PANDRIVE™
PANdrive™ for Stepper
PD42-x-1240 Hardware Manual
Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
The PANdrive™PD42-1-1240, PD42-2-1240, PD42-3-1240 amd PD42-4-1240 are small and compact full
mechatronic solutions including NEMA17 / 42mm flange size stepper motors, the TMCM-1240 controller / driver electronics and TRINAMIC™sensOstep™encoder for step-loss detection.
Features
•
•
•
•
•
•
•
•
Stepper Motor NEMA17 / 42mm
0.22 - 0.7Nm
with controller/driver
Linear and sixPoint™ ramps
+10. . . 30V DC supply voltage
Up to 2A RMS motor current
RS485, CAN & USB interface
integrated sensOstep encoder and
support for external encoder
• S/D interface
• multi-purpose inputs and outputs
Applications
• Laboratory Automation
• Manufacturing
• Semiconductor Handling
• Robotics
• Factory Automation
• Test & Measurement
Simplified Block Diagram
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at: www.trinamic.com
Read entire documentation.
• Life Science
• Biotechnology
• Liquid Handling
2 / 34
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
Contents
1 Features
4
2 Order Codes
6
3 Mechanical and Electrical Interfacing
8
3.1 Dimensions of PD42-x-1240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.2 Stepper motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.3 Integrated sensOstep™ encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Connectors
4.1 Power Supply Input Connector
4.2 Motor Connector . . . . . . . .
4.3 RS485 + CAN Connector . . . .
4.4 USB Connector . . . . . . . . .
4.5 I/O Connector . . . . . . . . . .
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11
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5 On-Board LEDs
15
6 Reset to Factory Defaults
15
7 I/Os
7.1 Analog input IN0 . . . . . . . . . . . .
7.2 Digital inputs IN1 and IN2 . . . . . . .
7.3 HOME/STOP_L/STOP_R switch inputs
7.4 External incremental encoder input .
7.5 Step/Direction inputs . . . . . . . . . .
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17
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8 Communication
20
8.1 RS485 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.2 CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9 Motor driver current
10 Torque curves
10.1 PD42-1-1240 Torque Curve
10.2 PD42-2-1240 Torque Curve
10.3 PD42-3-1240 Torque Curve
10.4 PD42-4-1240 Torque Curve
22
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24
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11 Functional Description
26
12 Operational Ratings and Characteristics
27
13 Abbreviations used in this Manual
29
14 Figures Index
30
15 Tables Index
31
16 Supplemental Directives
16.1 Producer Information . . . . . . . . . .
16.2 Copyright . . . . . . . . . . . . . . . . . .
16.3 Trademark Designations and Symbols .
16.4 Target User . . . . . . . . . . . . . . . .
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©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
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PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
3 / 34
16.5 Disclaimer: Life Support Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
16.6 Disclaimer: Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
16.7 Collateral Documents & Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
17 Revision History
34
17.1 Hardware Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
17.2 Document Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
1
4 / 34
Features
The PANdrive™PD42-1-1240, PD42-2-1240, PD42-3-1240 amd PD42-4-1240 are small and compact full
mechatronic solutions including NEMA17 / 42mm flange size stepper motors, the TMCM-1240 controller /
driver electronics and TRINAMIC™sensOstep™encoder for step-loss detection. The four PANdrives include
stepper motor with different lengths and different holding torques (PD42-1-1240: 0.22Nm, PD42-2-1240:
0.36Nm, PD42-3-1240: 0.44Nm and PD42-4-1240: 0.7Nm) but, same electronics and encoder setup. The
PANdrives support both, stand-alone operation e.g. using the on-board I/Os together with the build-in
TMCL scripting feature and remote operation using one of the available communication interfaces and
even a mixture of both.
