Applied Motion Products STAC6 Series User manual

STAC6-Q-H
920-0109 Rev A
7/12/2016
STAC6

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STAC6-Q-H Hardware manual
920-0109 Rev A
7/12/2016
Contents
Safety Instructions............................................................................................................................5
Over-Current Protection ...................................................................................................................7
Block Diagram - STAC6-Q-H .............................................................................................................................................8
Motion Control Options ...................................................................................................................9
STAC6-H Control Options..................................................................................................................................................9
Getting Started ...............................................................................................................................10
Connecting to the PC using RS-232 ..............................................................................................11
Connecting to the PC using RS-485 ..............................................................................................12
Converting USB to RS-485 ..............................................................................................................................................13
USB-COMi-M Switch Settings.........................................................................................................................................13
Assigning Addresses in Multi-axis Systems ....................................................................................................................13
Connecting AC Power....................................................................................................................14
Fusing..............................................................................................................................................................................14
Line Filter.........................................................................................................................................................................14
Connecting the Motor ....................................................................................................................15
Connecting an Encoder .................................................................................................................17
Encoder Feedback Options...............................................................................................................................................18
Wiring Inputs and Outputs .............................................................................................................19
Connecting Digital Inputs on the IN/OUT1 connector ....................................................................20
High Speed Digital Inputs ................................................................................................................................................20
Using High Speed Inputs with 12-24 Volt Signals............................................................................................................22
Standard Digital Inputs.....................................................................................................................................................23
Single Ended Inputs .........................................................................................................................................................23
What is COM? .................................................................................................................................................................24
Digital Input Connection Examples ..................................................................................................................................24
Connecting Limit switches to the STAC6 Drive ................................................................................................................26
Wiring a Mechanical Limit Switch....................................................................................................................................26
Wiring a Limit Sensor ......................................................................................................................................................27
Connecting Digital Outputs on the IN/OUT1 connector..................................................................28
Connecting Analog Inputs on the IN/OUT1 connector....................................................................30
Basic Specifications: ........................................................................................................................................................31
Connecting an Analog Input to a Potentiometer or Joystick .............................................................................................31
Differential Inputs ............................................................................................................................................................32
Mounting the Drive ........................................................................................................................34
Schedule of Limitations:...................................................................................................................................................34
Electrical Ratings:.............................................................................................................................................................35
Markings: ........................................................................................................................................................................35
Mechanical Outline ........................................................................................................................36

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Technical Specifications.................................................................................................................37
Mating Connectors and Accessories ...........................................................................................40
Accessories....................................................................................................................................41
Alarm Codes ..................................................................................................................................42

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Safety Instructions
Only qualified personnel are permitted to transport, assemble, commission, and maintain
this equipment. Properly qualified personnel are persons who are familiar with the trans-
port, assembly, installation, commissioning and operation of motors, and who have the
appropriate qualifications for their jobs. The qualified personnel must know and observe the
following standards and regulations:
IEC 364 resp. CENELEC HD 384 or DIN VDE 0100
IEC report 664 or DIN VDE 0110
National regulations for safety and accident prevention or VBG 4
To minimize the risk of potential safety problems, you should follow all applicable local and national codes
that regulate the installation and operation of your equipment. These codes vary from area to area and it is
your responsibility to determine which codes should be followed, and to verify that the equipment, installa-
tion, and operation are in compliance with the latest revision of these codes.
Equipment damage or serious injury to personnel can result from the failure to follow all applicable codes
and standards. We do not guarantee the products described in this publication are suitable for your particu-
lar application, nor do we assume any responsibility for your product design, installation, or operation.
• Read all available documentation before assembly and commissioning. Incorrect handling of products
in this manual can result in injury and damage to persons and machinery. Strictly adhere to the technical
information on the installation requirements.
• It is vital to ensure that all system components are connected to earth ground. Electrical safety is impos-
sible without a low-resistance earth connection.
• In operation, depending on the degree of enclosure protection, the product can have bare components that
are live or have hot surfaces. Control and power cables can carry a high voltage even when the motor is not
rotating.
• Never pull out or plug in the product while the system is live. There is a danger of electric arcing and
danger to persons and contacts.
• After powering down the product, wait at least ten minutes before touching live sections of the equipment
or undoing connections (e.g., contacts, screwed connections). Capacitors can store dangerous voltages for
long periods of time after power has been switched off. To be safe, measure the contact points with a meter
before touching.

