Applied Motion Products STR2 User manual

Hardware Manual
STR2
Step Motor Drive
920-0059A
4/20/2012

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Contents
Safety Instructions ............................................................................................................................................................................................................................. 3
Introduction........................................................................................................................................................................................................................................... 5
Features .................................................................................................................................................................................................................................................... 5
Block Diagram....................................................................................................................................................................................................................................... 6
Geing Started..................................................................................................................................................................................................................................... 7
Mounting the Drive........................................................................................................................................................................................................................... 8
Connecting the Power Supply.................................................................................................................................................................................................... 8
Choosing a Power Supply........................................................................................................................................................................................................... 10
Voltage ......................................................................................................................................................................................................................................... 10
Current ......................................................................................................................................................................................................................................... 10
Multiple Drives Sharing One Power Supply ........................................................................................................................................................... 11
System Wiring Recommendations ......................................................................................................................................................................................... 12
Connecting the Motor.................................................................................................................................................................................................................. 13
Four Lead Motor ................................................................................................................................................................................................................... 13
Eight Lead Motor.................................................................................................................................................................................................................... 13
Connecting Input Signals............................................................................................................................................................................................................. 14
Connector Pin Diagram....................................................................................................................................................................................................... 14
Connection Examples: STEP & DIR .............................................................................................................................................................................. 14
Internal Circuit Diagram...................................................................................................................................................................................................... 14
Connection Examples: EN.................................................................................................................................................................................................. 15
FAULT Output................................................................................................................................................................................................................................... 16
Conguring the Drive.................................................................................................................................................................................................................... 17
Step 1: Selecting a Motor and Seing the Current............................................................................................................................................. 17
Step 2: Fine Tuning the Motor Current ..................................................................................................................................................................... 18
Step 3: Seing Idle Current.............................................................................................................................................................................................. 18
Step 4: Load Inertia.............................................................................................................................................................................................................. 19
Step 5: Step Size...................................................................................................................................................................................................................... 19
Step 6: Step Pulse Type...................................................................................................................................................................................................... 21
Step 7: Step Pulse Noise Filter......................................................................................................................................................................................... 22
Self Test................................................................................................................................................................................................................................................. 22
Reference Materials........................................................................................................................................................................................................................ 23
Motor Outlines........................................................................................................................................................................................................................ 23
Torque-Speed Curves......................................................................................................................................................................................................... 25
Motor Heating......................................................................................................................................................................................................................... 30
Drive Heating............................................................................................................................................................................................................................ 34
Mechanical Outline............................................................................................................................................................................................................... 35
Technical Specications...................................................................................................................................................................................................... 36
Mating Connectors and Accessories........................................................................................................................................................................... 37
Alarm Codes............................................................................................................................................................................................................................. 38
Connector Diagrams............................................................................................................................................................................................................. 38

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Safety Instructions
Only qualied personnel are permied to transport, assemble, commission, and maintain
this equipment. Properly qualied personnel are persons who are familiar with the transport,
assembly, installation, commissioning and operation of motors, and who have the appropri-
ate qualications for their jobs. e qualied 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 na-
tional codes that regulate the installation and operation of your equipment. ese codes vary
from area to area and it is your responsibility to determine which codes should be followed,
and to verify that the equipment, installation, 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 ap-
plicable codes and standards. We do not guarantee the products described in this publica-
tion are suitable for your particular 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 impossible without a low-resistance earth connection.
• e STR2 contains electrostatically sensitive components that can be damaged by incorrect
handling. Discharge yourself before touching the product. Avoid contact with high insulating
materials (articial fabrics, plastic lm, etc.). Place the product on a conductive surface.
• During operation keep all covers and cabinet doors shut. Otherwise, there are deadly hazards
that could possibility cause severe damage to health or the product.

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• 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 volt-
age even when the motor is not rotating.
• Never pull out or plug in the product while the system is live. ere is a danger of electric arc-
ing and danger to persons and contacts.
• Aer 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 aer power has been switched o. To be
safe, measure the contact points with a meter before touching.
Be alert to the potential for personal injury. Follow the recommended precautions and safe
operating practices. Safety notices in this manual provide important information. Read and be
familiar with these instructions before aempting installation, operation, or maintenance. e
purpose of this section is to alert users to possible safety hazards associated with this equip-
ment and the precautions that need to be taken to reduce the risk of personal injury and dam-
age to the equipment. Failure to observe these precautions could result in serious bodily injury,
damage to the equipment, or operational diculty.

