Applied Motion Products STR4 User manual

Hardware Manual
STR4 & STR8
Step Motor Drives
920-0030E
2/3/2010
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Contents
Introduction ........................................................................................................................................................................................................................................... 3
Features .................................................................................................................................................................................................................................................... 3
Block Diagram....................................................................................................................................................................................................................................... 4
Geing Started..................................................................................................................................................................................................................................... 5
Mounting the Drive........................................................................................................................................................................................................................... 6
Connecting the Power Supply.................................................................................................................................................................................................... 6
Choosing a Power Supply.............................................................................................................................................................................................................. 8
Voltage ............................................................................................................................................................................................................................................ 8
Current ............................................................................................................................................................................................................................................ 8
Connecting the Motor.................................................................................................................................................................................................................. 11
Four Lead Motor ................................................................................................................................................................................................................... 11
Eight Lead Motor.................................................................................................................................................................................................................... 11
Connecting Input Signals............................................................................................................................................................................................................. 12
Connector Pin Diagram....................................................................................................................................................................................................... 12
Connection Examples: STEP & DIR .............................................................................................................................................................................. 12
Internal Circuit Diagram ...................................................................................................................................................................................................... 12
Connection Examples: EN.................................................................................................................................................................................................. 13
FAULT Output................................................................................................................................................................................................................................... 15
Conguring the Drive.................................................................................................................................................................................................................... 16
Step 1: Selecting a Motor.................................................................................................................................................................................................. 16
STR4 Motor Table............................................................................................................................................................................................................. 16
STR8 Motor Table............................................................................................................................................................................................................. 17
Step 2: Seing the Current ............................................................................................................................................................................................... 17
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......................................................................................................................................................................................................... 26
Motor Heating......................................................................................................................................................................................................................... 32
Drive Heating............................................................................................................................................................................................................................ 40
Mechanical Outline............................................................................................................................................................................................................... 41
Technical Specications...................................................................................................................................................................................................... 42
Mating Connectors and Accessories........................................................................................................................................................................... 43
Alarm Codes............................................................................................................................................................................................................................. 44
Connector Diagrams............................................................................................................................................................................................................. 44

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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 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•
Jumper selectable: 150 kHz or 2 MHz•
Rotary switch easily selects from many popular motors•
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
Automatic self test (switch selectable)•
STR4
Operates from a 24 to 48 volt DC power supply•
Running current up to 4.5 amps per phase•
STR8
Operates from a 24 to 75 volt DC power supply•
Running current up to 7.8 amps per phase•

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Block Diagram
AMPLIFIER
24-48 VDC (STR4)
24-75 VDC (STR8)
from external power supply
Status LEDs
Motor Selection
Current
Idle Current
Steps/Rev
Load Inertia
Self Test
STEP
DIR
OUT1
Overcurrent
Sensors
motor
3.3/5/15V
Regulators
Optical
Isolation
Optical
Isolation
Software
Filter
Digital
Filter
Optical
Isolation
EN
DSP
Voltage
Sensors
4
3
2
1
0
F
E
D
C
B
A
9
8
7
6
5
12345678

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Jumper S4:
Noise Filter Frequency
Jumper S3:
Step & Direction or
Step CW & Step CCW
Remove connectors
and cover to access
jumpers S3 and S4
Geing Started
is manual describes the use of two dierent drive models: the STR4 and STR8. ey dier
in maximum output current and maximum power supply voltage. For both models, you’ll need
the following:
• a24to48voltDCpowersupply(75VmaxforSTR8).Pleasereadthesection Choosing a
Power Supply for help in choosing the right power supply.
• oneofthemotorslistedonthedrivelabel(seesection Conguring the Drive ).
• 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
Run Current, Idle Current
Steps/rev, Inertia, Self Test
Input & Output
Signals
Motor Selector
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 page 40 for more details about drive
heating.
• 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 fuse in line with the + power supply lead. Use a 4 amp fuse for the STR4 and a 7 amp
fuse for the STR8.
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 two powers supplies that are excellent matches for the STR4 and STR8
drives: 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: STR4 Power Supply Current
All motors connected as indicated, except HT24 which have four leads.
Motor Current
(A)
Max Power Supply Current (A)
Switch Motor 24VDC 48VDC
0
reserved for custom motors1
2
3 HT17-068/268 1.6 parallel 1.1 1.1
4 HT17-071/271 2.0 parallel 1.1 1.1
5 HT17-075/275 2.0 parallel 1.1 1.1
6 HT23-394/594 3.4 parallel 1.9 2.0
7 HT23-398/598 4.5 parallel 3.2 3.3
8 HT23-401/601 4.5 parallel 3.2 3.4
9 HT24-100 3.36 2.6 2.3
A HT24-105 4.5 5.2 3.2
B HT24-108 4.5 4.3 3.4
C HT34-485 4.5 series 2.6 2.5
D HT34-486 4.5 series 2.4 2.7
E HT34-504 3.816 series 2.1 2.1
F HT34-505 3.816 series 2.4 2.1

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Motor Current
(A)
Max Power Supply Current (A)
Switch Motor 24VDC 48VDC 60VDC
0
reserved for custom motors
1
2
3
4 HT23-394/594 3.4 1.9 2.0 n/a
5 HT23-398/598 5 3.2 3.3 n/a
6 HT23-401/601 5 3.2 3.4 n/a
7 HT24-100 3.36 2.6 2.3 2.0
8 HT24-105 4.8 5.2 3.2 2.7
9 HT24-108 4.8 4.3 3.4 2.9
A HT34-485 8 5.1 5.0 5.0
B HT34-486 8 5.2 4.6 4.4
C HT34-487 8 5.2 5.4 5.3
D HT34-504 7.56 4.8 4.2 4.0
E HT34-505 7.56 4.4 4.2 4.2
F HT34-506 6.72 3.5 3.2 3.3
Table 2: STR8 Power Supply Current
All motors connected in parallel, except HT24 which have four leads.
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.