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Be alert to the potential for personal injury. Follow the recommended precautions and safe operating
practices. Safety notices in this manual provide important information. Read and be familiar with these
instructions before attempting installation, operation, or maintenance. The purpose of this section is to alert
users to possible safety hazards associated with this equipment and the precautions that need to be taken to
reduce the risk of personal injury and damage to the equipment.
Failure to observe these precautions could result in serious bodily injury, damage to the equipment ,or
operational difficulty.

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Over-Current Protection
The STAC6 has hardware over-current detection circuits that protect the drive against “phase to ground”
and “phase to phase” motor shorts. These circuits directly disable the amplifier in a rapid fashion to prevent
damage to the driver circuitry.
Typically, the over-current circuitry will react to an over-current condition in 3 to 5 micro-seconds. For a
short occurring in a motor, the motor leads provide enough resistance and inductance to keep the peak
current from exceeding the peak rating of the power transistors during this time period. The recommended
motors for the STAC6 all include 10 foot cables.
In essence the motor/cable system is a part of the over-current circuitry. If the drive is
directly shorted with a very short wire, this condition may cause current conditions that
exceed the peak current rating of our power transistors and therefore could weaken or
cause failure in the drive power devices.
Repetitive short circuits also risk damage to the drive. If a short circuit fault occurs,
please power off the drive and investigate carefully before restoring power.

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Block Diagram - STAC6-Q-H
MOSFET
PWM
Power
Amplifier
X1/STEP
X2/DIR
X3/ENABLE
X4/ALMRST
X5
X6/CCWLIM
ANALOG IN
PC/MMI
X7/CWLIM
Y1/FAULT
Y2/MOTION
Y3/BRAKE
RS232
Digital
Signal
Processor
Optical
Isolation
Internal
Logic
Supply
motor
encoder
RS485/422
Interface
DC
Power Supply
RS485/422
Regeneration
Clamp Circuit
120 VAC* 160 VDC**
Status

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Motion Control Options
STAC6-H Control Options
• Pulse & Direction, A/B Quadrature, CW/CCW Pulse.
• Velocity (Oscillator) Mode.
• Host command execution of SCL commands for control from a host PC or PLC using RS-232 or RS-
485 serial communication.
• Built-in Q controller
• Comprehensive single-axis programming language.
• Powerful feature set.
• Complex motion and machine control.
• Math functions.
• Register manipulation.
• Multi-tasking.
• Host interrogation/interface while executing internal programs.

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Getting Started
This manual describes the use of STAC6 series of step motor drives. What you need to know and what you
must have depends on the drive model. For all models, you’ll need the following:
• 120VAC single phase power.
• A compatible Hazadous Location Certied step motor. Consult Factory.
• A small at blade screwdriver for tightening the connectors (included).
• A personal computer running Microsoft Windows XP or Vista or 7 or 8, 32 or 64 bit.
If you’ve never used a STAC6 drive before you’ll need to get familiar with the drive and the set up software
before you try to deploy the system in your application. We strongly recommend the following software
applications available at www.applied-motion.com:
1. Install the ST Configurator™ and Q Programmer™ software applications.
2. Launch the software by clicking Start...Programs...Applied Motion...
3. Connect the drive to your PC with the programming cable.
4. Connect the drive to the motor.
5. Connect the drive to the AC power.
6. Apply power to the drive.

