serial communication. RS-485 communication allows connection of 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 300 meters or 1000 feet).

For electrically noisy environments we recommend twisted pair cable with an overall shield and drain wire. Connect the drain wire at one end of the cable to earth ground.

GND (circuit ground)

TX-

TX+

RS-485 can be used with

RXeither four-wire or two-wire configurations. Both types of configurations can be used for

RX+

RS-485 Connection

up to 32 drives).

To use the STP-MTRD-xxxxxR RS-485 with SureMotion Pro, the STP-MTRD-xxxxxR must be connected to the PC in the four-wire “point-to-point” configuration and configured one axis at a time. The DA command is useful in setting up multiple drives.

Four-Wire Configuration

Four-wire systems utilitize separate transmit and receive wires. One pair of wires must connect the host’s transmit signals to each drives RX+ and RX- terminals.

The other pair connects the drive’s TX+ and TX- terminals to the host’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.

One drive’s GND terminal should still be connected to the host computer ground.

to PLC Port GND to PLC Port Rxto PLC Port Rx+ to PLC Port Tx-

120

120 to PLC Port Tx+

+Rx- +Tx- GND

Drive 1

+Rx- +Tx- GND

Drive 2

+Rx- +Tx- GND

Drive n

A 120 ohm terminating resistor is required at the end of a four-wire network.

11–2 SureStep

TM

Stepping Systems User Manual 7th Ed. Rev D – 03/17/2022

Chapter 11: SureStep TM Communications

If the PC does not have an RS-485 serial port, a converter will be required. ADC part number STP-USB485-4W is recommended.

Two-Wire Configuration

Two-wire systems use the same pair of wires to transmit and receive. This can lead to trouble as 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

STP-MTRD-xxxxR includes 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

SureMotion Pro software. It is not necessary to set the transmit delay in a fourwire system.

2-wire communication is not recommended for STP-MTRD-xxxxxR systems. Some

SureMotion Pro features (firmware upgrade, etc.) may not work correctly. Use a

4-wire configuration for best results.

to PLC Port GND to PLC Port Tx- (A)

120 to PLC Port Tx+ (B)

120

+Rx- +Tx- GND

Drive 1

+Rx- +Tx- GND

Drive 2

RS-485 2-wire System

+Rx- +Tx- GND

Drive n

A 120 ohm terminating resistor is required at both ends of a 2-wire network.

Assigning RS-485 Addresses

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 using

SureMotion Pro if you want to assign addresses to the drives. This is required if you plan to talk to multiple drives that are on the same network. See the “DA”

SCL command. Use the programming cable and the SureMotion Pro software that came with your drive for this purpose.

Connect the drive to your PC and then launch the SureMotion Pro software. Select the com port that is connected to the drive. Finally, apply power to your drive. If you have already configured your drive, then you should click the Upload button so that the SureMotion Pro settings match those of your drive. Click on the Motion

& I/O button, then select the “SCL” operating mode. The RS-485 Address panel

7th Ed. Rev D – 03/17/2022 SureStep

TM

Stepping Systems User Manual 11–3

Chapter 11: SureStep TM Communications should appear. If you would like to assign the drive a unique address, just click on the address character of your choice. You can use the numerals 0-9, or any of the following special characters: ! “ # $ % & ‘ () * + , - . / : ; < = > ? @. 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 most adapters. Once you’ve made your configuration choices, click Download to save the settings to your drive.

If a drive is assigned an address (1) then it will respond to commands prefixed by that address (for example: 1FL2000) but it will also respond to the same command without the address (for example: FL2000). Commands without an address are known as global commands. The only difference is that the drive will not send an acknowledgement back to the host when given a global command. If you have four addressed drives on a network and you send FL2000, then all drives will respond to the command but none will send an acknowledgement.

Connecting to an STP-MTRD-xxxxR using the STP-USB485-4W Adapter

The STP-USB485-4W is an excellent chocie for USB to serial conversion. It can be used for all RS-232 and RS-485 applications.

For RS-485 two-wire systems, set the switches and make the connections to the

STP-MTRD-xxxxR according to the diagrams below:

Note: 2-wire is used by some AutomationDirect PLCs.

RS-485 Two-wire Settings

STP-USB485-4W

6-pin screw terminal connector

1

2

6

STP-MTRD-xxxxR

5-pin connector

RX-, TX-

RX+, TX+

GND

ON

1 2 3 4

RS-485 2-wire Switch Settings

For RS-485 four-wire systems, set the switches and make the connections to the

STP-MTRD-xxxxR according to the diagrams below:

RS-485 Four-wire Settings

STP-USB485-4W

6-pin screw terminal connector

3

4

6

1

2

STP-MTRD-xxxxR

5-pin connector

RX-

RX+

TX+

TX-

GND

ON

1 2 3 4

RS-485 4-wire Switch Settings

11–4 SureStep

TM

Stepping Systems User Manual 7th Ed. Rev D – 03/17/2022

Chapter 11: SureStep TM Communications

Note: 4-wire is needed for communications to SureMotion Pro.

Connecting to a drive using RJ12

Multiple drives can easily be configured by connecting them using the ZL-CDM-

RJ12X4 or ZL-CDM-RJ12X10 RJ12 feedthrough modules. Use SureMotion Pro to assign unique addresses to each drive, then use the feedthrough module to network them together. The diagram on the next page shows a very convenient way to configure (PC) and control (PLC) multiple RS-485 integrated stepper motor/ drives. This diagram uses a 2-wire RS-485 connection (CLICK and several other

AutomationDirect PLCs only support 2-wire RS-485).

Drive configuration using SureMotion Pro:

The drives must be configured one at a time using SureMotion Pro (they all have the same network address out-of-the-box). Disconnect all but one drive from the ZL-CDM-RJ12X4 or ZL-CDM-RJ12X10 breakout board. That drive can now be configured by the PC. Plug the cable with the DB9 connector into the USB/

RS-485 converter (the “Configure” option in the diagram on the next page).

Configure each drive (connect only one at a time to the network) with SureMotion

Pro. Remember that the PLC cannot be connected to the network while the PC is configuring drives, as there can only be one master on the network at a time.

Controlling the network of drives from a PLC using SCL commands:

Once all the drives are uniquely addressed, plug all the RJ12 cables back into the

ZL-CDM-RJ12X4 or ZL-CDM-RJ12X10 feedthrough module. Unplug the USB/

RS-485 converter from the RS-485 network and plug the DB9 connector into the ZL-RTB-DB09 feedthrough module (the “Control” option in the diagram).

Pins 1 & 4 need to be tied together and pins 2 and 3 need to be tied together for 2-wire RS-485 communications (Most AutomationDirect PLCs only support

2-wire RS-485. Only the 06 and 260 CPU support 4-wire RS-485). See “Two-Wire

Configuration” on page 9-3 for an example diagram.

7th Ed. Rev D – 03/17/2022 SureStep

TM

Stepping Systems User Manual 11–5

Chapter 11: SureStep TM Communications

+ _

_

+

LG

3

4

2

5

1

7

8

6

9

SH

D

BRN

RED

BLK

ORG

NC

OR

NC

RE

GR GRN

RJ12 Connection Methods with

Integrated Motor/Drives

11–6 SureStep

TM

Stepping Systems User Manual 7th Ed. Rev D – 03/17/2022

S ure S tep™

A

cceSSorieS

A ppendix

A

In This Appendix...

Braking Accessories � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �A–2

Regeneration Clamp Features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �A–2

Cables and Accessories � � � � � � � � � � � � � � � � � � � � � � � � � � � � �A–5

Encoder Options � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �A–8

Encoder Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �A–13

Differential Electrical Specifications � � � � � � � � � � � � � � � � � � � � � � � � � � � �A–15

Wiring Examples � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �A–16

Line Filters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �A–21

Appendix A: SureStep™ Accessories

Braking Accessories

If you plan to use a regulated or switching power supply, you might encounter problems from power regeneration. As a 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. The larger the motor the more common this becomes. If there is enough overhauling load on the motor, the

DC voltage will go above the drive and/or power supply limits.

Regeneration Clamp Features

• Built-in 50W power resistor

• Mounted on a heat sink

• Voltage range: 24–80 VDC; no user adjustments required

This can trip the overvoltage protection of a switching power supply or a drive, and cause it to shut down.

• Power: 50W continuous; 800W peak

• Indicators (LED):

Green = power supply voltage is present

Red = clamp is operating (usually when stepper is decelerating)

To solve this problem,

AutomationDirect offers a regeneration clamp STP-DRVA-RC-

050A. The regeneration clamp has a built-in 50W braking resistor. The

STP-DRVA-RC-050A does not have an external resistor.

STP-DRVA-RC-050 and the optional

100W braking resistor are no longer available, but are included here for reference purposes.

• 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 circuit fails, the diode will continue to protect the power supply from over-voltage.

STP-DRVA-RC-050 Features:

• External 100W resistor available

You can test whether regen is needed by installing a single unit in the first installation. If the regen LED

(red) never flashes, then you may not need the clamp.

Further information about braking accessories and regeneration

• Multiple drives in parallel up to 20A total output current

• Non-removable terminal blocks

• Uses 12-18 AWG wire for connections

STP-DRVA-RC-050A Features:

• Three drive connections, 7A max per channel, 15A total output current clamping can be found in the

REGENERATION CLAMP datasheet.

• Removable terminal blocks (replacement kit

STP-CON-4)

• Uses 18-20 AWG wire for connections

SureStep™ Stepping Systems – Braking Accessories

Part Number Description

STP-DRVA-RC-050* Regeneration Clamp: use with DC-powered stepper & servo drives; 50W, 24–80 VDC

STP-DRVA-RC050A* Regeneration Clamp: 50W, for DC input stepper and servo drives

STP-DRVA-BR-100 Braking Resistor: use with STP-DRVA-RC-050 regen clamp; 100W, 10 ohms

* Do not use the regeneration clamp in an atmosphere containing corrosive gases.

A–2 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

Block Diagram – STP-DRV-xxxx

STP-DRVA-RC-050 & STP-DRVA-BR-100 xx VDC

Power

Supply

(match power supply V to drive)

+

–

Vin+

Vin-

Vout-

Vout+

Regen

Clamp

STP-DRVA

-RC-050

Resistor (optional)

STP-DRVA-BR-100

10Ω 100W

R1

R2

STP-DRV-xxxx

Drive #2

(optional)

V+

V–

V+

V–

STP-DRV

-xxxx

Drive #1

STP-DRVA-RC-050

Dimensions – STP-DRVA-RC-050

Dimensions = in [mm]

4.00

[101.6]

2.50

[63.5]

4X Ø0.12

[Ø3.0]

3.75

[95.3]

Dimensions – STP-DRVA-BR-100

Dimensions = in [mm]

2X R0.16

[R4.0]

5.87

[149.1]

5.46

[138.7]

1.50

[38.1] 0.75

[19.1]

0.13

[3.3]

0.75

[19.0]

1.50

[38.1]

0.24

[6.1]

3.00

[76.2]

0.16

[4.0]

3.69

[93.7]

4-40 UNC

2.21

[56.2]

1.25

[31.8]

1.24

[31.5]

1.20

[30.6]

0.87

[22.1]

3X Ø0.12

[Ø3.0]

1.17

[29.7]

22.00

[558.8]

STP-DRVA-BR-100

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–3

Appendix A: SureStep™ Accessories

STP-DRVA-RC-050A

Dimensions – STP-DRVA-RC-050A

Dimensions = in [mm]

3.70

[94.0]

0.64

[16.2] 0.20

[5.0]

3.01

[76.4]

1.77

[45.0]

3.35

[85.0]

6X

R0.08

[R2.1]

0.67

[17.0]

1.13

[28.6]

0.20

[5.0]

0.20

[5.0]

A–4 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

Cables and Accessories

Replacement cables and connector kits are available for use with SureStep motors, drives, and integrated motors/drives. See the table below for available accessories and the parts they are compatible with. Encoder cables are located in the Encoder

Options section.

Part Number

STP-CON-1

STP-CON-2

STP-CON-3

STP-CON-4

STP-CON-5

STP-CON-6

Sure

Step Cables & Accessories

Description

SureStep replacement connector kit.

SureStep replacement connector kit.

SureStep replacement connector kit.

SureStep replacement connector kit.

SureStep replacement connector kit.

SureStep replacement connector kit.