Motion Controller
• Motion profile calculation in real-time
• On the fly alteration of motor parameters (e.g. position, velocity, acceleration)
• Linear and unique sixPoint™ramp in hardware
• Encoder interface and Reference / Stop switch inputs
Driver
• Motor current: up to 2A RMS (2.2A RMS max. / 3.1A peak, programmable in software)
• Supply voltage: +24V DC (+10. . . +30V DC)
• 256 microsteps per fullstep
• spreadCycle™highly dynamic current control chopper
• stealthChop™for quiet operation and smooth motion
• programmable Step/Dir interface for driver-only applications with microstep interpolation
Encoder
• integrated sensOstep absolut position magnetic encoder (resolution: 1024 increments per rotation)
for step-loss detection under all operating conditions and positioning supervision (accuracy: +/- 5
encoder steps)
• support for external A/B incremental encoder in addition / as an alternative for the integrated encoder
• programmable encoder scaling and support for motor stop on encoder deviation
Interfaces
• RS485 interface (up-to 1Mbit/s)
• CAN interface (up-to 1Mbit/s)
• USB 2.0 full speed (12Mbit/s) device interface (micro-USB connector)
• Step/Dir input (optically isolated)
• Left and Right STOP switch inputs (optically isolated, shared with Step/Dir inputs)
• 2 general purpose digital inputs
• Encoder input for incremental A/B encoder signals (shared with general purpose digital inputs)
• 1 analog input (0..10V nom. input range)
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
5 / 34
• HOME switch input (shared with analog input)
Software
• TMCL™ remote (direct mode) and standalone operation (memory for up to 1024 TMCL™ commands),
fully supported by TMCL-IDE (PC based integrated development environment). Please see PD42-x1240 TMCL firmware manual for more details
• CANopen firmware with CANopen standard protocol stack for the CAN interface. Please see PD42x-1240 CANopen firmware manual for more details.
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
2
6 / 34
Order Codes
The combination of motor and motor mounted controller/driver electronic is currently available with four
stepper motors (different length and holding torque):
The length of the PANdrives is specified without the length of the axis. For the overall length of the product
please add 26mm
Order Code
Description
Size (LxWxH)
PD42-1-1240-TMCL
PANdrive™with NEMA17 stepper motor, 0.22Nm
max. TMCM-1240 electronics, 2A RMS, +24V,
RS485, CAN, USB, sensOstep™encoder, TMCL
firmware
42mm x 42mm x 47mm
PD42-2-1240-TMCL
PANdrive™with NEMA17 stepper motor, 0.36Nm
max. TMCM-1240 electronics, 2A RMS, +24V,
RS485, CAN, USB, sensOstep™encoder, TMCL
firmware
42mm x 42mm x 51mm
PD42-3-1240-TMCL
PANdrive™with NEMA17 stepper motor, 0.44Nm
max. TMCM-1240 electronics, 2A RMS, +24V,
RS485, CAN, USB, sensOstep™encoder, TMCL
firmware
42mm x 42mm x 60mm
PD42-4-1240-TMCL
PANdrive™with NEMA17 stepper motor, 0.7Nm
max. TMCM-1240 electronics, 2A RMS, +24V,
RS485, CAN, USB, sensOstep™encoder, TMCL
firmware
42mm x 42mm x 73mm
PD42-1-1240-CANopen
PANdrive™with NEMA17 stepper motor, 0.22Nm
max. TMCM-1240 electronics, 2A RMS, +24V,
RS485, CAN, USB, sensOstep™encoder, CANopen
firmware
42mm x 42mm x 47mm
PD42-2-1240-CANopen
PANdrive™with NEMA17 stepper motor, 0.36Nm
max. TMCM-1240 electronics, 2A RMS, +24V,
RS485, CAN, USB, sensOstep™encoder, CANopen
firmware
42mm x 42mm x 51mm
PD42-3-1240-CANopen
PANdrive™with NEMA17 stepper motor, 0.44Nm
max. TMCM-1240 electronics, 2A RMS, +24V,
RS485, CAN, USB, sensOstep™encoder, CANopen
firmware
42mm x 42mm x 60mm
PD42-4-1240-CANopen
PANdrive™with NEMA17 stepper motor, 0.7Nm
max. TMCM-1240 electronics, 2A RMS, +24V,
RS485, CAN, USB, sensOstep™encoder, CANopen
firmware
42mm x 42mm x 73mm
Table 1: Order Code
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
7 / 34
A cable loom set is available for this module:
Order Code
Description
TMCM-1240-CABLE
Cable loom for TMCM-1240:
• 1x cable loom for power supply connector (cable length 200mm, 4pin
JST PH connector at one end, open wires at the other end)
• 1x cable loom for RS485 + CAN connector (cable length 200mm, 5pin
JST PH connector at one end, open wires at the other end)
• 1x cable loom for motor connector (cable length 200mm, 4pin JST PH
connector at one end, open wires at the other end)
• 1x cable loom for I/O connector (cable length 200mm, 8pin JST PH
connector at one end, open wires at the other end)
• 1x Micro-USB cable
Table 2: TMCM-1240 Cable Loom
The TMCM-1240 controller/driver electronics is also available separately. Please refer to TMCM-1240 hardware manual for further details.