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Connecting to the PC using RS-232
• Locate your computer within 8 feet of the drive.
• Your drive was shipped with a communication cable. Plug the large end into the serial port of your PC
and the small end into the PC/MMI jack on your drive. Secure the cable to the PC with the screws on the
sides.
CAUTION
1. Never connect a drive to a telephone circuit. It uses the same connectors and cords as
telephones and modems, but the voltages are not compatible.
2. Drive ground and PC ground should be at the same potential. Different ground potentials
for the drive and PC can result in excessive current through the ground pin of the RS-232
port, resulting in failure of the port.
If your PC does not have a serial port, you should purchase a USB-serial converter to convert one of your
PC’s USB ports into an RS-232 (COM) port.
For 32-bit Windows operating systems, we have had good results with the Port Authority “USB Serial DB9”
Adapter from CablesToGo.com and with the SW1301 from SewellDirect.com. Some laptops also have a
PCMCIA slot, in which case the SSP-100 from Sewell Direct is a good choice.
For 64-bit Windows operating systems, namely Windows Vista 64 and Windows 7 64, the Prolific-based
adapters listed above do not work. For these PCs we suggest the USB-COMi-M or USB-CBL from Byterun-
ner.com. These adapters also work the 32-bit operating systems.
For USB choices, refer to page 52.
ground (to PC ground)
TX (to PC RX) No connection
RX (to PC TX)
Pin Assignments of the PC/MMI Port (RJ11 connector)

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Connecting to the PC using RS-485
RS-485 allows you to connect more than one drive to a single host PC, PLC, HMI or other computer. It
also allows the communication cable to be long (more than 1000 feet). But the device to which you connect
must have an RS-422 or RS-485 port.
Pin diagram is shown to the right. Wiring diagrams can be found on this and the next
page. We recommend the use of Category 5 cable. It is widely used for computer net-
works, it is inexpensive, easy to get and certified for quality and data integrity.
The STAC6 drives can be used with four wire RS-485 implementations. The connection can be point to
point (i.e. one drive and one host) or a multi-drop network (one host and up to 32 drives).
Four wire systems utilize separate transmit and receive wires. One pair of wires must connect the host
computer’s transmit signals to each drive’s RX+ and RX- terminals. Another pair connects the TX+ and TX-
drive terminals to the host computer’s receive signals. A logic ground terminal is provided on each drive
and can be used to keep all drives at the same ground potential. This terminal connects internally to the DC
power supply return (V-), so if all the drives on the RS-485 network are powered from the same supply it is
not necessary to connect the logic grounds. You should still connect one drive’s GND terminal to
the host computer ground.
Four wire systems are better than two wire types because the host can send and receive data at the same
time, increasing system throughput. Furthermore, the host never needs to disable its transmitter, which
simplies your software. We recommend that a 120 ohm terminating resistor be connected between RX+
and RX- at the farthest drive from the host.
+RX- +TX- GND +RX- +TX- GND +RX- +TX- GND
to PC TX+
to PC TX-
to PC RX+
to PC RX-
to PC GND
Drive #1 Drive #2 Drive #3
120
RX+
RX–
TX–
TX+
GND
RS-485/422

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Converting USB to RS-485
The USB-COMi-M from www.byterunner.com is an excellent choice for USB to RS-485 conversion.
For four wire RS-485, set SW1,3,4 to ON and SW2 to OFF. On the USB-COMi-M screw terminal connec-
tor:
USB-COMi-M STAC6 Drive
pin 1 RX-
pin 2 RX+
pin 3 TX+
pin 4 TX-
pin 6 GND
USB-COMi-M Switch Settings
Note: Prolific-based USB serial adapters do not work with Vista 64 or Windows 7 64 bit operating systems.
Suggested adapters are Byterunner USB-COMi-M or Byterunner USB-COM-CBL.
Assigning Addresses in Multi-axis Systems
Before wiring the entire system, you’ll need to connect each drive individually to the host computer so that
a unique address can be assigned to each drive. Use the programming cable and the STAC Configurator™
software that came with your drive for this purpose.
Connect the drive to your PC, then launch ST Configurator™. Finally, apply power to your drive. If you
have already configured your drive, then you should click the Upload button so that the ST Configurator™
settings match those of your drive. Click on the Motion button, then select the “SCL” operating mode. If
you have a Q drive, you may want to select “Q Programming”. Either way, you’ll see the RS-485 Address
panel appear. Just click on the address character of your choice. You can use the numerals 0..9 or the
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 the adapters we’ve tried. Once you’ve made your choices, click Download to save the
settings to your drive.
1
ON
2 3 4
RS-232
1
ON
2 3 4
4 Wire
RS-485