Use With

STP-DRV-4845 & -6575

STP-DRV-4850

STP-DRV-80100

All STP-MTRD except STP-

MTRD-17038 and 17048E

STP-DRVA-RC-050A

STP-DRV-4830

STP-DRVAC-24025

STP-485DB9-CBL-2

STP-USB485-4W

STP-EXT-0xx

STP-EXTL-0xx

STP-EXTH-0xx

Integrated motor/drive programming cable

USB to RS-485 adapter, 4-wire

Motor to drive extension cable, xx = length in feet

Motor to drive extension cable, xx = length in feet

Motor to drive extension cable, xx = length in feet

STP-MTRD-xxxxxR(E)

STP-MTRD-xxxxxR(E)

STP-MTR-xxxxx(x)

STP-MTRL-xxxxx(x)

STP-MTRH-xxxxx(x)

STP-EXTW-0xx IP65 rated motor to drive extension cable, xx = length in feet STP-MTR-xxxxxW

STP-EXTHW-0xx

STP-MTRA-42ENC

CUI-KIT-1

IP65 rated motor to drive extension cable, xx = length in feet

STP-LA-EXT17-0xx

STP-LA-EXT23-0xx

STP-CBL-CAxx

STP-MTRA-17DMP

STP-MTRA-23DMP

SureStep extension cable, 6-pin connector to pigtail (4 wires used), 6, 10, or 20ft cable length.

SureStep extension cable, 6-pin connector to pigtail (4 wires used), 6, 10, or 20ft cable length.

Control cable for 17038 series integrated motor/drives, xx = length in feet

Metal body SureStep damper. For use with NEMA 17 stepper motors with 5mm shafts.

Metal body SureStep damper. For use with NEMA 23 stepper motors with 1/4 in. shafts.

STP-MTRA-SCRWKT-1 SureStep encoder mounting screw kit.

NEMA 42 Encoder adapter plate for CUI Devices AMT31/

AMT33 encoders

CUI Devices encoder accessory kit, replacement. Includes

(1) AMT102 base, (1) AMT102 wide base, and (1) AMT10 sleeve kit (9 sleeves sized 2-8mm).

STP-MTRH-xxxxxW

STP-LE17-xxxxxx

STP-LE23-xxxxxx

STP-MTRD-17038/17038E

STP-MTR-17xxx(x)

STP-MTR-23xxx(x)

STP-MTRAC-23xxxD

All stepper encoders1

STP-MTRAC(H)-42xxxD

CUI Devices AMT102 encoders

CUI-KIT-2

(1) AMT10 sleeve kit (9 sleeves sized 2-8mm).

1 - For NEMA42 motors, screws are not included in this kit. Screws are included with the STP-MTRA-

42ENC adapter plate.

CUI Devices encoder accessory kit, replacement. Includes

(1) AMT standard base, (1) AMT standard wide base, and

CUI Devices Devices

AMT103 encoders

Continued on next page

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–5

Appendix A: SureStep™ Accessories

CUI-KIT-4

STP-LA-NTFA

STP-LA-NTFB

STP-LA-NTFC

STP-LA-NTFD

STP-LA-NTFE

STP-LA-NTFF

STP-LA-NTFG

STP-LA-NTFH

STP-LA-NTFK

STP-LA-NRFA

STP-LA-NRFB

STP-LA-NRFC

STP-LA-NRFD

STP-LA-NRFE

STP-LA-NRFF

STP-LA-NRFG

STP-LA-NRFH

STP-LA-NRFK

Part Number

CUI-KIT-3

Sure

Step Cables & Accessories (continued)

Description

CUI Devices encoder accessory kit, replacement.

Includes (1) AMT standard base, (1) AMT standard wide base, and (1) AMT standard sleeve kit (9 sleeves sized from 2-8mm).

CUI Devices encoder sleeve kit, replacement. Includes

(8) sleeves sized from 9-14mm.

SureStep lead screw flange nut, replacement, triangular,

0.25in/rev, 0.25in lead screw diameter.

SureStep lead screw flange nut, replacement, triangular,

0.5in/rev, 0.25in lead screw diameter.

SureStep lead screw flange nut, replacement, triangular,

3mm/rev, 6.5mm lead screw diameter.

SureStep lead screw flange nut, replacement, triangular,

1.25mm/rev, 8mm lead screw diameter.

SureStep lead screw flange nut, replacement, triangular,

8mm/rev, 8mm lead screw diameter.

Use With

CUI Devices AMT11 and

AMT31 encoders

CUI AMT13 and AMT33 encoders

SureStep STP-LE series screw code A

SureStep STP-LE series screw code B

SureStep STP-LE series screw code C

SureStep STP-LE series screw code D

SureStep STP-LE series screw code E

SureStep STP-LE series screw code F

SureStep lead screw flange nut, replacement, triangular,

10.5mm/rev, 10mm lead screw diameter.

SureStep lead screw flange nut, replacement, triangular,

2mm/rev, 12mm lead screw diameter.

SureStep STP-LE series screw code G

SureStep lead screw flange nut, replacement, triangular,

6mm/rev, 12mm lead screw diameter.

SureStep lead screw flange nut, replacement, triangular,

1in/rev, 0.5in lead screw diameter.

SureStep STP-LE series screw code H

SureStep STP-LE series screw code K

SureStep lead screw flange nut, round, 0.25in/rev, 0.25in lead screw diameter.

SureStep lead screw flange nut, round, 0.5in/rev, 0.25in lead screw diameter.

SureStep lead screw flange nut, round, 3mm/rev, 6.5mm lead screw diameter.

SureStep lead screw flange nut, round, 1.25mm/rev, 8mm lead screw diameter.

SureStep lead screw flange nut, round, 8mm/rev, 8mm lead screw diameter.

SureStep STP-LE series screw code A

SureStep STP-LE series screw code B

SureStep STP-LE series screw code C ureStep STP-LE series screw code D

SureStep STP-LE series screw code E

SureStep lead screw flange nut, round, 10.5mm/rev,

10mm lead screw diameter.

SureStep lead screw flange nut, round, 2mm/rev, 12mm lead screw diameter.

SureStep lead screw flange nut, round, 6mm/rev, 12mm lead screw diameter.

SureStep lead screw flange nut, round, 1in/rev, 0.5in lead screw diameter.

SureStep STP-LE series screw code F

SureStep STP-LE series screw code G

SureStep STP-LE series screw code H

SureStep STP-LE series screw code K

A–6 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

STP-EXTx-0xx Extension Cable Wiring Diagram

STP-EXTW-0xx and STP-EXTHW-0xx Extension Cable Wiring Diagram

(

1.8

[46.35]

)

(

0.50

[12.70]

)

L ±0.50

[L ±12.70]

1.00±0.25

[25.40±6.35]

3

4

1

2

5

6

PIN #

PIN OUT CONNECTION

COLOR

RED

WHITE

GREEN

BLACK

GROUND

N/A

PHASE

A+

A-

B+

B-

GROUND

N/A

(

Ø0.77

[Ø19.60]

)

PIN # 5

PIN # 1

PIN # 2

PIN # 6

PIN # 4 PIN # 3

VIEW FROM PIN CONNECTION

Connector: Bulgin # PXP4011/06P/6065

LABEL:

STP-EXTW-0XX or

STP-EXTHW-0XX

18AWG SHIELDED CABLE:

BELDEN # 9418

(OR EQUIVALENT)

STP-485DB9-CBL-2 Wiring Diagram

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–7

Appendix A: SureStep™ Accessories

STP-CBL-CAxx Control Cable Wiring Diagram

*

* Refer to STP-CBL-CAxx part number

for cable length information

Note: For Rev A of this cable, STEP+ is Grey/Pink and EN- is Red/Blue

ECN REV DATE

STP-LE17-xxxxxx Cable Wiring Diagram

REVISION HISTORY

DESCRIPTION

ORIGINAL

[

L (IN)  13

L (mm)  0.5

]

INIT.

BJR

CONNECTOR

JST #

PHR-6

PIN

JST #

SPH-002T-P0.5

AUTOMATION DIRECT

STP-LA-EXT17-XXX

CABLE

ALHPAWIRE # 1604

(24AWG/4C)

OR EQUIVALENT

PIN 1

PIN #

1

2

3

4

5

6

PINOUT CHART

COLOR

RED

N/A

YELLOW

GREEN

N/A

BLACK

WIRE

A+

A-

B+

CABLE PART #

STP-LA-EXT17-006

STP-LA-EXT17-010

STP-LA-EXT17-020

VIEW FROM

WIRE ENTRANCE

B-

ECN

46416

REV

A0

DATE

7/1/19

STP-LE23-xxxxxx Cable Wiring Diagram

CABLES

LENGTH L (IN)

72

120

240

REVISION HISTORY

DESCRIPTION

ORIGINAL

LENGTH L (mm)

1828

3048

6096

[

L (IN)

L (mm)

 13

 0.5

]

INIT.

BJR

CONNECTOR

JST #

XHP-6

PIN

JST #

SXH-001T-P0.6

PIN 1

PIN #

1

2

3

4

5

6

PINOUT CHART

COLOR

RED

N/A

WHITE

GREEN

N/A

BLACK

WIRE

A+

A-

B+

B-

VIEW FROM

WIRE ENTRANCE

AUTOMATION DIRECT

STP-LA-EXT23-XXX

CABLE

BELDEN # 8444

(22AWG/4C)

OR EQUIVALENT

CABLE PART #

STP-LA-EXT23-006

STP-LA-EXT23-010

STP-LA-EXT23-020

CABLES

LENGTH L (IN)

72

120

240

LENGTH L (mm)

1828

3048

6096

A–8 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

CABLE NUMBER

STP-EXT42-006

STP-EXT42-010

STP-EXT42-020

Appendix A: SureStep™ Accessories

6 Feet

10 Feet

20 Feet

STP-EXT42(H)-xxx Cable Wiring Diagram

HEAT SHRINK

LABEL UL2517 18AWG 8C HEAT SHRINK

26±2

80±3

STP-EXT42- XXX

Automation Direct

YYDDD

75±3

L

Pin

7

6

8

4

3

5

2

1

9

Wire Description

A - White

A - Orange

C - Green

C - Brown

B - Red

B - Yellow

D - Black

D - Blue

GND - Drain wire

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–9

Appendix A: SureStep™ Accessories

Encoder Options

The standard integrated motors and dual-shaft stepper motors have options for mounting an external encoder. The NEMA 14, 17, 23/24, and 34 dual-shaft motors come with pre-tapped holes on the rear end cap for mounting the STP-

MTRA-ENCx encoders. The NEMA 42 dual-shaft motors require an STP-MTRA-

42ENC adapter plate for encoder moutning. All high bus voltage dual-shaft motors also come with pre-tapped holes. The “E” stepper motors and integrated models come with an encoder installed. This encoder can be replaced with other options. All STP-MTRA-ENCx encoders are incremental A/B quadrature type.

Please see the compatibility table below. For these encoders, the hardware in

STP-MTRA-SCRWKT-1 is used to attach the encoder to the compatible motor.

NOTE: Using the CLICK or BRX PLC requires the use of an FC-ISO-C signal conditioner.

Encoder Part

Number

PPR

SureStep Brand Encoder Compatibility

Bore

Diameter

Output

Type

PLC

Compatibility

Motor

Compatiblity

Matching

Cable

STP-MTRA-ENC1

STP-MTRA-ENC3

1000

400

STP-MTRA-ENC2 1000

STP-MTRA-ENC4 400

5mm

Line Driver

Push-pull

(totem)

P2-HSI, P3-HSI,

BRX2, CLICK

C0-1xDxE-D2

BRX2, CLICK

C0-1xDxE-D2

STP-MTRx-14xxxD

STP-MTRx-14xxxE

STP-MTRx-17xxxD

STP-MTRx-17xxxE

Standard STP-MTRDxxxxxE

STP-CBL-EAxx

STP-CBL-EDxx

STP-MTRA-ENC5

STP-MTRA-ENC6

1000

STP-MTRA-ENC7 400

1000

STP-MTRA-ENC8 400

0.25 inch

Line Driver

Push-pull

(totem)

P2-HSI, P3-HSI,

BRX2, CLICK

C0-1xDxE-D2

BRX2, CLICK

C0-1xDxE-D2

STP-MTRx-23xxxD

STP-MTRx-23xxxE

STP-MTRAC-23xxxD

STP-MTRA-ENC9

(AMT-112Q-V)

STP-MTRA-ENC10

(AMT-112S-V)

48 to

40961

2mm - 8mm

Line Driver

Push-pull

(totem)

P2-HSI, P3-HSI,

BRX2, CLICK

C0-1xDxE-D2

BRX2, CLICK

C0-1xDxE-D2

STP-MTRx-14xxxD

STP-MTRx-14xxxE

STP-MTRx-17xxxD

STP-MTRx-17xxxE

STP-MTRx-23xxxD

STP-MTRx-23xxxE

STP-MTRAC-23xxxD

Std STP-MTRD-xxxxE

STP-LE17-xxxADJ

STP-LE23-xxxADJ

STP-MTRA-ENC11 1000

STP-MTRA-ENC13 400

STP-MTRA-ENC12 1000

STP-MTRA-ENC14 400

0.375 inch

Line Driver

Push-pull

(totem)

P2-HSI, P3-HSI,

BRX2, CLICK

C0-1xDxE-D

BRX2, CLICK

C0-1xDxE-D2

STP-MTRAC-34xxxD

1 - Configurable (default=400). Requires configuration cable STP-USBENC-CBL-1

2 - Requires FC-ISO-C (see wiring diagrams below for DIP switch settings).