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Introduction
ank you for selecting an Applied Motion Products motor control. We hope our dedication
to performance, quality and economy will make your motion control project successful.
If there’s anything we can do to improve our products or help you use them beer, please call
or fax. We’d like to hear from you. Our phone number is [phone], or you can reach us
by fax at [phone]. You can also email [e-mail].
Features
• Low cost, digital step motor driver in compact package
• Operates from a 12 to 48 volt DC power supply
• Running current up to 2.2 amps per phase
• Operates from Step & Direction signals or Step CW & Step CCW (jumper selectable)
• Enable input
• Fault output
• Optically isolated I/O
• Digital lters prevent position error from electrical noise on command signals
• switch selectable: 150 kHz or 2 MHz
• Electronic damping and anti-resonance
• 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), 2000, 5000, 12800, or
20000 steps/rev
• Switch selectable microstep emulation provides smoother, more reliable motion in full and
half step modes
• Self test (switch selectable)

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Block Diagram
AMPLIFIER
12-48 VDC
from external power supply
Status LEDs
Run Current
STEP
DIR
EN
OUT
Overcurrent
Sensors
motor
3.3/5/15V
Regulators
Optical
Isolation
Digital
Filter
Optical
Isolation
DSP
Voltage
Sensors
123456781234
Motor Selection
Steps/rev
Step Pulse Type
Load Inertia
Idle Current
Step Noise Filter
Self Test

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Geing Started
To use your STR2 step motor drive, you’ll need the following:
• a 12 to 48 volt DC power supply. Please read the section Choosing a Power Supply for
help in choosing the right power supply.
• one of the motors listed recommended in this manual.
• a small at blade screwdriver for tightening the connectors.
• a source of step signals, such as a PLC or motion controller.
e connectors and other points of interest are illustrated below. ese are detailed later in
the manual.
Motor &
Power Supply
Connector
SWITCH A
Self Test
Step Noise Filter
Idle Current
Run Current
Steps/rev
Input & Output
Signals
SWITCH B
Motor Selection
Load Inertia
Status LEDs

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Mounting the Drive
You can mount your drive on the wide or the narrow side of the chassis using #6 screws. If
possible, the drive should be securely fastened to a smooth, at metal surface that will help
conduct heat away from the chassis. If this is not possible, then forced airow from a fan may be
required to prevent the drive from overheating. See “Drive Heating” for more details.
• Never use your drive in a space where there is no air ow or where other devices
cause the surrounding air to be more than 50°C.
• Never put the drive where it can get wet or where metal or other electrically con-
ductive particles can get on the circuitry.
• Always provide air ow around the drive. When mounting multiple drives near
each other, maintain at least one half inch of space between drives.
Connecting the Power Supply
If you need information about choosing a power supply, please read the section Choosing a
Power Supply .
• Connect the power supply “+” terminal to the connector terminal labeled “V+”.
• Connect power supply “-” to the connector terminal labeled “V-”.
• e green ground screw on the corner of the chassis should be connected to earth ground.
• Use 18 or 20 gauge wire.
e STR drives contain an internal fuse that connects to the power supply + terminal. is fuse
is not user replaceable. If you want to install a user serviceable fuse in your system install a fast
acting 3 amp fuse in line with the + power supply lead.
Be careful not to reverse the wires. Reverse connection will destroy your
drive, void your warranty and generally wreck your day.
!

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If you plan to use a regulated power supply you may encounter a problem with regeneration.
If you rapidly decelerate a load from a high speed, much of the kinetic energy of that load is
transferred back to the power supply. is can trip the overvoltage protection of a switching
power supply, causing it to shut down. We oer the RC-050 “regeneration clamp” to solve this
problem. If in doubt, buy an RC-050 for your rst installation. If the “regen” LED on the RC-050
never ashes, you don’t need the clamp.
RC-050 Regen Clamp
Power Supply and Ground Connections
Locate fuse in-line with “+” connection
regen LED

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Choosing a Power Supply
When choosing a power supply, there are many things to consider. If you are manufacturing
equipment that will be sold to others, you probably want a supply with all the safety agency
approvals. If size and weight are an issue get a switching supply.
And you must decide what size of power supply (in terms of voltage and current) is needed for
your application.
Applied Motion oers three powers supplies that are excellent matches for the STR2 drive:
PS50A24 (24V, 2.1A), PS150A24 (24V, 6.3A) and PS320A48 (48V, 6.7A).
Voltage
Your motor can provide more torque at higher speeds if a higher power supply voltage is used.
Please consult the speed-torque curves later in this manual for guidance.
If you choose an unregulated power supply, make sure the no load voltage of the supply does
not exceed the drive’s maximum input voltage specication.
Current
e maximum supply current you could ever need is two times the motor current. However,
you will generally need a lot less than that, depending on the motor type, voltage, speed and
load conditions. at’s because the STR uses a switching amplier, converting a high voltage
and low current into lower voltage and higher current. e more the power supply voltage ex-
ceeds the motor voltage, the less current you’ll need from the power supply. A motor running
from a 48 volt supply can be expected to draw only half the supply current that it would with a
24 volt supply.
We recommend the following selection procedure:
1. If you plan to use only a few drives, get a power supply with at least twice “per
phase” current rating of the step motor. Example: for a motor that’s rated for 2 A/phase use a 4
A power supply..
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. is will tell you how much current you really need so you can design in a lower cost