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
3
8 / 34
Mechanical and Electrical Interfacing
All PD42-x-1240 consist of one out of four available NEMA17 / 42mm stepper motors with 2A RMS rated coil
current with the same TMCM-1240 controller / driver electronics mounted on its backside and integrated
sensOstep™encoder. The PD42-1-1240 uses the QSH4218-34-20-022 stepper motor with 0.22Nm holding
torque, the PD42-2-1240 uses the QSH4218-38-20-036 stepper motor with 0.36Nm holding torque, the
PD42-3-1240 uses the QSH4218-47-20-044 stepper motor with 0.44Nm holding torque and the PD42-41240 uses the QSH4218-60-20-070 stepper motor with 0.7Nm holding torque. Please see also stepper
motor manuals and TMCM-1240 hardware and firmware manuals for more details.
NOTICE
3.1
Note: In order to make proper use of the integrated sensOstep™encoder (the
sensor IC is placed on the bottom of the pcb) the TMCM-1240 electronics should
not be removed/moved relative to the motor. In case the integrated encoder
feature is not used, the electronics may be moved or even removed from the
motor and placed somewhere else according to application requirements.
Dimensions of PD42-x-1240
Figure 1: PD42-x-1240 with different NEMA17 / 42mm stepper motors (all dimensions in mm)
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
9 / 34
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
3.2
Stepper motor
Main characteristics of the four different motors available as part of the PD42-x-1240 PANdrive™:
Specifications
Unit
PD42-1-1240
PD42-2-1240
PD42-3-1240
PD42-4-1240
Step angle
°
1.8
1.8
1.8
1.8
Step angle accuracy
%
+/-5
+/-5
+/-5
+/-5
Ambient temperature
°C
-20. . . +50
-20. . . +50
-20. . . +50
-20. . . +50
Max. motor temperature
°C
80
80
80
80
Shaft radial play (450g load)
mm
0.02
0.02
0.02
0.02
Shaft axial play (450g load)
mm
0.08
0.08
0.08
0.08
Max radial force (20mm
from front flange)
N
28
28
28
28
Max axial force
N
10
10
10
10
Rated voltage
V
2.0
2.4
2.4
4.4
Rated phase current
A
2.0
2.0
2.0
2.0
Phase resistance at 20°C
Ω
1.0
1.2
1.4
2.3
Phase inductance (typ.)
mH
1.6
2.2
2.1
6.0
Holding torque
Nm
0.22
0.36
0.44
0.70
B
B
B
B
g cm2
35
57
68
102
kg
0.22
0.24
0.35
0.5
Insulation class
Rotor inertia
Weight
Table 3: NEMA17 / 42mm stepper motor technical data
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
3.3
10 / 34
Integrated sensOstep™ encoder
The PD42-x-1240 PANdrives offer integrated sensOstep™ encoders based on hall sensor technology. As
the name “sensOstep™“ already indicates intended use of this type of compact and highly integrated
encoder is step loss detection of motor movements. As soon as the motor has been moved to a new
location the position may be verified using this encoder feedback. In case the stepper motor has lost one
or multiple steps during movement e.g. due to overload / any obstacle encountered during movement
the motor axes will jump for at least one electrical period / 4 full steps. This can be detected using the
integrated encoder. In addition, step losses may be already detected during motor movements using
the “deviation” setting available as part of the TMCL firmware (see PD42-x-1240 / TMCM-1240 firmware
manual for more details).