STP-CBL-EAxx

STP-CBL-EDxx

STP-CBL-EBxx

STP-USBENC-

CBL-1

STP-CBL-EAxx

STP-CBL-EDxx

A–10 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

For all encoders listed below, please use the hardware contained in STP-MTRA-

SCRWKT-1 to attach the encoder to the compatible motor.

CUI Devices Brand Encoder Compatibility

Encoder Part

Number

PPR

Bore

Diameter

Output

Type

PLC

Compatibility

Motor

Compatiblity

Matching

Cable

AMT102-V

AMT103-V2

AMT112S-V

AMT112Q-V

AMT312D-V

48 to

2048

48 to

4096

2mm - 8mm push-pull

(totem) line driver

(differential) line driver

(differential)

BRX1, CLICK

C0-1xDxE-D2

P2-HSI, P3-HSI,

BRX1, CLICK

C0-1xDxE-D2

P2-HSI, P3-HSI,

BRX1, CLICK

C0-1xDxE-D2

STP-MTRx-14xxxD

STP-MTRx-14xxxE

STP-MTRx-17xxxD

STP-MTRx-17xxxE

STP-MTRx-23xxxD

STP-MTRx-23xxxE

STP-MTRAC-23xxxD

Standard STP-MTRDxxxxxE

STP-LE17-xxxADJ

STP-LE23-xxxADJ

CUI-313x-xxx

CUI-435-xxx or

CUI-3934-6FT

AMT-17C-1-xxx

AMT-17C-1-xxx

AMT312S-V

AMT132S-V

AMT132Q-V

AMT332S-V

48 to

4096

9mm - 5/8" push-pull

(totem) line driver

(differential) push-pull

(totem)

BRX1, CLICK

C0-1xDxE-D2

P2-HSI, P3-HSI,

BRX1, CLICK

C0-1xDxE-D2

BRX1, CLICK

C0-1xDxE-D2

AMT332D-V line driver

(differential)

P2-HSI, P3-HSI,

BRX1, CLICK

C0-1xDxE-D2

1 - Requires FC-ISO-C (see wiring diagrams below for DIP switch settings).

STP-MTRx-34xxxD

STP-MTRAC(H)-

42xxxD3

(Does not fit STP-

MTRAC-34 motors)

AMT-18C-3-xx

2 For AMT103-V to maintain NEMA23 compatibility, CUI-KIT-2 must be purchased to use the standard wide base for mounting.

3 STP-MTRA-42ENC adapter plate required for STP-MTRAC(H)-42xxxD compatibility.

AMT102 and AMT103 encoders can be configured with on-board DIP switches.

All other CUI Devices encoders come preset at 400ppr as factory default. For other resolutions, a USB configuration cable is required (separate from the signal cables above).

• AMT11 and AMT31 encoders are configured with AMT-PGRM-17C.

• AMT13 and AMT33 encoders are configured with AMT-PGRM-18C.

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–11

Appendix A: SureStep™ Accessories

STP-USBENC-CBL-1 Wiring Diagram

STP-CBL-EAxx Encoder Cable Wiring Diagram

Z

Z

#

9

10

11

12

13

4

6

8

STP-CBL-EBxx Encoder Cable Wiring Diagram

NOTE:

1. Case_GND is connected internally to GND (BLACK/RED)

2. Ground connected internally to cable shielding-customer ref. only

3. Tolerance: ± 0.2” [5] unless otherwise specified

4. All materials must be ROHS compliant

CABLE NUMBER

STP-CBL-EB3

STP-CBL-EB6

STP-CBL-EB10

STP-CBL-EB20

L ±0.5

TABLE INFORMATION

CABLE LENGTH L

3 Feet

6 Feet

10 Feet

20 Feet

1.50 ±0.05 [38.100 ±1.270] 6.0 [152.400]

2

A

3 1 round dual shielding jacket

Case_GND

Note 1

#8 Insulated Terminal

Ring or Equivalent

A–12

A

3.0 [76.20]

0.5 [13] heat shrink tube with glue 2X (1 [25])

Special Label

PANDUIT # LJSL5-Y3-2.5

AUTOMATION DIRECT

STP-CBL-EBxx

Connector Pinout

Function

Color

GND

+5V

B+

B-

A+

A-

Z+

Z-

Primary

Black

Red

Green

Black

White

Black

Blue

Black

Stripe

Red

Black

Black

Green

Black

White

Black

Blue

17 15 13 11 9 7 5 3 1

16 14 12 10 8 6 4 2

SECTION A-A

SCALE 3:1

(Back of Connector Housing)

#

1

2

3

PART

CABLE

CONNECTOR

CRIMP PINS

PARTS LIST

DESCRIPTION

3M # 3600B/14

JAE # FI-W175

JAE #FI-C3-A1-15000

QTY

1

1

8

SureStep™ Stepping Systems User Manual

0.25±0.05 [6.350±1.270]

3.0 [76.20]

#8 Insulated Terminal

Ring or Equivalent

Leads Stripped and Tinned

Ground

Note 2

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

STP-CBL-EDxx Encoder Cable Wiring Diagram

Color

Black

Green

White

Red

Brown

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–13

Appendix A: SureStep™ Accessories

NOTE: Stepper motors can vibrate and resonate more than most motors. If this is an issue for your application use thread locking adhesive on the mounting screws.

Step Motor

STP-LE17-xxxADJ

Required Encoder Mounting Screws1 2

Qty

Screw

Description

Part Number

2

M2.5 X 0.45 mm thread, 4mm long

SS Slotted Screws,

Narrow Cheese

Head

McMaster Carr

PN#:

91613A060

Image

STP-MTRL-14xxxD or E

STP-MTR-17040D or E

STP-MTR-17048D or E

STP-LE23-xxxADJ

2

M2.5 X 0.45 mm,

5mm long, 8-18 SS

Button Head Hex

Drive Screw

McMaster Carr

PN#:

92095A457

STP-MTR-17060D or E 3

M2 X 0.4 mm,

5mm long 18-8 SS

Pan Head Phillips

Screws

McMaster Carr

PN#:

92000A012

STP-MTR-23xxxD or E

STP-MTRH-23xxxD or E

STP-MTRAC-34xxxD

2

4-40, 0.25 in long,

18-8 SS Pan Head

Phillips Screw with captive washer

Olander.com

PN#: 4C25PPIS

STP-MTR-34xxxD

STP-MTRH-34xxxD

STP-MTRAC-23xxxD

2

M3 X 0.5 mm,

15mm long 18-8 SS

Button Head Hex

Drive Screws

McMaster Carr

PN#:

992095A119

2

2-56, 0.25 in long,

Zinc plated Steel

Pan Head Phillips

Screw with captive washer

McMaster Carr

PN#:

90403A079

STP-MTR D -xxxxxE 2

M3 X 0.5 mm,

8mm long 18-8 SS

Pan Head Phillips

Screws

McMaster Carr

PN#: 94102A103

1 - STP-MTRA-SCRWKT-1 contains all these screws.

2 - Encoder mounting screws for STP-MTRAC(H)-42xxxD motors are included in STP-MTRA-42ENC, not

STP-MTRA-SCRWKT-1.

A–14 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

Encoder Mounting Accessories

STP-MTRA-42ENC

The STP-MTRA-42ENC mounting kit is required to mount an AMT13 or AMT33 encoder on the STP-MTRAC(H)-42xxxD series step motors.

2.50

63.5

0.91

23.0

2.12

53.9

0.61

15.6

0.13

3.2

1.22

31.1

0.61

15.6

0.61

15.6

1.81

46.0

4X

0.14

3.5

1.18

30.0

1.81

46.0

B.C.

1.73

44.0

B.C.

4X

R0.19

4.8

4X

4-40 UNC-2B THRU

2.50

63.5

NOTES:

1. DIMENSIONS CAN BE CHANGED BY MANUFACTURER WITHOUT NOTICE.

2. DIMENSIONS DO NOT IMPLY TOLERANCE.

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–15

Appendix A: SureStep™ Accessories

Encoder Specifications

Encoder

Operating

Temperature, CPR <

2000

Operating

Temperature, CPR ≥

2000

Vibration

Electrostatic Discharge

Encoder General Specifications

STP-MTRA-ENC1,

3, 5, 7, 11, 13

STP-MTRA-ENC2,

4, 6, 8, 12, 14

STP-MTRA-

ENC9

-40 to 100°C (-40 to 212°F)

-25 to 100°C (-13 to 212°F)

20G (5Hz to 20kHz)

± 2kV ± 4kV

STP-MTRA-

ENC10

Max. Shaft Axial Play

Max Shaft Eccentricity plus Radial Play

Max Acceleration

Typical Product Weight

Hub Set Screw

±0.010 inches [0.254 mm]

0.004 inches

250000 rad/sec2

0.91 oz. [25.8 g]

#4-48

0.82 oz [23.2 g]

See

AMT112Q-V datasheet

See

AMT112S-V datasheet

Hex Wrench Size 0.050 inches

Phase Relationship

A leads B for clockwise shaft rotation, and

B leads A for counterclockwise rotation as viewed from the cover side of the encoder.

For CUI Devices encoder specifications, please refer to the specific datasheet found on the encoder Item Page on www.automationdirect.com

.

SureStep Brand Bolt Circle Mounting Specifications

(mm [inches])

Bolt Hole

Circle

Encoder

STP-MTRA-ENC1

STP-MTRA-ENC3

STP-MTRA-ENC2

STP-MTRA-ENC4

STP-MTRA-ENC5

STP-MTRA-ENC7

STP-MTRA-ENC6

STP-MTRA-ENC8

STP-MTRA-ENC9

(AMT-112Q-V)

STP-MTRA-ENC10

(AMT-112S-V)

STP-MTRA-ENC11

STP-MTRA-ENC13

STP-MTRA-ENC12

STP-MTRA-ENC14

Two Holes

19.05 [0.75]

16 [0.63]

19.05 [0.75]

32.44 [1.28]

46.02 [1.81]

19.05 [0.75]

46.02 [1.812]

Three Holes

20.9 [0.823]

20.9 [0.823]

21.55 [0.85]

22 [0.87]

20.9 [0.823]

Four Holes

–

25.4 [1])

–

A–16 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

CUI Devices Brand Bolt Circle Mounting Specifications

(mm [inches])

Bolt Hole

Circle

Encoder

AMT102-V

AMT103-V

AMT112S-V

AMT112Q-V

AMT312D-V

AMT312S-V

AMT132S-V

AMT132Q-V

AMT332S-V

AMT332D-V

Two Holes

16.00 [0.630]

19.05 [0.750]

32.430 [1.277]

46.025 [1.812]

43.84 [1.726]

Three Holes

22.00 [0.866]

22.00 [0.866]

21.55 [0.848]

20.90 [0.823]

–

Four Holes

25.40 [1.000]

–

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–17

Appendix A: SureStep™ Accessories

Differential Electrical Specifications

The following specifications apply over the entire operating temperature range. Typical values are specified at Vcc = 5.0VDC and 25°C.

Encoder

Min.