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Connecting AC Power
Using the connector supplied connect to the AC supply per the diagram below. Use solid or stranded copper
wire, minimum -50°C to 125°C 250V, 16 AWG - 12 AWG, 1 conductor per terminal, stripping length 7 mm,
tightening torque 0.5 Nm - 0.6 Nm.
Care should always be taken when working with high voltages.
In regions where the single-phase supply is higher, an auto transformer can be used to drop the voltage to
the correct level.
Fusing
The STAC6 contains an internal 8A fast acting fuse. If an external fuse is desired, we recommend a 6A fast
acting fuse.
Line Filter
For applications requiring CE EMC compliance, a Corcom 6ET1 line filter is required in series with the AC
input.
To Earth Ground
To Neutral
To Line (Hot)
g
r
e
e
n
bl
ac
k
o
r
b
r
o
w
n
w
h
i
t
e
o
r
b
l
u
e
AC Power Plug

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Connecting the Motor
Never connect or disconnect the motor while the power is on.
Note: it is highly recommended that you use a motor with a shielded cable with the STAC6.
Connection diagrams are shown below for industry standard wire colors. If the wire colors of your motor do
not match these diagrams, please consult the factory.
Four lead motors can only be connected one way. Please follow the sketch below.
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 the rated current to prevent overheating. Winding diagrams for both connec-
tion methods are shown below. NC means not connected.
A+
A–
B+ B–
4
lead
motor
Red
Blue
Yellow White
4 Leads
A+
A–
NC
B+
B– NC
6
lead
motor
Red Black
Red/
Wht
Green
Grn/Wht
White A+
A–
NC
B+B– NC
6
lead
motor
Grn/Wht
White
Green
Red
Red/
Wht
Black
6 Leads Series Connected 6 Leads Center Tap Connected

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Eight lead motors can also be connected in two ways: series and parallel. As with six lead motors, series
operation gives you less torque at high speeds, but may result in lower motor losses and less heating. In
series operation, the motor should be operated at 30% less than the unipolar rated current. The wiring
diagrams for eight lead motors are shown below.
A+
A–
B+ B–
8
lead
motor
8 Leads Series Connected 8 Leads Parallel Connected
A+
A–
B+ B–
8
lead
motor
Orange
Org/Wht
Blk/Wht
Black
Red Red/
Wht Yel/
Wht
Yellow
Orange
Org/
Wht
Blk/Wht
Black
Red
Red/Wht
Yel/
Wht
Yel
low

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Connecting an Encoder
The motors recommended for use with STAC6 drives are available with rear-shaft mounted encoders. Note:
remember to always order a double-shaft motor if you need an encoder option. The mating cables available
for these encoders come with an HD-15 connector on one end that connects directly to the Encoder connec-
tor on the STAC6, and a mating connector on the other end that connects directly to the encoder. Simply
connect the cable between the encoder and the drive and you’re done. For applications where you might use
your own encoder, you’ll need to connect to the STAC6 drive’s encoder connector using the pin assignments
below.
encoder Z+ (5)
NC (10)
encoder B- (4)
NC (9)
encoder B+ (3)
NC (13)
NC (14)
NC (15)
(12) NC
(11) NC
(6) encoder Z-
(1) encoder A+
(7) +5VDC 200mA
(2) encoder A-
(8) GND
If you are using an encoder with single ended outputs, shame on you. Differential connections are far less
sensitve to electrical interference and life is too short to waste time deciphering the bizarre problems that
can occur with a poor quality encoder. That said, single ended encoders should be connected to the A+ and
B+ terminals. Leave A- and B- unconnected. They are internally biased to the proper voltage for best results.
You’ll also need to select the “single ended” box in the Encoder button of ST Configurator™ or the drive will
think you have a broken encoder wire. That’s another good reason to use a differential encoder, the STAC6
can detect a broken wire or bad signal and alert you to the problem.

