SureStep STP-DRV-4035 User manual

GettinG Started 1
1
1
Chapter
Chapter
Chapter
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 � � � � � � � � � � � � � � � � � � � �1–7
Standard Microstepping Drives � � � � � � � � � � � � � � � � � � � � � � � � � �1–7
Advanced Microstepping Drive � � � � � � � � � � � � � � � � � � � � � � � � � �1–9
Standard Integrated Motors/Drives � � � � � � � � � � � � � � � � � � � � � �1–10
Advanced Integrated Motors/Drives � � � � � � � � � � � � � � � � � � � � �1–11
Bipolar Step Motor Introduction� � � � � � � � � � � � � � � � � � � � � 1–12
Stepping System Power Supply Introduction � � � � � � � � � � �1–13
Selecting the Stepping System � � � � � � � � � � � � � � � � � � � � � �1–14
Use with AutomationDirect PLCs � � � � � � � � � � � � � � � � � � � � 1–14
High-Speed Pulse Output Control (Standard Drives) � � � � � � � � �1–14
Serial Communication Control (Advanced Drives) � � � � � � � � � � �1–14

Chapter 1: Getting Started
SureStepTM Stepping Systems User Manual
1–2 5th Ed., Rev. B 01/2019
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: [phone]
(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 “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).
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.

SureStepTM Stepping Systems User Manual 1–3
Chapter 1: Getting Started
5th Ed., Rev. B 01/2019
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-DRV- 6575
Component Capacity
2-digit max nominal voltage followed by
max current with 1 implied decimal place
4035: 40V, 3.5 A
4850: 48V, 5.0 A
6575: 65V, 7.5 A
80100: 80V, 10.0 A
Component Type
DRV: stepper drive
DRVA: drive accessory
SureStep Series Designation: STP
Motors
STP-MTRx-23079 x
Component Capacity
2-digit NEMA frame size followed by
approximate stack* length in mm
Component Type
MTRL: low-power stepper motor
MTR: high-power stepper motor
MTRH: higher-power stepper motor
MTRA: motor accessory
SureStep Series Designation:
STP
Motor Shaft Type/Variant
blank: single shaft
D: dual shaft
E: encoder pre-mounted
W: IP65 (washdown)
* The length of the motor that produces torque

Chapter 1: Getting Started
SureStepTM Stepping Systems User Manual
1–4 5th Ed., Rev. B 01/2019
Power Supplies
STP-PWR-3204
Component Capacity
2-digit output voltage followed by
output current
Component Type
PWR: power supply
SureStep Series Designation:
STP
Integrated Motors/Drives
STP-MTRD-23042 x
Component Capacity
2-digit NEMA frame size followed by
approximate stack* length in mm
Component Type
MTRD: integrated motor/drive
SureStep Series Designation: STP
Integrated Drive Type
blank: Standard
R: Advanced
V: Variable I/O
E: Encoder included
* The length of the motor that produces torque
Cables and Accessories
SureStep Cables & Accessories
Part Number Description
STP-EXTx-xx Motor extension cable, xx = cable length in feet,
x=H for high power, L for low power, W for IP65
STP-DRVA-xx Drive accessory, xx= accessory descriptor
STP-MTRA-xx Motor accessory, xx = accessory descriptor
Note: See Appendix A for the full range of SureStep accessories

SureStepTM Stepping Systems User Manual 1–5
Chapter 1: Getting Started
5th Ed., Rev. B 01/2019
SureStep™ System Recommended Component Compatibility
SureStep Power Supply / Drive Compatibility
Drive (1)(2) Recommended Linear Power Supply (1)(2)(3)
Model Number STP-PWR
-3024
STP-PWR
-4805
STP-PWR
-4810
STP-PWR
-7005(3)
STP-DRV-4035
12-32 VDC input (40V max) √No No No
STP-DRV-4850
24-48 VDC input (48V max) √√√No
STP-DRV-6575
24-65 VDC input (65V max) √√√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. If using a non-STP linear
power supply, ensure that the unloaded voltage does not oat 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 oat above the allowable input voltages of some drives if it is fed
with a high AC input voltage (greater than 120VAC).
SureStep Power Supply / Drive Compatibility
Drive (1)(2) Recommended Switching Power Supply (1)(2)
Model Number PSB12-xxxS PSB24-xxxS PSB48-xxxS
STP-DRV-4035
12-32 VDC input (40V max) √ √ No
STP-DRV-4850
24-48 VDC input (48V max) No √ √
STP-DRV-6575
24-65 VDC input (65V max) No √ √
STP-DRV-80100
24-80 VDC input (80V max) No √ √
STP-MTRD-17
12-48 VDC input √√√
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.