Encoder Electrical Specifications

STP-MTRA-

ENC1, 3, 5, 7,

11, 13

STP-MTRA-

ENC2, 4, 6, 8,

12, 14

STP-MTRA-

ENC9

4.5

STP-MTRA-

ENC10

Supply

Voltage (V)

Typical 5

Max

Supply

Current

(mA)1

Low-level

Output2 (V)

Typical

Max

Typical

Max

29 (CPR < 500)

56 (CPR ≥ 500)

36 (CPR < 500)

65 (CPR ≥ 500)

0.2

5.5

27 (CPR < 500)

54 (CPR ≥ 500)

33 (CPR < 500)

62 (CPR ≥ 500) n/a

0.4

0.5

See AMT112Q-V datasheet

See AMT112S-V datasheet

High-level

Output3 (V)

Min

Typical

2.4

3.4

2.0

n/a

Rise/Fall Time (nS) 15 110/100

1: No load

2: IOL (Amps at Output Low) = 20mA max. (for all -ENC1 through -ENC14, except -ENC9 and 10)

3: IOH (Amps at Output High) = 20mA max. (for all -ENC1 through -ENC14, except -ENC9 and 10)

A–18 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

Wiring Examples

Please see the pages below for wiring examples:

For STP-MTRA-ENC1, -ENC3, -ENC5, -ENC7, -ENC11, -ENC13

STP-MTRA-ENC1 STP-CBL-EAx

Pin

+5V

7 +5V

GND

2 GND

D

A+

A−

6

5

BLU

BLU/WHT

A+

A−

D

B+

B−

10

9

BRN

BRN/WHT

B+

B−

D

Z+

Z−

4

3

ORG

ORG/WHT

Z+

Z−

Optical Encoder Line Driver Wiring Diagram

For STP-MTRA-ENC2, -ENC4, -ENC6, -ENC8, -ENC12, -ENC14

STP-MTRA-ENC2, 4, 6, 8

Pin

+5V

4

GND

1

A

3

B

5

2

Z

(Index)

STP-CBL-EDx

RED

BLACK

WHITE A+

BROWN

B+

GREEN Z+

A−

B−

Z−

Optical Encoder Single Ended (Push-pull/Totem) Wiring Diagram

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–19

Appendix A: SureStep™ Accessories

For STP-MTRA-ENC9 and CUI Devices Encoders

Encoder Cable

+5V

D

GND

A+

A−

A+

A −

D

B+

B−

B+

B −

D

Z+

Z−

Z+

Z −

Configurable Encoder Line Driver Wiring Diagram

Line Driver Encoder Wiring Colors

Encoder

Pin Function

AMT112Q-V

AMT312D-V

STP-MTRA-ENC9

Pin #

STP-CBL-EBx

AMT-17C-1-xxx

Wire Color

+5V

GND

A+

A-

B+

B-

Z+

Z-

12

13

8

9

10

11

6

4

RED/BLK

BLK/RED

WHT/BLK

BLK/WHT

GRN/BLK

BLK/GRN

BLU/BLK

BLK/BLU

Pin #

10

11

12

13

8

9

6

4

AMT132Q-V

AMT332D-V

AMT-18C-3-xxx

Wire Color

RED/GRN

GRN/RED

BRN/WHT

WHT/BRN

GRN/WHT

WHT/GRN

BLU/WHT

WHT/BLU

A–20 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

For STP-MTRA-ENC10 and CUI Devices Encoders

Encoder Cable

+5V

GND

A+

N/A

A+

B+

N/A

Z+

N/A

B+

Z+

Configurable Encoder Single Ended (Push-pull/Totem) Wiring Diagram

+5V

GND

A+

N/A

B+

N/A

Z+

N/A

Encoder

Pin

Function

Single Ended (Push-pull/Totem) Encoder Wiring Colors

AMT112S-V

AMT312S-V

STP-MTRA-

ENC10

AMT132S-V

AMT332S-V

AMT102-V AMT103-V

Pin

#

STP-CBL-EBx

AMT-17C-1-xxx

Wire Color

Pin

#

AMT-18C-

3-xxx

Wire Color

Pin

#

CUI-3131xxx

Wire Color

CUI-3132-

1FT

Wire Color

Pin

#

CUI-435xxx

Wire Color

CUI-3934-

6FT

Wire Color

8

9

12

13

6

4

10

11

RED/BLK

BLK/RED

WHT/BLK

BLK/WHT

GRN/BLK

BLK/GRN

BLU/BLK

BLK/BLU

8

9

6

4

RED/GRN 5V

GRN/RED G

BRN/WHT A

WHT/BRN –

10 GRN/WHT

11 WHT/GRN

12 BLU/WHT

13 WHT/BLU

B

–

X

–

RED

BLACK

WHT

–

BRN

–

GRN

–

ORG

BRN

BLU

–

YEL

–

PUR

–

B

–

X

–

5V

G

A

–

ORG

BRN

BLU

–

YEL

–

PUR

–

RED

BLACK

WHT

–

BRN

–

GRN

–

Single Ended (Push-pull/Totem) Commutation Wiring Colors

Encoder AMT312S-V AMT332S-V

Pin Function Pin #

+5V

GND

U+

W+

V+

3

5

6

4

7

AMT-17C-1-xxx

Wire Color

RED/BLK

BLK/RED

BRN/BLK

ORG/BLK

RED/WHT

Pin #

3

5

6

4

7

AMT-18C-3-xxx

Wire Color

RED/GRN

GRN/RED

BRN/RED

ORG/RED

BLU/RED

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–21

Appendix A: SureStep™ Accessories

Productivity PLCs

P2-HSI or P3-HSI

A+

1A

169Ω

A−

B+

1A

1B 169Ω

A+

B−

1B

1Z 169Ω

A−

B+

Z+

Z−

1Z

B−

Productivity PLC Wiring

Diagram

SureStep Advanced Stepper Drives

STEP+

330Ω

Internal to the

STP-DRV-xxxx

STEP-

220pF

DIR+

330Ω

DIR-

220pF

SureStep Advanced Stepper

Drive Wiring Diagram

A+

SureServo SVA-2xxx

Terminal Block & Cable

ZL-RTB50 &

ZL-SVC-CBL50 Servo Drive

24VDC

Max. input pulse frequence is

500kpps

/SIGN

5V

270Ω

A−

B+

SIGN

COM−

/PULSE

270Ω

B−

5V

PULSE

COM−

VDD GND

SureServo Wiring Diagram

A–22 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

Appendix A: SureStep™ Accessories

BRX High Speed Inputs

Line Driver (Differential) BRX MPU Input

B+

B−

A+

A−

Z+

Z−

FC-ISO-C

+Ai

-Ai

+Bi

-Bi

+Zi

-Zi

COM

COM

V+

0V

Ao

Ao

Zo

0V

0V

Bo

Bo

Zo

FC-ISO-C nC 0 1 2 3 4

12-24 VDC

BRX PLC Wiring Diagram

CLICK High Speed Inputs

Line Driver (Differential)

A+

A−

B+

B−

Z+

Z−

ISOLATION

BOUNDARY

FC-ISO-C

+Ai

-Ai

+Bi

-Bi

+Zi

-Zi

COM

COM

V+

0V

Ao

Ao

Bo

Bo

Zo

Zo

0V

0V

12-24 VDC

FC-ISO-C

CLICK PLC Wiring Diagram

C1

X1

X2

X3

7th Ed. Rev D – 03/17/2022

SureStep™ Stepping Systems User Manual A–23

Appendix A: SureStep™ Accessories

Line Filters

Drive

STP-DRV-4035

STP-DRV-4830

STP-DRV-4845

STP-DRV-6575

STP-DRV-4850

STP-DRV-80100

STP-MTRD-17x

STP-MTRD-23x

STP-MTRD-24x

STP-DRVAC-24025

Line Filters

Line Filter

RES10F06

RES10F03

RES10F06

RES10F10

RES10F06

RES10F10

RES10F03

RES10F06

RES10F06

RES10F03

A–24 SureStep™ Stepping Systems User Manual

7th Ed. Rev D – 03/17/2022

U

sing

s ure s tep™

with

A

UtomAtion

D

irect

PLc

s

A ppendix

B

In This Appendix...

Compatible AutomationDirect PLCs and Modules � � � � � � � �B–2

Typical Connections to a Productivity PLC � � � � � � � � � � � � � �B–6

Typical Connections to a DL05 PLC � � � � � � � � � � � � � � � � � � �B–7

Typical Connections to an H0-CTRIO � � � � � � � � � � � � � � � � � �B–8

Typical Connections – Multiple Drives/Motors � � � � � � � � � � �B–9

Typical

Direct

LOGIC PLC RS-232

Serial Connections to an Advanced SureStep Drive� � � � � � �B–10

Typical CLICK, P-Series, & BRX PLC RS-232

Serial Connections to an Advanced SureStep Drive� � � � � � �B–11

Typical RS-485 Connections to

Integrated Motor/Drives � � � � � � � � � � � � � � � � � � � � � � � � � � �B–12

Appendix B: Using SureStep™ with AutomationDirect PLCs

Compatible AutomationDirect PLCs and Modules

The following tables show which high-speed pulse-output PLCs and modules can be used with the Sure Step Microstepping Motor Drives.

Productivity

PLCs/Modules for Use with

Sure

Step Drives

Productivity Series High Speed Counter I/O Modules

P3-HSO

Productivity3000 high-speed pulse output module, 1MHz maximum switching frequency,

2-channel, 4 general purpose output points, 5-24 VDC, sinking/sourcing, 6 general purpose input points, external 24 VDC required.

P2-HSO

Productivity2000 high-speed pulse output module, 1MHz maximum switching frequency,

2-channel, 4 general purpose output points, 5-24 VDC, sinking/sourcing, 6 general purpose input points, external 24 VDC required.

BRX Series

PLCs/Modules for Use with

Sure

Step Drives

BRX Series High Speed Counter I/O Modules

BX-DM1-

10ED1-D

BRX Do-more PLC, 12-24 VDC required, serial port, microSD card slot, Discrete Input:

6-point, AC/DC, Discrete Output: 4-point, sinking.

BX-DM1-

10ED2-D

BRX Do-more PLC, 12-24 VDC required, serial port, microSD card slot, Discrete Input:

6-point, AC/DC, Discrete Output: 4-point, sourcing.

BX-DM1E-

10ED13-D

BX-DM1E-

10ED23-D

BRX Do-more PLC, 12-24 VDC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 6-point, AC/DC, Analog Input: 1-channel, current/voltage, Discrete Output:

4-point, sinking, Analog Output: 1-channel, current/voltage.

BRX Do-more PLC, 12-24 VDC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 6-point, AC/DC, Analog Input: 1-channel, current/voltage, Discrete Output:

4-point, sourcing, Analog Output: 1-channel, current/voltage.

BX-DM1-

18ED2-D

BX-DM1-

18ED1-D

BRX Do-more PLC, 12-24 VDC required, serial port, microSD card slot, Discrete Input:

10-point, AC/DC, Discrete Output: 8-point, sourcing.

BRX Do-more PLC, 12-24 VDC required, serial port, microSD card slot, Discrete Input:

10-point, AC/DC, Discrete Output: 8-point, sinking.

BX-DM1E-

18ED23-D

BRX Do-more PLC, 12-24 VDC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 10-point, AC/DC, Analog Input: 1-channel, current/voltage, Discrete Output:

8-point, sourcing, Analog Output: 1-channel, current/voltage.

BX-DM1E-

18ED13-D

BRX Do-more PLC, 12-24 VDC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 10-point, AC/DC, Analog Input: 1-channel, current/voltage, Discrete Output:

8-point, sinking, Analog Output: 1-channel, current/voltage.

BX-DM1-

18ED2

BX-DM1-

18ED1

BRX Do-more PLC, 120-240 VAC required, serial port, microSD card slot, Discrete Input:

10-point, AC/DC, Discrete Output: 8-point, sourcing.

BRX Do-more PLC, 120-240 VAC required, serial port, microSD card slot, Discrete

Input: 10-point, AC/DC, Discrete Output: 8-point, sinking.

Table continued next page.

B–2 SureStep™ Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Appendix B: Using SureStep™ with AutomationDirect PLCs

BX-DM1E-

18ED23

BX-DM1E-

18ED13

BRX Series

PLCs/Modules for Use with

Sure

Step Drives

BRX Do-more PLC, 120-240 VAC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 10-point, AC/DC, Analog Input: 1-channel, current/voltage, Discrete Output:

8-point, sourcing, Analog Output: 1-channel, current/voltage.

BRX Do-more PLC, 120-240 VAC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 10-point, AC/DC, Analog Input: 1-channel, current/voltage, Discrete Output:

8-point, sinking, Analog Output: 1-channel, current/voltage.

BX-DM1-

36ED2-D

BRX Do-more PLC, 12-24 VDC required, serial port, microSD card slot, Discrete Input:

20-point, AC/DC, Discrete Output: 16-point, sourcing.

BX-DM1-

36ED1-D

BRX Do-more PLC, 12-24 VDC required, serial port, microSD card slot, Discrete Input:

20-point, AC/DC, Discrete Output: 16-point, sinking.

BX-DM1E-

36ED23-D

BX-DM1E-

36ED13-D

BRX Do-more PLC, 12-24 VDC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 20-point, AC/DC, Analog Input: 4-channel, current/voltage, Discrete Output:

16-point, sourcing, Analog Output: 2-channel, current/voltage.

BRX Do-more PLC, 12-24 VDC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 20-point, AC/DC, Analog Input: 4-channel, current/voltage, Discrete Output:

16-point, sinking, Analog Output: 2-channel, current/voltage.

BX-DM1-

36ED2

BX-DM1-

36ED1

BRX Do-more PLC, 120-240 VAC required, serial port, microSD card slot, Discrete Input:

20-point, AC/DC, Discrete Output: 16-point, sourcing.

BRX Do-more PLC, 120-240 VAC required, serial port, microSD card slot, Discrete Input:

20-point, AC/DC, Discrete Output: 16-point, sinking.

BX-DM1E-

36ED23

BRX Do-more PLC, 120-240 VAC required, Ethernet and serial ports, microSD card slot,

Discrete Input: 20-point, AC/DC, Analog Input: 4-channel, current/voltage, Discrete Output:

16-point, sourcing, Analog Output: 2-channel, current/voltage.