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Encoder Feedback Options
The following encoder feedback options are configured and enabled using the ST Configurator™ software.
Stall Detection continuously compares the actual motor position, as reported by the encoder, against the
theoretical motor position. If the motor lag reaches 7.2 mechanical degrees behind the target position, a
position fault occurs. This includes a motor at rest being driven out of position by an external force.
Stall Prevention can prevent many stalls before they occur. The STAC6 achieves this by using the encoder to
monitor the lead angle of the motor, a measure of torque utilization. If the motion profile begins to demand
more torque than the motor can produce, the velocity is automatically reduced before the motor stalls. To
engage stall prevention, simply check the Stall Prevention box in the ST Configurator™ software and enter
the maximum torque utilization you want to allow.
In the event that the motor cannot move at all, such as hitting a hard stop, you may want to fault the drive
after a given amount of time by checking the Hard Stop box and entering a time limit.

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Wiring Inputs and Outputs
The STAC6 drives come with a number of inputs and outputs for interfacing to external control hardware:
• High speed digital inputs for step & direction commands or encoder following, 5V logic. These
inputs, X1/STEP and X2/DIR, are available on all models. They can also be used to connect
sensors and other types of devices. Connections to these inputs can be sourcing, sinking or
differential.
• Lower speed digital inputs for other signals, 12 - 24 volt logic, accepting sourcing, sinking or
differential signals. All STAC6 models have 5 of these inputs on the IN/OUT1 connector.
• Analog inputs for analog speed and positioning modes, included on all drives. Can be congured
for 0-10V, 0-5V, ±10V or ±5V, with or without offset.
• Digital Outputs rated at 30V, 100mA. There are three outputs on IN/OUT1, which is present on
all models.
Connector Pin Diagram
Front View
X COMMON
X7 / CW Limit
X3 / Enable
X5
X4 / Alarm Reset
Analog IN-
Analog IN+
X2 / DIR-
X2 / DIR+
X1 / STEP +
X1 / STEP -
GND
GND
+5V OUT
Y COMMON
Y3 / FAULT
Y2 / MOTION
Y1 / BRAKE
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
2
3
1
19
20
21
22
23
24
25
X6 / CCW Limit
IN/OUT 1
+5V OUT
+12V OUT
GND
GND
IN/OUT1 connector, this connector
is present on all models

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Connecting Digital Inputs on the IN/OUT1 connector
High Speed Digital Inputs
All STAC6 drives include two high speed inputs called STEP and
DIR. They accept 5 volt single-ended or differential signals, up to
2 MHz. Normally these inputs connect to an external controller
that provides step & direction command signals. You can also
connect a master encoder to the high speed inputs for follow-
ing applications. Or you can use these inputs with Wait Input, If
Input, Feed to Sensor, Seek Home and other such commands.
Connection diagrams follow.
STAC6
Stepper
Drive
IN/OUT 1
COM DIR-
DIR DIR+
STEP-
STEP STEP+
Indexer
with
Sourcing
Outputs
Connecting to indexer with Sourcing Outputs
STAC6
Stepper
Drive
IN/OUT 1
+5V OUT DIR+
DIR DIR-
STEP+
STEP STEP-
Indexer
with
Sinking
Outputs
Connecting to Indexer with Sinking Outputs
inside drive
X1/STEP+
X1/STEP -
11
12
IN/OUT1 Connector
X2/DIR+
X2/DIR -
9
10