While the encoder offers 10bit (1024 steps) resolution per motor revolution the absolute position information is less accurate and depends on the displacement of the hall sensor based encoder IC relative to the
magnet and motor axis among other factors. Every PANdrive™ has been tested for maximum deviation
of +/- 5 encoder steps (static performance) relative to commanded microstep target position during final
tests after assembly at our factory. This will ensure more than adequate performance of the integrated
sensOstep™ encoder for step loss detection during motor movements.
NOTICE
Do not disassemble PANdrive™ when using integrated encoder In order to
make proper use of the integrated sensOstep™ encoder (the sensor IC is placed
on the bottom center of the pcb) the TMCM-1240 electronics should not be
removed/moved relative to the motor! Otherwise encoder performance might
suffer / not work.
Note: In case the integrated encoder feature is not used, the TMCM-1240
electronics may be moved or even removed from the motor and placed
somewhere else according to application requirements.
NOTICE
Keep the electronics free of (metal) particles! The integrated sensOstep™
encoder uses a magnet at the end of the motor axis in order to monitor position
of the motor axis. The magnet naturally attracts especially tiny metal particles.
These particles might be held on the top side of the PCB and – even worse
– start moving in accordance with the rotating magnetic field as soon as the
motor starts moving. This might lead to shorts of electronic contacts / wires on
the board and totally erratic behavior of the module! Use compressed air for
cleaning the module if necessary (especially in prototype setups).
In order to prevent shorts and better protect the electronics the TMCM-1240
printed circuit board is coated after assembly of components.
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
4
11 / 34
Connectors
The PD42-x-1240 offers five connectors including the motor connector which is used for connecting the
motor coils to the electronics. There is one motor and one power supply connector - both with four pins and two interface connectors - one with five pins for RS485 and CAN and a dedicated micro-USB connector.
All other inputs and outputs are concentrated on one 8 pin connector.
NOTICE
Start with power supply OFF and do not connect or disconnect motor during operation! Motor cable and motor inductivity might lead to voltage spikes
when the motor is (dis)connected while energized. These voltage spikes might exceed voltage limits of the driver MOSFETs and might permanently damage them.
Therefore, always switch off / disconnect power supply or at least disable driver
stage before connecting / disconnecting motor.
RS485 + CAN
USB
5
1
1
4
Power
I/O
1
8
4
1
Motor
Figure 2: PD42-x-1240 connectors
Connector Types and Mating Connectors
Connector
Connector type on-board
Mating connector type
Power
JST B4B-PH-K-S
(JST PH series, 4pins, 2mm pitch)
Connector housing: JST PHR-4
Contacts: JST SPH-002T-P0.5S
Wire: 0.22mm2, AWG 24
Motor
JST B4B-PH-K-S
(JST PH series, 4pins, 2mm pitch)
Connector housing: JST PHR-4
Contacts: JST SPH-002T-P0.5S
Wire: 0.22mm2, AWG 24
RS485+CAN
JST B5B-PH-K-S
(JST PH series, 5pins, 2mm pitch)
Connector housing: JST PHR-5
Contacts: JST SPH-002T-P0.5S
Wire: 0.22mm2, AWG 24
USB
USB-micro B female connector
USB-micro B male connector
I/O
JST B8B-PH-K-S
(JST PH series, 8pins, 2mm pitch)
Connector housing: JST PHR-8
Contacts: JST SPH-002T-P0.5S
Wire: 0.22mm2, AWG 24
Table 4: Connector Types and Mating Connectors of the PD42-x-1240
©2021 TRINAMIC Motion Control GmbH & Co. KG, Hamburg, Germany
Terms of delivery and rights to technical change reserved.