BX-DM1E-

36ED13

BRX Do-more PLC, 120-240 VAC required, Ethernet and serial ports, microSD card slot, Discrete Input: 20-point, AC/DC, Analog Input: 4-channel, current/voltage,

Discrete Output: 16-point, sinking, Analog Output: 2-channel, current/voltage.

Table continued next page.

7th Ed. Rev D –03/17/2022

SureStep™ Stepping Systems User Manual B–3

Appendix B: Using SureStep™ with AutomationDirect PLCs

Direct

LOGIC PLCs/Modules for Use with

Sure

Step Drives (1)

DL05 PLCs

D0-05AD

D0-05DD

D0-05DD-D

DL05 CPU, 8 AC in / 6 DC out, 110/220 VAC power supply. Inputs: 8 AC inputs, 90-120

VAC, 2 isolated commons. Outputs: 6 DC outputs, 6-27 VDC current sinking, 1.0 A/pt max,

1 common. Two outputs are configurable for independent CW/CCW pulse train output or step and direction pulse output up to 7kHz (0.5 A/pt.).

DL05 CPU, 8 DC in / 6 DC out, 110/220 VAC power supply. Inputs: 8 DC inputs, 12-24

VDC current sinking/sourcing, 2 isolated commons. Outputs: 6 DC outputs, 6-27 VDC current sinking, 1.0 A/pt max, 1 common. Two outputs are configurable for independent

CW/CCW pulse train output or step and direction pulse output up to 7kHz (0.5 A/pt) (not available when using high-speed inputs).

DL05 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 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).

DL06 PLCs

D0-06DD1

D0-06DD2

D0-06DD1-D

D0-06DD2-D

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 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).

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 commons (4 inputs per common). Outputs: 16 DC outputs, 12-24 VDC current sourcing 1.0A/pt max, 4 commons non-isolated (4 points per common). Two outputs are configurable for independent CW/CCW pulse train output or step and direction pulse output up to 10 kHz (0.5 A/pt) (not available when using high-speed inputs).

DL06 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 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).

DL06 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 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/DL06 High Speed Counter I/O Module

H0-CTRIO

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 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, 20Hz-25kHz per channel, pulse and direction or CW/CCW pulses.

Table continued next page.

B–4 SureStep™ Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Appendix B: Using SureStep™ with AutomationDirect PLCs

Direct

LOGIC PLCs/Modules for Use with

Sure

Step Drives (1) (continued)

DL105 PLCs

F1-130AD

F1-130DD

DL130 CPU, 10 AC in / 8 DC out, 110/220 VAC power supply. Inputs: 10 AC inputs,

80-132 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 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).

F1-130DD-D

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 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).

DL205 and Do-More High Speed Counter I/O Modules

H2-CTRIO2

DL205 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 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.

D2-CTRINT

Counter Interface Module, 4 isolated DC inputs, 1 pulse train output (CW) or 2 pulse train outputs (CW/CCW) with DC input restrictions, accepts two up-counters when used with

D2-240 or D2-250(-1) (one only with D2-230), or one up/down counter. (not available when using high-speed inputs).

Terminator I/O High Speed Counter I/O Module

T1H-CTRIO

Terminator I/O 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 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. (Use with T1K-16B or

T1K-16B-1 terminal base.)

DL405 High Speed Counter I/O Module

H4-CTRIO

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 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 DirectLOGIC PLC capable of RS-232 ASCII communication can write serial commands to the

SureStep Advanced Microstepping Drives (STP-DRV-4850 & -80100). These PLCs include DL 05, 06,

250-1, 260, 350, and 450/454. However, we strongly recommend using DL06 or DL260 PLCs for serial commands due to their more advanced ASCII instruction set which includes PRINTV and VPRINT commands.

7th Ed. Rev D –03/17/2022

SureStep™ Stepping Systems User Manual B–5

Appendix B: Using SureStep™ with AutomationDirect PLCs

Typical Connections to a Productivity PLC

The following wiring diagrams show typical connections between any SureStep

Drive or Integrated motor/drive and a Productivity P3-HSO or P2-HSO (wiring is identical). All SureStep drives can be wired for Line Driver signals (preferred for noise immunity) or Open Collector. Refer to the Productivity User Manual for detailed programming instructions when using the HSO module.

Line Driver/Differential Wiring (preferred)

P3-HSO

D

1A

1A

COM

Any SureStep Drive or Motor/Drive

Step+

Step-

R

Shielded/Twisted Pair

D

1B

1B

Dir+

Dir-

R

24VDC

PWR+

PWR-

SHLD

Tie shield to panel ground this end only.

Open Collector/Single-ended wiring

P3-HSO

1A SNK

COM

1B SNK

COM

SHLD

Shielded/Twisted Pair

SureStep Driver #1

STEP -

STEP +

DIR +

DIR -

24VDC

2A SNK

COM

2B SNK

COM

PWR+

PWR-

Tie shield to panel ground this end only.

V1

SureStep Driver #2

STEP -

STEP +

DIR +

DIR -

Pick Resistor:

V1, use 1/4W resistor

24V, use 2.2K ohm

12V, use 820 ohm

5V, none required

A voltage dropping resistor is only needed if the PLC cannot generate 5VDC high speed pulses and the drive can only accept 5VDC pulses. These resistor values result in a 10mA signal [Amps = Volts/(internal drive R + external R)]. Other values can be used, but ensure that [5mA < signal current < 15mA]. See the individual drive chapters for more information.

B–6 SureStep™ Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Appendix B: Using SureStep™ with AutomationDirect PLCs

Typical Connections to a DL05 PLC

The following wiring diagram shows typical connections between the Sure Step

Stepping System components and a Direct LOGIC DL05 PLC. Refer to the DL05

Micro PLC User Manual, p/n D0-USER-M, High-Speed Input and Pulse Output

Features chapter, for detailed programming instructions when using the PLC for the Mode 30: Pulse Output function.

D0-05DD PLC DL05 PLC programmed for

Mode 30: Pulse Output

AC(L) AC(N)

G LG

C0 X1 X3 X4 X6 C2 Y1 Y3 Y5

X0 X2 C1 X5 X7 Y0 Y2 Y4 +V

Step Motor

Power Supply

STP-PWR-xxxx

GND

L2

L1

–

+

–

+

Cable Color Code

Term

A+

A–

B+

B–

Wire

Red

White

Green

Black

Pin #

3

4

1

2

L1 L2

AC Power

GND

24 VDC

Power Supply

+

–

GND

L2

L1

Y1

0 VDC

+5 VDC

Step Motor Drive

STP-DRV-xxxx

VDC+

VDC–

A+

A–

B+

B–

EN–

EN+

DIR–

DIR+

STEP–

STEP+

4 3

2 1

Front View

Extension Cable with Connector

STP-EXT( H )-020

Connector

12" Motor Pigtail with Connector

N/C

N/C

Y0

Step Motor

STP-MTR( H )-xxxxx

7th Ed. Rev D –03/17/2022

SureStep™ Stepping Systems User Manual B–7

Appendix B: Using SureStep™ with AutomationDirect PLCs

Typical Connections to an H0-CTRIO

The following wiring diagram shows typical connections between the Sure Step

Stepping System components and a Direct LOGIC H0-CTRIO High Speed Counter

I/O Interface Module installed in either a DL05 or DL06 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 H0-CTRIO module.

0 1

G

AC(L)

LG

AC(N) 24V

0V

C0

Y0

Y1

Y2

Y3

50 - 60Hz 2.0A, 6 - 27V

C1

2 3 4 5 6 7

Y4

Y5

2.0A

Y6

Y7

C2

Y10

Y11

Y12

Y13

C3

Y14

Y15

Y16

Y17

N.C.

PWR: 100-240V

10 11 12 13 14 15 16

50-60Hz 40VA

D0-06DR

3 - 15mA

LOGIC

06

Koyo

C0

X0

X1

X2

X3

C1

X4

X5

X6

X7

C2 X11 X13 X14

X10 X12 C3

X16 C4 X21 X23 N.C.

X15 X17 X20 X22 N.C.

PORT1 PORT2

TERM

RUN STOP

PWR

RUN

CPU

TX1

RX1

TX2

RX2

Step Motor

Power Supply

STP-PWR-xxxx

GND

L2

L1

–

+

–

+

Cable Color Code

Term

A+

A–

B+

B–

Wire

Red

White

Green

Black

Pin #

3

4

1

2

ERR

OK

A

Y0

B

Y1

CTR/TMR IN

9–30V 5–12mA

DC/Pulse Out

5–36V 1A

IN

A

B

C

D

M

YC

Y0

Y1

OUT

H0–CTRIO

Y1

0 VDC

+5 VDC

Step Motor Drive

STP-DRV-xxxx

VDC+

VDC–

A+

A–

B+

B–

EN–

EN+

DIR–

DIR+

STEP–

STEP+

4 3

2 1

Front View

Extension Cable with Connector

STP-EXT( H )-020

Connector

12" Motor Pigtail with Connector

N/C

N/C

Y0

Step Motor

STP-MTR( H )-xxxxx

B–8 SureStep™ Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Appendix B: Using SureStep™ with AutomationDirect PLCs

Typical Connections – Multiple Drives/Motors

The following wiring diagram shows typical connections between the Sure Step

Stepping System components and a Direct LOGIC H2-CTRIO(2) High Speed

Counter I/O Interface Module installed in a DL205 PLC. Refer to the CTRIO

High-Speed Counter Module User Manual, p/n Hx-CTRIO-M, for detailed programming instructions when using the H2-CTRIO module.

Step Motor

Power Supply

STP-PWR-xxxx

GND

L2

L1

–

+

NC

C 0

Y 0

C 1

Y 1

1A

1B

1C

1D

1M

2M

C 2

Y 2

C 3

Y 3

2A

2B

2C

2D

CTR

I N

C

C TR

O

E

1

2

K

R

H2--CTRI O

IN -

O T -

1.0A max per point

+24VDC

OUT

2

3

0

1

2A

1A

1B

–

+ +5 VDC

0 VDC 2B

1C

2C

Step Motor Drive

1D

STP-DRV-xxxx

VDC+

VDC–

A+

A–

B+

B–

EN–

EN+

DIR–

DIR+

STEP–

STEP+

N/C

N/C

2D

2M

C2

Y2

1M

NC

C0

Y0

C3

C1

Step Motor

STP-MTR( H )-xxxxx

Y3

Y1

Step Motor Drive

STP-DRV-xxxx

4 3

2 1

Front View

Cable Color Code

Term Wire Pin #

A+

A–

B+

B–

Red

White

Green

Black

3

4

1

2

Extension Cable with Connector

STP-EXT( H )-020

VDC+

VDC–

A+

A–

B+

B–

12" Motor Pigtail with Connector

EN–

EN+

DIR–

DIR+

STEP–

STEP+

Step Motor

STP-MTR( H )-xxxxx

N/C

N/C

7th Ed. Rev D –03/17/2022

SureStep™ Stepping Systems User Manual B–9

Appendix B: Using SureStep™ with AutomationDirect PLCs

Typical Direct LOGIC PLC RS-232

Serial Connections to an Advanced SureStep Drive

The following wiring diagrams show typical serial connections between a

Sure Step Advanced Microstepping Drive and a Direct LOGIC 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

PLC - DL05 ADVANCED STEPPER DRIVE

DL05 PLC STP-DRV-4850

STP-DRV-80100

RS-232 Port 2

6P6C RJ12

Receptacle

TXD 4

RXD 3

GND 1

RJ12 plug

4 Red

3 Green

1 Blue

STP-232RJ12-CBL-2

Red 5

Green 3

Blue 2

RJ12 plug

5 RX

3 TX

2 GND

Modular

6P4C RJ11

Receptacle

5

15

6

1

PLC

DL06

DL250-1

DL260

Port 2

15 pin HD

3 RX

2 TX

7 GND

4 RTS

5 CTS

HD15 plug

7

4

3

2

5

STP-232HD15-CBL-2

ADVANCED STEPPER DRIVE

STP-DRV-4850

STP-DRV-80100

Yellow 3

Blue 5

Black 2

RJ12 plug

3 TX

5 RX

2 GND

Modular

6P4C RJ11

Receptacle

Serial Connection Using Custom Cables

Use Belden 9841 or equivalent cable, and wire according to the Automation

Direct cable diagrams shown above (including RTS/CTS jumper for DL06, DL250-

1, and DL260).

B–10 SureStep™ Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

Appendix B: Using SureStep™ with AutomationDirect PLCs

Typical CLICK, P-Series, & BRX PLC RS-232

Serial Connections to an Advanced SureStep Drive

The following wiring diagrams show typical serial connections between a

Sure Step Advanced Microstepping Drive and a CLICK, BRX, or P1/P2/P3 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

PLC

CLICK PLC

P-Series PLC

BRX PLC

Port 2 (CLICK)

RS232 Port (P-Series)

RJ12 Receptacle

TXD 4

RXD 3

GND 1

RJ12 plug

4 Red

3 Green

1 Blue

STP-232RJ12-CBL-2

Red 5

RJ12 plug

Green 3

Blue 2

ADVANCED

STEPPER DRIVE

STP-DRV-4850

STP-DRV-80100

5 RX

3 TX

2 GND

Modular

6P4C RJ11

Receptacle

For BRX RS-232 connectivity:

CPU has a field wireable connector for serial port

TXD = TX/D+

RXD = RX/D-

GND = GND

BX-P-SER2-RJ12 is an optional POM accessory that adds a 2nd serial port (RJ12)

Serial Connection Using Custom Cables

Use Belden 9841 or equivalent cable, and wire according to the Automation

Direct STP-232RJ12-CBL-2 diagram shown above.