Chapter 1: Getting Started
SureStepTM Stepping Systems User Manual
1–6 5th Ed., Rev. B 01/2019
SureStep Drive / Motor Compatibility(3)
Motor (1)(2) Recommended Drive (1)
Model Number (1)(2)
Rated
Amps
Extension
Cable
STP-DRV
-4035(1)
(3.5A max
output)
STP-DRV
-4850(1)
(5.0A max
output)
STP-DRV
-6575(1)
(7.5A max
output)
STP-DRV
-80100(1)
(10.0A max
output)
STP-MTRL-14026x 0.35 STP-
EXTL-
0xx
√ √ – –
STP-MTRL-14034x 0.8 √ √ – –
STP-MTR-17040x 1.7
STP-
EXTx-
0xx
√ √ √ √
STP-MTR-17048x 2.0 √ √ √ √
STP-MTR-17060x 2.0 √ √ √ √
STP-MTR-23055x 2.8 √ √ √ √
STP-MTR-23079x 2.8 √ √ √ √
STP-MTR-34066x 2.8 √ √ √ √
STP-MTRH-23079x 5.6
STP-
EXTHx-
0xx
–
√ √
STP-MTRH-34066x 6.3 √ √
STP-MTRH-34097x 6.3 √ √
STP-MTRH-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.

SureStepTM Stepping Systems User Manual 1–7
Chapter 1: Getting Started
5th Ed., Rev. B 01/2019
Microstepping Drives Introduction
There are two different basic types of microstepping drives offered in the
SureStep™ series. Two 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-6575
The SureStep™ STP-DRV-6575 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:
• A 24–65 VDC power supply for the motor drive. SureStep STP-PWR-3204 or STP-
PWR-48xx linear 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 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 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.
The STP-DRV-6575 standard microstepping drive is an enclosed design.
Refer to the “SureStep STP-DRV-6575 Microstepping Drive” chapter of this user
manual for complete details on the installation, configuration, and wiring of this
drive.
STP-DRV-6575

Chapter 1: Getting Started
SureStepTM Stepping Systems User Manual
1–8 5th Ed., Rev. B 01/2019
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.
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.
STP-DRV-4035

SureStepTM Stepping Systems User Manual 1–9
Chapter 1: Getting Started
5th Ed., Rev. B 01/2019
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.
Refer to the “SureStep™ Advanced Microstepping Drives” chapter of this user
manual for complete details on the installation, configuration, and wiring of this
drive.
STP-DRV-80100

Chapter 1: Getting Started
SureStepTM Stepping Systems User Manual
1–10 5th Ed., Rev. B 01/2019
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.
Refer to Chapter 5: “SureStep Integrated Motors/Drives” for complete details on
the installation, configuration, and wiring of this motor/drive.
STP-MTRD-23042

SureStepTM Stepping Systems User Manual 1–11
Chapter 1: Getting Started
5th Ed., Rev. B 01/2019
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.
Refer to Chapter 5: “SureStep Integrated Motors/Drives” for complete details on
the installation, configuration, and wiring of this motor/drive.
STP-MTRD-17038RE

Chapter 1: Getting Started
SureStepTM Stepping Systems User Manual
1–12 5th Ed., Rev. B 01/2019
Bipolar Step Motor Introduction
AutomationDirect offers many different models of bipolar step motors with
mounting flanges in two different shaft configurations (single and dual-shaft), and
in four different NEMA frame sizes (14, 17, 23, and 34). There are a variety of
motor types available: low torque (STP-MTRL), high torque (STP-MTR), and higher
torque (STP-MTRH). 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 except for the NEMA 34 motors are
encoder ready with pre-drilled and tapped holes on the rear face for encoder
mounting. All of the motors have a 12 inch connectorized pigtail 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.
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.
STP-MTRx Motors Available in Single-shaft, Dual-shaft (encoder
ready), Encoder Mounted, and IP65 (washdown) Models
STP-MTRx
NEMA 14, 17, 23, 34
Frame Sizes

SureStepTM Stepping Systems User Manual 1–13
Chapter 1: Getting Started
5th Ed., Rev. B 01/2019
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, PSB24-
xxxS, 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 7: “SureStep System 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
REGENERATION CLAMP datasheet.
Linear Power
Supplies
Switching Power Supplies

Chapter 1: Getting Started
SureStepTM Stepping Systems User Manual
1–14 5th Ed., Rev. B 01/2019
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 high-
speed 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.