Download newest version at www.trinamic.com
PD42-x-1240 Hardware Manual • Hardware Version V1.10 | Document Revision V1.04 • 2021-AUG-18
4.1
12 / 34
Power Supply Input Connector
The PD42-x-1240 offers one 4pin JST PH series power supply input connector. In addition to main power
supply input and related ground connection this connector offers a separate logic supply input with the
option to keep the on-board logic alive while the driver stage is switched off. It is not necesary to connect
the logic supply input in case separate supplies are not required as the main power supply input will
always supply power to the driver stage and the logic part.
The power supply input connector offers a driver enable input. This input has to be connected to any
voltage above 3.5V up-to max. supply voltage of 30V in order to enable the driver stage. Leaving this pin
unconnected or connected to ground (voltage below 2.4V) will disable the driver stage regardless of any
settings in software. This input may be connected to main power supply input permanently in case an
enable input in hardware is not required.
Power Supply Connector Pin Assigment
Pin
Label
Direction
Description
1
GND
Power (GND)
Common system supply and signal ground
2
VMAIN
Power (input)
Main power supply input for the driver and on-board logic
10. . . 30V
3
Enable
Digital input
Driver enable input. A voltage above 3.5V is required here in
order to enable the on-board stepper motor driver. This input maybe connected to main power supply input in order to
enable the driver stage (+24V tolerant input).
4
VLOGIC
Power (input)
Optional separate power supply input for the on-board logic
10. . . 30V
Table 5: Power Supply Connector Pin Assignment
4.2
NOTICE
Do not connect or disconnect motor during operation! Motor cable and motor inductivity might lead to voltage spikes when the motor is (dis)connected
while energized. These voltage spikes might exceed voltage limits of the driver
MOSFETs and might permanently damage them. Therefore, always switch off
/ disconnect power supply or at least disable driver stage before connecting /
disconnecting motor.
NOTICE
Take care of polarity, wrong polarity can destroy the board!
NOTICE
Connect Enable pin to voltage >3.5V in order to enable motor movements!
Motor Connector
A second 4pin JST PH series connector is available for connection of a 2-phase bipolar stepper motor.
Motor Connector Pin Assignment
Pin
Label
Direction
Description
1
B1
out
Pin 1 of motor coil B
2
B2
out
Pin 2 of motor coil B
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Pin
Label
Direction
3
A1
out
Pin 1 of motor coil A
4
A2
out
Pin 2 of motor coil A
13 / 34
Description
Table 6: Motor Connector Pin Assignment
4.3
NOTICE
Do not connect or disconnect motor during operation! Motor cable and motor inductivity might lead to voltage spikes when the motor is (dis)connected
while energized. These voltage spikes might exceed voltage limits of the driver
MOSFETs and might permanently damage them. Therefore, always switch off
/ disconnect power supply or at least disable driver stage before connecting /
disconnecting motor.
NOTICE
Do not mix-up power supply and motor connectors!
RS485 + CAN Connector
For serial communication the PD42-x-1240 offers selection between RS485, CAN and USB interfaces. While
the USB interface is available for configuration and service of the board, mainly (e.g. parameter settings,
firmware updates) a 5-pin JST PH series connector offers 2-wire RS485 and CAN interfaces for in system
communication.
NOTICE
Due to hardware ressource sharing USB and CAN communication interfaces are
not available at the same time. As soon as USB is physically attached to a host or
hub the CAN interface will be switched off.