7th Ed. Rev D –03/17/2022

SureStep™ Stepping Systems User Manual B–11

Appendix B: Using SureStep™ with AutomationDirect PLCs

Typical RS-485 Connections to

Integrated Motor/Drives

Most AutomationDirect PLCs support 2-wire RS-485 serial communication (3 wires on the connector: Transmit (+), Receive (-), and Ground). For 2-wire communication, the integrated motor/drive must have its Tx+ and Rx+ connected; and Tx- and Rx- connected.

The drive’s Tx+/Rx+ signal should be connected to the “+” connection of the

PLC’s RS-485 port.

The drive’s Tx-/Rx- signal should be connected to the “-” connection of the PLC’s

RS-485 port.

The drive’s RS-485 ground terminal should be connected to the PLC’s serial port ground terminal.

to PLC Port GND to PLC Port Tx- (A)

120 120 to PLC Port Tx+ (B)

+Rx- +Tx- GND

Drive 1

+Rx- +Tx- GND

Drive 2

RS-485 2-wire System

Terminal Connections per PLC

Drive

Connection

CLICK P-Series

Tx+, Rx+ + +

Tx-, Rx-

GND

–

LG

–

G

BRX

TX/D+

RX/D-

GND

+Rx- +Tx- GND

Drive n

B–12 SureStep™ Stepping Systems User Manual

7th Ed. Rev D –03/17/2022

S

electing the

S ure S tep™

S

tepping

S

yStem

A ppendix

C

In This Appendix...

Selecting the SureStep™ Stepping System � � � � � � � � � � � � � �C–2

The Selection Procedure � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �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 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �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–9

Step 3 – Determine the Motion Profile � � � � � � � � � � � � � � � � � � � � � � � � � �C–9

Step 4 – Determine the Required Motor Torque � � � � � � � � � � � � � � � � � � �C–9

Step 5 – Select & Confirm the Stepping Motor & Driver System � � � � �C–10

Belt Drive – Example Calculations � � � � � � � � � � � � � � � � � � � �C–15

Step 1 – Define the Actuator and Motion Requirements � � � � � � � � � � � �C–15

Step 2 – Determine the Positioning Resolution of the Load � � � � � � � � � �C–16

Step 3 – Determine the Motion Profile � � � � � � � � � � � � � � � � � � � � � � � � �C–16

Step 4 – Determine the Required Motor Torque � � � � � � � � � � � � � � � � � �C–16

Step 5 – Select & Confirm the Stepping Motor & Driver System � � � � �C–17

Index Table – Example Calculations � � � � � � � � � � � � � � � � � �C–19

Step 1 – Define the Actuator and Motion Requirements � � � � � � � � � � � �C–19

Step 2 – Determine the Positioning Resolution of the Load � � � � � � � � � �C–19

Step 3 – Determine the Motion Profile � � � � � � � � � � � � � � � � � � � � � � � � �C–20

Step 4 – Determine the Required Motor Torque � � � � � � � � � � � � � � � � � �C–20

Step 5 – Select & Confirm the Stepping Motor & Driver System � � � � �C–21

Engineering Unit Conversion Tables,

Formulae, & Definitions: � � � � � � � � � � � � � � � � � � � � � � � � � � �C–22

Appendix C: Selecting the SureStep™ Stepping System

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

• 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

Indexing

Speed

Acceleration

Move Time

Deceleration the final analysis, we need to achieve the required motion with acceptable positioning accuracy.

How many pulses from the PLC to make the move?

The total number of pulses to make the entire move is expressed with the equation:

Equation

D total a

: P

total

= total pulses = (D

total

÷ (d

= total move distance load

÷ i)) x

u step d load

= lead or distance the load moves per revolution of the actuator’s drive shaft

( P = pitch = 1/ d load

) u step

= driver step resolution (steps/rev motor i = gear reduction ratio (rev motor

/rev gearshaft

)

)

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?

P total

= (5.5 rev disk

÷ (1 rev disk x 400 steps/rev motor

= 2200 pulses

/rev driveshaft

÷ 1 rev motor

/rev driveshaft

))

C–2 SureStep™ Stepping Systems User Manual

7th Ed. Rev C – 06/30/2021

Appendix C: Selecting the SureStep™ Stepping System

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?

P total

= (45 mm ÷ (10 mm/rev screw

= 4500 pulses

÷ 1 rev motor

/rev screw

)) x 1000 steps/rev motor

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?

P total

= (45 mm ÷ (10mm/rev

= 9000 pulses screw

÷ 2 rev motor

/rev screw

)) x 1000 steps/rev motor

What is the positioning resolution of the load?

We want to know how far the load will move for one pulse or step of the motor shaft. The equation to determine the positioning resolution is:

Equation b : L u

= load positioning resolution = (d load

÷ i) ÷ u step

Example 4: What is the positioning resolution for the system in example 3?

L u

= ( d load

÷ i ) ÷ u step

= (10 mm/rev screw

÷ 2 rev

= 0.005mm/step

P 0.0002in/step motor

/rev screw

) ÷ 1000 steps/rev motor

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 acceleration or deceleration period.

This type of motion profile is only used for 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:

Indexing

Speed

Start - Stop Profile

Move Time

Equation c : f

SS

= indexing speed for start-stop profiles = P total

÷ t total t total

= move time

7th Ed. Rev C – 06/30/2021

SureStep™ Stepping Systems User Manual C–3

Appendix C: Selecting the SureStep™ Stepping System

Example 5: What is the indexing speed to make a “start-stop” move with 10,000 pulses in 800 ms?

f

SS

= indexing speed = P total

= 12,500 Hz

÷ t total

= 10,000 pulses ÷ 0.8 seconds

For higher speed operation, the

“trapezoidal” motion profile includes controlled acceleration

& deceleration and an initial non-zero starting speed. With the acceleration and deceleration periods equally set, the indexing speed can be found using the equation:

Indexing

Speed

Start

Speed

Trapezoidal Profile

Acceleration

Move Time

Deceleration

Equation d : f

TRAP

= (P total

- (f start

x t ramp

)) ÷ (t for trapezoidal motion profiles total

- t ramp

) f start t ramp

= starting speed

= 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?

f

TRAP

= (10,000 pulses - (40 pulses/sec x 0.2 sec)) ÷ (0.8 sec - 0.2 sec)

P 16,653 Hz

Calculating the Required Torque

The required torque from the stepping system is the sum of acceleration torque and the running torque. The equation for required motor torque is:

Equation e : T motor

= T accel

+ T run

T accel

= motor torque required to accelerate and decelerate the total system inertia

(including motor inertia)

Torque

Pullout torque is the maximum torque that the stepping system can provide at any speed. The typical safety factor is to keep the required torque under 50% of the ideal available torque to avoid pullout or stalling.

Required Motor Torque

Versus Speed

Speed

T run

= constant motor torque requirement to run the mechanism due to friction, external load forces, etc.

In Table 1 we show how to calculate torque required to accelerate or decelerate an inertia from one speed to another and the calculation of running torque for common mechanical actuators.

C–4 SureStep™ Stepping Systems User Manual

7th Ed. Rev C – 06/30/2021

Appendix C: Selecting the SureStep™ Stepping System

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 f : T accel

= J total

x (  speed ÷  time) x (2 p ÷ 60)

J total

is the motor inertia, plus load inertia (“reflected” to the motor shaft).

The (2 p ÷ 60) is a factor used to convert “change in speed” expressed in RPM into angular speed (radians/ second). Refer to information in this table to calculate “reflected” load inertia for several common shapes and mechanical mechanisms.

Velocity

Torque

Accel

Period

T

1

Indexing Velocity

T

2

Decel

Period

T

3 time time

Example 7: What is the required torque to accelerate an inertia of 0.002 lb·in·sec 2 (motor inertia is 0.0004 lb·in·sec

600 RPM in 50 ms?

2 and “reflected” load inertia is 0.0016 lb·in·sec 2 ) from zero to

T accel

= 0.002 lb·in·sec

P 2.5 lb·in

2 x (600 RPM ÷ 0.05 seconds) x (2 p ÷ 60)

J motor

Leadscrew Equations

W F gravity

J

W

J coupling

F ext

J gear

J screw

Description:

Motor RPM

Torque required to accelerate and decelerate the load

Motor total inertia

Equations: n motor

= (v load

x P) x i, n motor

(RPM), v load

(in/min)

T accel

 J total

x (  speed ÷  time) x 0.1

Inertia of the load

Pitch and Efficiency

J total

= J motor

+ J gear

+ ((J coupling

+ J screw

+ J

W

) ÷ i 2 )

J

W

= (W ÷ (g x e)) x (1 ÷ 2 p P) 2

P = pitch = revs/inch of travel, e = efficiency

Running torque

Torque due to preload on the ballscrew

Force total

T run

= ((F total

÷ (2 p P)) + T preload

) ÷ i

T preload

= ballscrew nut preload to minimize backlash

F total

= F ext

+ F friction

+ F gravity

Force of gravity and Force of friction F gravity

= Wsin u , F friction

= µWcos u

Incline angle and

Coefficient of friction u = incline angle, µ = coefficient of friction

7th Ed. Rev C – 06/30/2021

SureStep™ Stepping Systems User Manual C–5

Appendix C: Selecting the SureStep™ Stepping System

Table 1 (cont’d)

Material: ball nut acme with plastic nut acme with metal nut

Typical Leadscrew Data

e = efficiency

0.90

Material:

0.65

0.40

Conveyor steel on steel steel on steel (lubricated) teflon on steel ball bushing

Rack & Pinion

J motor

J gear

Belt Drive (or Rack & Pinion) Equations

F gravity

J gear

W

J motor

W

1

J

W

F ext

J

W

F ext

J pinion

F gravity W

2

µ = coef. of friction

0.580

0.150

0.040

0.003

J pinion

Description:

Motor RPM

Torque required to accelerate and decelerate the load

Inertia of the load

Equations: n motor

= (v load

x 2 p r) x i

T accel

 J total

x (  speed ÷  time) x 0.1

J total

= J motor

+ J gear

+ ((J pinion

+ J

W

) ÷ i 2 )

Inertia of the load J

W

= (W ÷ (g x e)) x r 2 ; J

W

= ((W

1

+ W

2

) ÷ (g x e)) x r 2

Radius of pulleys

Running torque r = radius of pinion or pulleys (inch)

T run

= (F total

x r) ÷ i

Force total F total

= F ext

+ F friction

+ F gravity

Force of gravity and Force of friction F gravity

= Wsin u ; F friction Gearing u

Belt (or Gear) Reducer Equations

J motorpulley

J motorpulley

C–6

J motor

J loadpulley

Description:

Motor RPM

Torque required to accelerate and decelerate the load

Inertia of the load

Motor torque

J

Load

J motor

J

Load

J loadpulley

Equations: n motor

= n load

x i

T accel

 J total

x (  speed÷  time) x 0.1

J total

= J motor

+ J motorpulley

+ ((J loadpulley

+ J

Load

) ÷ i 2 )

T motor

x i = T

Load

SureStep™ Stepping Systems User Manual

7th Ed. Rev C – 06/30/2021

Table 1 (cont’d)

Description:

Inertia

Inertia

Volume

Appendix C: Selecting the SureStep™ Stepping System

Hollow

Cylinder

Inertia of Hollow Cylinder Equations

L D o

= 2r o

Equations:

J = (W x (r o

2 + r i

2 )) ÷ (2g)

J = ( p x L x r x (r o

4 volume = p/ 4 x (D

– r i

4

- D

)) ÷ (2g)

Solid

Cylinder

D i

= 2r i

Inertia of Solid Cylinder Equations

L D = 2r

Description:

Inertia

Inertia

Volume

Equations:

J = (W x r 2 ) ÷ (2g)

J = ( p x L x r x r 4 Recttangular

Block volume = p x r 2 x L

Inertia of Rectangular Block Equations

l h w

Description:

Inertia

Volume

Equations:

J = (W ÷ 12g) x (h 2 + w 2 ) volume = l x h x w

J = inertia

L = Length h = height w = width

W = weight

D = diameter r = radius g = gravity = 386 in/sec 2 p  3.14

Symbol Definitions

r = density r = 0.098 lb/in 3 (aluminum) r = 0.28 lb/in 3 (steel) r = 0.04 lb/in 3 (plastic) r = 0.31 lb/in 3 (brass) r = 0.322 lb/in 3 (copper)

7th Ed. Rev C – 06/30/2021

SureStep™ Stepping Systems User Manual C–7

Appendix C: Selecting the SureStep™ Stepping System

Step 1 – Define the Actuator and Motion Requirements

W F gravity

J

W

J coupling

F ext

J gear

J screw

J motor

Weight of table and workpiece = 200 lb, where W = 200 lb

Angle of inclination = 0°

Friction coefficient of sliding surfaces = 0.05, where µ = 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, where P = 1/0.6 = 1.67 rev/in

Desired Resolution = 0.001 inch/step

Gear reducer = 2:1, where i = 2, preliminary (for the 3:1 example, i = 3)

Stroke = 4.5 inch

Move time = 1.7 seconds

Acceleration time = Deceleration time = 0.425 sec / 2 = 212.5 ms

Lead screw efficiency = 0.9, where e = 0.9

Coupling and gear reducer inertias are negligible, which are considered to be 0

Definitions

d load

= lead or distance the load moves per revolution of the actuator’s drive shaft (P = pitch = 1/d load

)

D total

= total move distance u step

= driver step resolution (steps/rev motor

) i = gear reduction ratio (rev motor

/rev gearshaft

)

T accel

= motor torque required to accelerate and decelerate the total system inertia (including motor inertia)

T run

= constant motor torque requirement to run the mechanism due to friction, external load forces, etc.

t total

= move time

Start frequency = 20 Hz (as defined with a Module H0-CTRIO

C–8 SureStep™ Stepping Systems User Manual

7th Ed. Rev C – 06/30/2021

Appendix C: Selecting the SureStep™ Stepping System

Step 2 – Determine the Positioning Resolution of the Load

One revolution of the lead screw shaft advances 0.6 inches. We are looking for a

0.001 inch per step precision.