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power supply.
e tables below and on the net page list the maximum current required for each motor at sev-
eral common power supply voltages. Please consider this information when choosing a power
supply.
Table 1: STR2 Power Supply Current
All motors connected as indicated.
Multiple Drives Sharing One Power Supply
You can use one supply to power multiple drives. e worst case condition occurs when all the
drives are running simultaneously. In this case, just add up the power supply currents for each to
determine the total power supply current requirement.
Motor Connection Current
Seing (A)
Max Power Supply Current (A)
12VDC 24VDC 48VDC
HT08-020 4 leads 0.42 0.95A 0.95A N/A
HT08-021 4 leads 0.42 0.95A 0.95A N/A
HT11-012 4 leads 1.20 0.6A 0.6A N/A
HT11-013 4 leads 1.20 0.95A 0.95A N/A
5014-842 4 leads 1.20 0.87A 0.87A N/A
HT17-268 parallel 1.61 1.0A 1.0A 1.0A
HT17-271 parallel 2.04 1.3A 1.3A 1.3A
HT17-275 parallel 2.04 1.32A 1.32A 1.32A
HT23-595 series 2.20 1.36A 1.36A 1.36A
HT23-598 series 2.20 1.56A 1.56A 1.56A
HT23-601 series 2.20 1.4A 1.4A 1.4A

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Regeneration
If you plan to use a regulated power supply you may encounter a problem with regeneration.
If you rapidly decelerate a load from a high speed, much of the kinetic energy of that load is
transferred back to the power supply. is can trip the overvoltage protection of a switching
power supply, causing it to shut down. Unregulated power supplies are beer because they
generally do not have overvoltage protection and have large capacitors for storing energy
coming back from the drive. ey are also less expensive. See previous section on Connecting
the Power Supply for details on the RC-050 regeneration clamp.
System Wiring Recommendations
1. Separate the DC power supply cable by at least 2” from the small signal input cable and the
encoder feedback cable.
2. A shielded cable for the DC power supply connections will result in a quieter system.
Ground the shield at the power supply.
3. A shielded cable is recommended for the small signal connections. Ground the shield at
the signal source.

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Connecting the Motor
Never connect or disconnect the motor while the power is on.
If the motor has a shield or grounding wire, please connect it to the chassis
ground screw located on the chassis near the motor-power connector.
Four Lead Motor
ese motors can only be connected one way. Please follow the sketch
below.
!
V+ V
-
A
-
A+
MOTOR
B+ B
-
MOTOR/POWER
CONNECTOR
A+
A–
B+ B–
4
lead
motor
Red
Blue
Yellow White
4 Leads
Chassis Ground Screw
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
Eight Lead Motor
ese motors can be connected in series or parallel. A series connected motor needs less cur-
rent than one that is connected in parallel but it will not be able to run as fast. Once you have
determined which way you want to connect your motor to the drive, please follow the wiring
diagrams below.

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Connecting Input Signals
e STR drives 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 5-24V 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 the inter-
nal jumper. See “Step 6: Step Pulse Type”.
Connector Pin Diagram Internal Circuit Diagram
STEP
DIR
EN
OUT+
OUT–
COM+
inside drive
220 pF
COM+
STEP
220 pF
DIR
220 pF
EN
OUT+
OUT-
Connecting to Indexer with Sinking Outputs
STR2
+V OUT COM+
DIR DIR
STEP STEP
Indexer
with
Sinking
Outputs
Connection Examples: STEP & DIR
See “System Wiring Recommendations” for cable instructions

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Connecting an Input to a Switch or Relay
STR2
switch or relay
(closed=logic low)
EN
COM+
5-24
VDC
Power
Supply
-
+
Connection Examples: EN
Connecting another drive to EN
(When output closes, input closes)
Connecting an NPN Type Proximity Sensor to an input
(When prox sensor activates, input closes)
STR
EN
COM+
-
+
Si drive
OUT+
OUT–
5-24
VDC
Power
Supply
STR2
NPN
Proximity
Sensor
EN
COM+
output
+
–
5-24
VDC
Power
Supply
-
+