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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 S3. See Page 5.
Connector Pin Diagram Internal Circuit Diagram
STEP+
STEP–
DIR–
EN+
EN–
FAULT+ FAULT–
DIR+
inside drive
220 pF
STEP+
STEP-
220 pF
DIR+
DIR-
220 pF
EN+
EN-
FAULT+
FAULT-
Connection Examples: STEP & DIR
Connecting to indexer with Sourcing Outputs
STR
COM DIR-
DIR DIR+
STEP-
STEP STEP+
Indexer
with
Sourcing
Outputs

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Connecting to Indexer with Dierential Outputs
(Many High Speed Indexers have Dierential Outputs)
Connecting to Indexer with Sinking Outputs
STR
+V OUT DIR+
DIR DIR-
STEP+
STEP STEP-
Indexer
with
Sinking
Outputs
STR
DIR+ DIR+
DIR- DIR-
STEP+
STEP-
STEP+
STEP-
Indexer
with
Differential
Outputs
Connecting an Input to a Switch or Relay
STR
switch or relay
(closed=logic low)
EN-
EN+
5-24
VDC
Power
Supply
-
+
Connection Examples: EN

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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-
EN+
Si drive
OUT+
OUT–
5-24
VDC
Power
Supply
-
+
STR
NPN
Proximity
Sensor
EN-
EN+
output
+
–
5-24
VDC
Power
Supply
-
+
Connecting a PNP Type Proximity Sensor to an input
(When prox sensor activates, input closes)
STR
PNP
Proximity
Sensor
EN+
output
+
–
EN-
5-24
VDC
Power
Supply
-
+

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FAULT Output
e STR drives feature 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
STR
5-24 VDC
Power Supply
+ –
Load
FAULT-
FAULT+
!
STR
5-24 VDC
Power Supply
+ –
Load
FAULT-
FAULT+
Sourcing Output
Driving a Relay
STR
FAULT-
FAULT+
1N4935 suppression diode
5-24 VDC
Power Supply
+ –
relay
FAULT+
FAULT-

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Conguring the Drive
Step 1: Selecting a Motor
e STR drives are optimized for use with carefully selected motors. To
select a motor, simply move the rotary switch to the leer or number
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.
If your motor is not on the list, please set the switch to a selection whose rotor inertia, holding
torque and current are within 10% of your motor. Custom congurations can be added for
qualifying applications.
STR4 Motor Table
Current Holding Torque Rotor Inertia
Switch Motor Wiring Aoz-in g-cm2
0
reserved for custom congurations1
2
3 HT17-068/268 parallel 1.6 31.4 35
4 HT17-071/271 parallel 2 51 54
5 HT17-075/275 parallel 2 62.8 68
6 HT23-394/594 parallel 3.4 76.6 120
7 HT23-398/598 parallel 4.5 159.3 300
8 HT23-401/601 parallel 4.5 237.6 480
9 HT24-100 4 leads 3.36 123 280
A HT24-105 4 leads 4.5 166 450
B HT24-108 4 leads 4.5 332 900
C HT34-485 series 4.5 585 1400
D HT34-486 series 4.5 1113 2680
E HT34-504 series 3.816 396 1100
F HT34-505 series 3.816 849 1850

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Step 2: Seing the Current
e maximum current for the motor you have selected is set automatically when you set the
rotary switch. But you may want to reduce the current to save power or lower motor tempera-
ture. 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%.
Two of the small switches on the front of the STR drive are used to set the percent of rated
STR8 Motor Table
Max Current Holding Torque Rotor Inertia
Switch Motor Wiring Aoz-in g-cm2
0
reserved for custom congurations
1
2
3
4 HT23-394/594 parallel 3.4 76.6 120
5 HT23-398/598 parallel 5 177 300
6 HT23-401/601 parallel 5 264 480
7 HT24-100 4 leads 3.36 123 280
8 HT24-105 4 leads 4.8 177 450
9 HT24-108 4 leads 4.8 354 900
A HT34-485 parallel 8 507 1400
B HT34-486 parallel 8 965 2680
C HT34-487 parallel 8 1439 4000
D HT34-504 parallel 7.56 396 1100
E HT34-505 parallel 7.56 849 1850
F HT34-506 parallel 6.72 1260 2750

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current that will be applied to the motor: SW1 and SW2. 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 STR 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.
12
100%
12
90%
12
80%
12
70%
4
50%
4
90%

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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 by seing the rotary switch. To further enhance performance, you must set a switch 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 3 ac-
cordingly, as shown. For assistance in calculating the load inertia of your application contact our
Applications department.
Step 5: Step Size
e STR 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 STR drives 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 STR drive, as shown
in the table on the next page.
3
5-10X
3
0-4X

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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. If you
select “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
567
20000
567
12800
567
5000
567
2000
567
400
SMOOTH
567
400
567
200
SMOOTH
567
200