Check to see if 400 pulses/rev will achieve the desired precision:

With a reduction of 2:1, there will be two motor shaft revolutions to get a displacement of 0.6 inches.

(2 rev) x (400 pulses/rev) = 800 pulses for every 0.6 inches of displacement.

Therefore, (0.6 in) / (800 pulses) = 0.00075 in/pulse.

This is within the desired 0.001 in/step.

How many pulses are needed for the displacement?

With the 2:1 gear reduction, the stepping system can be set at 400 steps/rev to exceed the required load positioning resolution.

Since the lead screw advances 0.6 inches / rev, in the required stroke of 4.5 inches we will need:

(4.5 in) / (0.6 rev/in) = 7.5 revolutions on the lead screw

Since we have a reduction of 2:1, the motor shaft shall rotate 15 revolutions.

Step 3 – Determine the Motion Profile

Since we know that 400 pulses gets one revolution on the motor and we need 15 revolutions, then 400 x 15 = 6,000 pulses to move 4.5 inches.

From Equation d , the indexing frequency for a trapezoidal move is: f

TRAP

= (P total

- (f start

x t ramp

)) ÷ (t total

- t where the starting speed is 20 Hz ramp

)

= (6,000 - (20 x 0.425s)) ÷ (1.7 - 0.425) = 4,699 Hz,

(4,699 Hz) / (400 steps/rev) = 11.7475 rev/s

To get it in rpm, (11.7475 rev/s) x (60 s/min) = 704.85 rpm.

Step 4 – Determine the Required Motor Torque

Using the equations in Table 1 :

(Total inertia seen by the motor is the sum of all inertias)

J total

= J motor

+ J gear

+ (( J coupling

+ J screw

+ J

W

) ÷ i

2

)

For this example, we assume the gearbox and coupling inertias are zero.

Load inertia:

J

W

= (W ÷ (g x e)) x (1 ÷ 2 p P) 2

= (200 ÷ (386 x 0.9)) x (1 ÷ 2 x 3.1416 x 1.67)

= 0.00523 lb·in·sec 2

2

Lead screw inertia:

J screw

= ( p x L x r x r 4 ) ÷ (2g)

= (3.1416 x 23.6 x 0.28 x 0.3

4 ) ÷ (2 x 386)

= 0.0002178 lb·in·sec 2

The inertia of the load and screw reflected to the motor is the sum of both values divided by the square of the reduction ratio

J

J

(screw + load) referred to motor

= ((J screw

+ J

W

) ÷ i 2 ) total less the motor inertia

= ((0.0002178 + 0.00523) ÷ 2 2 ) = 0.001362 lb·in·sec 2

7th Ed. Rev C – 06/30/2021

SureStep™ Stepping Systems User Manual C–9

Appendix C: Selecting the SureStep™ Stepping System

The dynamic torque required to accelerate the inertia (without the motor rotor inertia) is:

T accel

= J total

x ((  rpm

÷  time

) x (2 p ÷60))

= 0.001362 x ((704.85 ÷ 0.2125) x (2 x 3.1416 ÷ 60))

= 0.474309 lb·in

Determine the running torque, or in this case the friction torque:

The forces are:

F total

= F ext

+ F friction

+ F gravity

= 0 + (µ x W x cos u ) + 0

= 0.05 x 200 = 10 Ib

[External forces and gravity are zero in this case.]

And the formula to be used is:

T run

= ((F total

÷ (2 p P)) + T preload

) ÷ i

= (10 ÷ (2 x 3.1416 x 1.67)) ÷ 2 [related to the motor side]

= 0.4765 Ib·in [where, we have assumed the preload torque to be zero]

From Equation e , the minimum required motor torque @ 704.85 rpm is:

T motor

= T accel

+ T run

= (0.474309 lb·in) + (0.4765 lb·in)

= 0.9508 Ib·in, or 15.21 oz·in

However, this is the required motor torque before we have picked a motor and included the motor inertia.

Step 5 – Select & Confirm the Stepping Motor & Driver System

There are two commonly used criteria to select a motor and drive:

• Take into account the calcluated torque. From step 4, we find we need 15.21 oz·in.

• Per a rule of thumb, the load to motor inertia ratio should be kept below 10.

• In step 4 we calculated that the J

(screw + load)

= 0.001362 lb·in·sec 2 the ratio, we use the formula: J

(screw + load)

÷ J motor motor is found in the motor specifications sheet.

. To find

The inertia of the

8

6

4

16

14

12

2

0

Speed rev/s

Torque oz-in

-2

0 0.5 1 1.5 2 2.5 3 3.5

Seconds

C–10 SureStep™ Stepping Systems User Manual

7th Ed. Rev C – 06/30/2021

Appendix C: Selecting the SureStep™ Stepping System

We will check the criteria with 2 motors:

Figure 2 shows the Torque vs. Speed curves for STP-MTR-17040 and figure 3 shows STP-MTR-17048. We use this as an example to observe how different power supply voltages affect the torque output of a motor.

Consider STP-MTR-17040:

Figure 2: Torque for STP-MTR-17040 at 4.7 kHz

According to the torque/speed curves for this motor, the torque at 4.7 kHz is approximately 39 oz·in at 48VDC and 34 oz·in at 70VDC. Based on the torque, this motor meets the desired 15.21 oz·in with any power supply.

The rotor intertia, per the motor specification is 0.28 oz·in 2 or 0.0000454 lb·in·sec 2 .

Load/Motor inertia ratio:

J

(screw + load)

÷ J motor

= 0.001362

= 30 lb·in·sec 2 ÷ 0.0000454 lb·in·sec 2

The ratio of 30 is well above the desired ratio of 10, so the STP-MTR-17040 motor is not suitable.

7th Ed. Rev C – 06/30/2021

SureStep™ Stepping Systems User Manual C–11

Appendix C: Selecting the SureStep™ Stepping System

Consider STP-MTR-17048:

C–12

Figure 3: Torque for STP-MTR-17048 at 4.7 kHz

For the purpose of this example, the torque vs. speed curves for this motor at

4.7 kHz will be approximately 48 oz·in at 48VDC, and 46 oz·in at 70VDC. This motor also meets the desired 15.21 oz·in requirement.

The rotor intertia, per the motor specification is 0.45 oz·in 2 lb·in·sec 2 . or 0.000024

Load/Motor inertia ratio:

J

(screw + load)

÷ J motor

= 0.001362

= 18.683

lb·in·sec 2 ÷ 0.000024 lb·in·sec 2

The ratio of 18.683 is still above the desired ratio of 10, so the STP-MTR-17048 motor is not suitable.

We can keep increasing the motor size, or maybe change the reflected load inertia by changing the reduction ratio from 2:1 to 3:1.

Reduction Ratio 3:1 ( Step 2 revisited) – Determine the Positioning

Resolution of the Load

One revolution of the lead screw shaft advances 0.6 inches. We are looking for a

0.001 inch per step precision.

Check to see if 400 pulses/rev will achieve the desired precision:

With a reduction of 3:1, there will be three motor shaft revolutions to get a

SureStep™ Stepping Systems User Manual

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Appendix C: Selecting the SureStep™ Stepping System displacement of 0.6 inches.

(3 rev) x (400 pulses/rev) = 1200 pulses for every 0.6 inches of displacement.

Therefore, (0.6 in) / (1200 pulses) = 0.0005 in/pulse.

This is within the desired 0.001 in/step.

How many pulses are needed for the displacement?

With the 3:1 gear reduction, the stepping system can be set at 400 steps/rev to exceed the required load positioning resolution.

Since the lead screw advances 0.6 inches / rev, in the required stroke of 4.5 inches we will need:

(4.5 in) / (0.6 rev/in) = 7.5 revolutions on the lead screw

Since we have a reduction of 3:1, the motor shaft shall rotate 22.5 revolutions.

Reduction Ratio 3:1 (Step 3 revisited) – Determine the Motion Profile

Since we know that 400 pulses gets one revolution on the motor and we need

22.5 revolutions, then 400 x 22.5 = 9,000 pulses to move 4.5 inches.

From Equation d , the indexing frequency for a trapezoidal move is: f

TRAP

= (P total

- (f start

x t ramp

)) ÷ (t total

- t where the starting speed is 20Hz ramp

)

= (9,000 - (20 x 0.425s)) ÷ (1.7 - 0.425) = 8,991.5 Hz,

(8,991.5 Hz) / (400 steps/rev) = 22.48 rev/s

To get it in rpm, (22.48 rev/s) x (60 s/min) = 1349 rpm.

Reduction Ratio 3:1 (Step 4 revisited) – Determine the Required Motor

Torque

Using the equations in Table 1 :

(Total inertia seen by the motor is the sum of all inertias)

J total

= J motor

+ J gear

+ (( J coupling

+ J screw

+ J

W

) ÷ i

2

)

For this example, we assume the gearbox and coupling inertias are zero.

Load inertia:

J

W

= (W ÷ (g x e)) x (1 ÷ 2 p P) 2

= (200 ÷ (386 x 0.9)) x (1 ÷ 2 x 3.1416 x 1.67)

= 0.00523 lb·in·sec 2

2

Lead screw inertia:

J screw

= ( p x L x r x r

4

) ÷ (2g)

= (3.1416 x 23.6 x 0.28 x 0.3

= 0.0002178 lb·in·sec

2

4 ) ÷ (2 x 386)

The inertia of the load and screw reflected to the motor is the sum of both values divided by the square of the reduction ratio

J

J

(screw + load) referred to motor

= ((J screw

+ J

W

) ÷ i

2

) total less the motor inertia

= ((0.0002178 + 0.00523) ÷ 3 2 ) = 0.000605 lb·in·sec 2

The dynamic torque required to accelerate the inertia (without the motor rotor inertia) is:

T accel

= J total

x ((  rpm

÷  time

) x (2 p ÷60))

= 0.000605 x ((1349 ÷ 0.2125) x (2 x 3.1416 ÷ 60))

= 0.4022 lb·in

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Appendix C: Selecting the SureStep™ Stepping System

Determine the running torque, or in this case the friction torque:

The forces are:

F total

= F ext

+ F friction

+ F gravity

= 0 + (µ x W x cos u ) + 0

= 0.05 x 200 = 10 Ib

[External forces and gravity are zero in this case.]

And the formula to be used is:

T run

= ((F total

÷ (2 p P)) + T preload

) ÷ i

= (10 ÷ (2 x 3.1416 x 1.67)) ÷ 3 [related to the motor side]

= 0.3177 Ib·in [where, we have assumed the preload torque to be zero]

From Equation e , the minimum required motor torque @ 1349 rpm is:

T motor

= T accel

+ T run

= (0.4022 lb·in) + (0.3177 lb·in)

= 0.7199 Ib·in, or 11.51 oz·in

Consider STP-MTR-17048 with the new values:

Figure 3: Torque for STP-MTR-17048 at 8.99 kHz

For the purpose of this example, the torque vs. speed curves for this motor at 8.99 kHz will be approximately 26 oz·in at 32VDC and 44 oz·in at 70VDC. Based on the torque, this motor meets the desired 11.51 oz·in requirement.