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FAULT Output
e STR2 features a digital FAULT output. is output closes to
signal a fault condition.
is output can be used to drive LEDs, relays and the inputs of
other electronic devices like PLCs. e “+” (collector) and “-” (emier) terminals of the output
transistor are available at the connector. is allows you to congure the output for current
sourcing or sinking.
Diagrams of each type of connection follow.
Do not connect the output to more than 30VDC.
e current through the output terminal must not exceed 80 mA.
Sinking Output
STR2
5-24 VDC
Power Supply
+ –
Load
OUT-
OUT+
!
STR2
5-24 VDC
Power Supply
+ –
Load
OUT-
OUT+
Sourcing Output
Driving a Relay
STR2
OUT-
OUT+
1N4935 suppression diode
5-24 VDC
Power Supply
+ –
relay
FAULT+
FAULT-

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Conguring the Drive
Step 1: Selecting a Motor and Seing the Current
e STR2 is optimized for use with carefully selected motors. To select a motor, simply move
switches B1, B2 and B3 to the seing that corresponds to the motor of your choice. You can do
this while power is on, but it is safer to select the motor before applying power to the drive so
that you do not risk applying too much current to your motor.
Motor Wiring Current
Seing (A)
Holding Torque
(oz-in)
Rotor Inertia
(g-cm2)Switch B
HT08-020 4 leads 0.42 2.4 1.9
123
HT08-021 4 leads 0.42 4.4 4.0
123
HT11-012 4 leads 1.20 7.4 8
123
HT11-013 4 leads 1.20 15.3 18
123
5014-842 4 leads 1.20 26 20
123
HT17-268 parallel 1.61 31 38
123
HT17-271 parallel 2.04 52 57
123
HT17-275 parallel 2.04 78 82
123
HT23-595 series 2.20 76 135
123
HT23-598 series 2.20 158 260
123
HT23-601 series 2.20 269 460
123

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Step 2: Fine Tuning the Motor Current
e maximum current for the motor you have selected was set automatically when you selected
the motor in Step1. But you may want to reduce the current to save power or lower motor
temperature. is 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%.
Switches A4 and A5 on the front of the STR2 drive are used to set the percent of rated current
that will be applied to the motor. Please set them according to the illustration below.
Step 3: Seing Idle Current
Motor heating and power consumption can also be reduced by lowering the motor current
when it is not moving. e STR2 will automatically lower the motor current when it is idle to
either 50% or 90% of the running current. e 50% idle current seing will lower the holding
torque to 50%, which is enough to prevent the load from moving in most applications. is
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 below. e idle current switch is located in switch bank A, on the front of the STR2.
3
50%
3
90%
45
100%
45
90%
45
80%
45
70%

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Step 4: Load Inertia
e STR drives include 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 you select the
motor using switches B1, B2 and B3. To further enhance performance, you must set switch B4
to indicate the approximate inertia ratio of the load and motor. e ranges are 0 to 4X and 5 to
10X. e motors table shown in Step 1 of this section include the rotor inertia of each motor.
Please divide the load inertia by the rotor inertia to determine the ratio, then set switch B4 as
shown. For assistance in calculating the load inertia of your application contact our Applications
department.
Step 5: Step Size
e STR2 requires a source of step pulses to command motion. is may be a PLC, an indexer,
a motion controller or another type of device. e 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. e smallest step size of the STR2 is
1/20,000th of a motor turn. To command a motor speed of 50 revolutions per second (3000
rpm) the step pulses frequency must be 50 x 20,000 = 1 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. Six dierent seings are provided in the STR2 drive, as shown
in the table on the next page.
4
5-10X
4
0-4X

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678
200
678
200
SMOOTH
678
400
678
400
SMOOTH
678
2000
678
5000
678
12800
678
20000
Please choose the one that best matches the capability of your system.
At lower step resolutions such as 200 steps/ rev (full step) and 400 steps/rev (half step), motors
run a lile rough and produce more audible noise than when they are microstepped (2000
steps/rev and beyond). e STR drives include a feature called “microstep emulation”, also
called “step smoothing”, that can provide smooth motion from coarse command signals. By
selecting “200 smooth” or “400 smooth”, this feature is automatically employed to provide the
smoothest possible motion from a less than ideal signal source.
Because a command lter is used as part of the step smoothing process, there will be a slight
delay, or “lag” in the motion. If this delay is objectionable for your application, please choose
the non-ltered seing “200” or “400”. e chart on the next page shows an example of the
delay that can occur from using the step smoothing lter.