The rotor intertia, per the motor specification is 0.45 oz·in 2 lb·in·sec 2 . or 0.000024

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Appendix C: Selecting the SureStep™ Stepping System

Load/Motor inertia ratio:

J

(screw + load)

÷ J motor

= 0.00605

= 2.52

lb·in·sec

2

÷ 0.000024 lb·in·sec

2

The ratio of 2.52 is below the desired ratio of 10, so the STP-MTR-17048 motor is suitable.

A small change in the mechanical design allowed us to use the motor STP-

MTR-17048. The torque in the point of operation is more than enough, and the ratio of intertia criteria is fulfilled with any level of voltage in the drive. To be sure the safety factor is high, it would be better to select a 48V power supply and drive.

Conveyor

Belt Drive – Example Calculations

Step 1 – Define the Actuator and Motion Requirements

W

F gravity

J motor

F ext

J

W

J gear

J pinion

Weight of table and workpiece = 3 lb

External force = 0 lb

Friction coefficient of sliding surfaces = 0.05

Angle of table = 0º

Belt and pulley efficiency = 0.8

Pulley diameter = 1.5 inch

Pulley thickness = 0.75 inch

Pulley material = aluminum

Desired Resolution = 0.001 inch/step

Gear Reducer = 5:1

Stroke = 50 inch

Move time = 4.0 seconds

Accel and decel time = 1.0 seconds

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Appendix C: Selecting the SureStep™ Stepping System

Definitions

d load

= lead or distance the load moves per revolution of the actuator’s drive shaft (P = pitch = 1/d load

)

D total

= total move distance u step

= driver step resolution (steps/rev motor

) i = gear reduction ratio (rev motor

/rev gearshaft

)

T accel

= motor torque required to accelerate and decelerate the total system inertia (including motor inertia)

T run

= constant motor torque requirement to run the mechanism due to friction, external load forces, etc.

t total

= move time

Step 2 – Determine the Positioning Resolution of the Load

Rearranging Equation d to calculate the required stepping drive resolution: u step

= ( d load

÷ i ) ÷ L u

= ((3.14 x 1.5) ÷ 5) ÷ 0.001

= 942 steps/rev where d load

= p 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.

Step 3 – Determine the Motion Profile

From Equation a , the total pulses to make the required move is:

P total

= ( D total

÷ ( d load

÷ i )) x u step

= 50 ÷ ((3.14 x 1.5) ÷ 5) x 1000

P 53,079 pulses

From Equation d , the running frequency for a trapezoidal move is: f

TRAP

= ( P total

- ( f start

x t ramp

= 53,079 ÷ (4 - 1)

)) ÷ ( t total

- t ramp

)

P 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

P 1,062 RPM motor speed

Step 4 – Determine the Required Motor Torque

Using the equations in Table 1 :

J total

= J motor

+ J gear

+ (( J pulleys

+ J

W

) ÷ i 2 )

For this example, let’s assume the gearbox inertia is zero.

J

W

= ( W ÷ (g x e)) x r 2

= (3 ÷ (386 x 0.8)) x 0.752

P 0.0055 lb·in·sec 2

Pulley inertia (remember there are two pulleys) can be calculated as:

J pulleys

P (( p x L x r x r 4 ) ÷ (2g)) x 2

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Appendix C: Selecting the SureStep™ Stepping System

P ((3.14 x 0.75 x 0.098 x 0.754) ÷ (2 x 386)) x 2

P 0.00019 lb·in·sec 2

The inertia of the load and pulleys reflected to the motor is:

J

(pulleys + load) to motor

= (( J pulleys

+ J

W

) ÷ i 2 )

P ((0.0055 + 0.00019) ÷ 52) P 0.00023 lb·in·sec 2

The torque required to accelerate the inertia is:

T acc

P J total

x ( i speed ÷ i time) x 0.1

= 0.00023 x (1062 ÷ 1) x 0.1

= 0.025 lb·in

T run

= ( F total

x r ) ÷ i

F total

= F ext

+ F friction

+ F gravity

= 0 + µWcos u + 0 = 0.05 x 3 = 0.15 lb

T run

= (0.15 x 0.75) ÷ 5

P 0.0225 lb·in

From Equation e , the required motor torque is:

T motor

= T accel

+ T run

= 0.025 + 0.0225 P 0.05 lb·in

However, this is the required motor torque before we have picked a motor and included the motor inertia.

Step 5 – Select & Confirm the Stepping Motor & 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:

J motor

= 0.00006 lb·in·sec 2

The actual motor torque would be modified:

T accel

= J total

x ( i speed ÷ i time) x 0.1

= (0.00023 + 0.00006

) x (1062 ÷ 1) x 0.1 P 0.03 lb·in so that:

T motor

= T accel

+ T run

= 0.03 + 0.0225 P 0.0525 lb·in P 0.84 oz·in

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SureStep™ Stepping Systems User Manual C–17

STP-MTR-17L (32VDC, 2A)

Appendix C: Selecting the SureStep™ Stepping System

40

30

20

10

70

60

50

Required

Torque vs. Speed

1/2 Stepping

400 steps/rev

1/10 Stepping

2000 steps/rev

STP-MTR-17048

0

0 150 300 450 600 750 900 1050 1200 1350

RPM:

1500 1650 1800 1950 2100 2250

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

÷ J motor

= 0.00023 ÷ 0.00006 = 3.8

It is best to keep the load-to-motor inertia ratio below 10, so 3.8 is within an acceptable range.

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Appendix C: Selecting the SureStep™ Stepping System

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

Number of workpieces = 8

Desired Resolution = 0.036º

Gear Reducer = 25:1

Index angle = 45º

Index time = 0.7 seconds

Definitions

d load

= lead or distance the load moves per revolution of the actuator’s drive shaft (P = pitch = 1/d load

)

D total

= total move distance u step

= driver step resolution (steps/rev motor

) i = gear reduction ratio (rev motor

/rev gearshaft

)

T accel

= motor torque required to accelerate and decelerate the total system inertia (including motor inertia)

T run

= constant motor torque requirement to run the mechanism due to friction, external load forces, etc.

t total

= move time

Step 2 – Determine the Positioning Resolution of the Load

Rearranging Equation d to calculate the required stepping drive resolution: u step

= ( d load

÷ i ) ÷ L u

= (360º ÷ 25) ÷ 0.036º

= 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.

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Appendix C: Selecting the SureStep™ Stepping System

Step 3 – Determine the Motion Profile

From Equation a , the total pulses to make the required move is:

P total

= ( D total

÷ ( d load

÷ i )) x u step

= (45º ÷ (360º ÷ 25) x 400

= 1250 pulses

From Equation d , the running frequency for a trapezoidal move is: f

TRAP

= ( P total

- ( f start

x t ramp

)) ÷ ( t total

- t ramp

)

= 1,250 ÷ (0.7 - 0.17) P 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

P 354 RPM

Step 4 – Determine the Required Motor Torque

Using the equations in Table 1 :

J total

= J motor

+ J gear

+ ( J table

÷ i 2 )

For this example, let’s assume the gearbox inertia is zero.

J table

P ( p x L x r x r 4 ) ÷ (2g)

P (3.14 x 2 x 0.28 x 1296) ÷ (2 x 386)

P 2.95 lb·in·sec 2

The inertia of the indexing table reflected to the motor is:

J table to motor

= J table

÷ i 2

P 0.0047 lb·in·sec 2

The torque required to accelerate the inertia is:

T accel

P J total

x ( i speed ÷ i time) x 0.1

= 0.0047 x (354 ÷ 0.17) x 0.1

P 1.0 lb·in

From Equation e , the required motor torque is:

T motor

= T accel

+ T run

= 1.0 + 0 = 1.0 lb·in

However, this is the required motor torque before we have picked a motor and included the motor inertia.

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Appendix C: Selecting the SureStep™ Stepping System

Step 5 – Select & Confirm the Stepping Motor & 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:

J motor

= 0.0012 lb·in·sec 2

The actual motor torque would be modified:

T accel

= J total

x ( i speed ÷ i time) x 0.1

= (0.0047 + 0.0012

) x (354 ÷ 0.17) x 0.1

P 1.22 lb·in

STP-MTR-34S (32 VDC, 2.8A) so that:

T motor

= T accel

+ T

= 1.22 + 0 run

= 1.22 lb·in = 19.52 oz·in

350

1/2 Stepping

400 steps/rev STP-MTR-34066

300

1/10 Stepping

2000 steps/rev

250

200

150

100

Required

Torque vs. Speed

50

0

0 75 150 225 300

RPM:

375 450 525

It looks like the STP-MTR-34066 stepping motor will work. However, we still need to check the load to motor inertia ratio:

Ratio = J table to motor

÷ J motor

= 0.0047 ÷ 0.0012 = 3.9

It is best to keep the load-to-motor inertia ratio below 10, so 3.9 is within an acceptable range.

600

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Appendix C: Selecting the SureStep™ Stepping System

Engineering Unit Conversion Tables,

Formulae, & Definitions:

To convert A to B, multiply A by the entry in the table.

µm mm

A m mil in ft

µm

1

1.000E+03

1.000E+06

2.540E+01

2.540E+04

3.048E+05

Conversion of Length

B mm

1.000E–03

1 m

1.000E–06

1.000E–03 mil

3.937E–02

3.937E+01

1.000E+03

2.540E–02

2.540E+01

3.048E+02

1

2.540E–05

2.540E–02

3.048E–01

3.937E+04

1

1.000E+03

1.200E+04 in

3.937E–05

3.937E–02

3.937E+01

1.000E–03

1

1.200E+01 ft

3.281E–06

3.281E–03

3.281E+00

8.330E–05

8.330E–02

1

To convert A to B, multiply A by the entry in the table.

N·m

A kg·m kg·cm oz·in lb·in lb·ft

N·m

1

9.810E+00

7.060E–03

1.130E–01

1.356E+00

Conversion of Torque

kg·m

1.020E–01

1

1.000E–02

7.200E–04

1.150E–02

1.380E–01 kg·cm

1.020E+01

1.000E+02

1

7.200E–02

1.150E+00

1.383E+01

B oz·in

1.416E+02

1.390E+03

1.390E+01

1

1.600E+01

1.920E+02 lb·in

8.850E+00

8.680E+01

8.680E–01

6.250E–02

1

1.200E+01 lb·ft

7.380E-01

7.230E+00

7.230E–02

5.200E–03

8.330E–02

1

Conversion of Moment of Inertia

To convert A to B, multiply A by the entry in the table.

kg·m 2 kg·cm·s 2 oz·in·s 2

B lb·in·s 2 oz·in 2 lb·in 2 lb·ft 2 kg·m 2 1 1.020E+01 1.416E+02 8.850E+00 5.470E+04 3.420E+03 2.373E+01 kg·cm·s 2 9.800E–02 1 oz·in·s 2 7.060E–03 7.190E–02

1.388E+01 8.680E–01 5.360E+03 3.350+02 2.320E+00

1 6.250E–02 3.861E+02 2.413E+01 1.676E–01

A lb·in·s 2 1.130E–01 1.152E+00 1.600E+01 oz·in 2

1

1.830E–05 1.870E–04 2.590E–03 1.620E–04 lb·in 2 lb·ft 2

6.180E+03 3.861E+02 2.681E+00

1

2.930E–04 2.985E–03 4.140E–02 2.590E–03 1.600E+01

6.250E–02 4.340E–04

1

4.210E–02 4.290E–01 5.968E+00 3.730E–01 2.304E+03 1.440E+02

6.940E–03

1

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Appendix C: Selecting the SureStep™ Stepping System

Engineering Unit Conversion Tables, Formulae, & Definitions (cont’d):

General Formulae & Definitions

Description: Equations:

Gravity

Torque gravity = 9.8 m/s 2 ; 386 in/s 2

T = J · a ; a = rad/s 2

Power (Watts) P (W) = T (N·m) · v (rad/s)

Power (Horsepower) P (hp) = T (lb·in) · n (rpm) / 63,024

Horsepower 1 hp = 746W

Revolutions 1 rev = 1,296,000 arc·sec / 21,600 arc·min

Equations for Straight-Line Velocity & Constant Acceleration

Description: Equations:

Final velocity

Final position

Final position

Final velocity squared v f

= v i

+ at final velocity = (initial velocity) + (acceleration)(time) x f

= x i

+ ½(v i

+v f

)t final position = initial position + [(1/2 )(initial velocity + final velocity)(time)] x f

= x i

+ v i t + ½at 2 final position = initial position + (initial velocity)(time) + (1/2)(acceleration)(time squared) v f

2 = v i

2 + 2a(x f

– x i

) final velocity squared = initial velocity squared + [(2)(acceleration)(final position – initial position)]

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Appendix C: Selecting the SureStep™ Stepping System

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PAGE

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