RS485 + CAN Connector Pin Assignment
Pin
Label
Direction
Description
1
GND
Power (GND)
Common system supply and signal ground
2
RS485+
Bidirectional
RS485 interface, diff. signal (non-inverting)
3
RS485-
Bidirectional
RS485 interface, diff. signal (inverting)
4
CAN_H
Bidirectional
CAN interface, diff. signal (non-inverting)
5
CAN_L
Bidirectional
CAN interface, diff. signal (inverting)
Table 7: RS485 + CAN Connector Pin Assignment
4.4
USB Connector
For serial communication the PD42-x-1240 offers selection between RS485, CAN and USB interfaces. The
USB interface via on-board micro-USB connector (type B) is available for configuration and service of the
board, mainly (e.g. parameter settings, firmware updates). The USB device interface supports full speed
(12Mbit/s) communication and supports bus powered and self-powered operation. During bus-powered
operation the low voltage logic part of the board will be powered, only. This includes the microcontroller
and the non-volatile memory and therefore allows parameter settings and firmware updates of the board
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using a standard USB cable, only. Of course, for any motor movement main supply via supply input
connector is required.
Due to hardware ressource sharing USB and CAN communication interfaces are
not available at the same time. As soon as USB is physically attached to a host or
hub the CAN interface will be switched off.
NOTICE
USB Connector Pin Assignment
Pin
Label
Direction
Description
1
VBUS
Power (+5V)
USB +5V nom. power supply input
2
D-
Bidirectional
USB interface, diff. signal (inverting)
3
D+
Bidirectional
USB interface, diff. signal (inverting)
4
ID
Input
connected to GND (via 100k resistor)
5
GND
Power (GND)
Common system supply and signal ground
Table 8: USB Connector Pin Assignment
4.5
I/O Connector
The PD42-x-1240 offers several inputs (two of them optically isolated) and one digital (open-drain) output.
The inputs include support for stop switches (left and right), home switch, step/direction, incremental A/B
channel encoder and analog (0. . . +10V) input. All this functionality is available via one 8pin JST PH series
I/O connector.
I/O Connector Pin Assignment
Pin
Label
Direction
Description
1
GND
Power (GND)
2
IN0/HOME
Input
Analog input (0. . . +10V)
HOME switch input
+24V tolerant, programmable (separate) pull-up to +5V
3
IN1/ENC_A
Input
General purpose digital input
Incremental encoder input channel A
+24V tolerant, programmable pull-up (for IN1/IN2 together) to
+5V
4
IN2/ENC_B
Input
General purpose digital input
Incremental encoder input channel B
+24V tolerant, programmable pull-up (for IN1/IN2 together) to
+5V
5
STOP_L/STEP
Input
STOP left switch input
STEP pulse input
input optically isolated, +24V compatible
6
STOP_R/DIR
Input
STOP right switch input
DIR input
input optically isolated, +24V compatible
Common system supply and signal ground
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Pin
Label
Direction
Description
7
ISO_COM
Power
Common positive (+24V_ISO) or negative (GND_ISO) isolated
supply input for optically isolated inputs
8
OUT0
Output (OD)
Open-Drain output. Output will be pulled low when activated.
Voltages up-to logic supply input level (or main supply input in
case separate logic supply is not used) are supported here. Max.
continuous pull-down current: 100mA
Table 9: I/O Connector Pin Assignment
All pins marked light green offer functional isolation towards main supply input. In case this is not required
ISO_COM may be connected to main ground or supply input, of course. The opto-couppler used are AC
types. This way, either high side switches or low side switches for both inputs are supported.
5
On-Board LEDs
The board offers two LEDs in order to indicate board status. The function of both LEDs is dependent on the
firmware version. With standard TMCL firmware the green LED should be flashing slowly during operation
and the red LED should be off. When there is no valid firmware programmed into the board or during
firmware update the red and green LEDs are permanently switched on. During reset to factory default
values the green LED will be flashing fast. With CANopen firmware both LEDs are switched on/off/flashing
according to standard defintion.
Red LED
Green LED
Figure 3: PD42-x-1240 LEDs
6
Reset to Factory Defaults
It is possible to reset all settings in firmware for the PD42-x-1240 to factory defaults without establishing
a working communication connection. This might be helpful in case communication parameters of the
preferred interface have been set to unknown values or got lost.
For this procedure two pads on the bottom side of the module have to be shorted (electrically connected
with each other) during power-on.
Please perform the following steps:
1. Switch power supply OFF (and disconnect USB cable if applicable)
2. Short CLK and DIO pads of programming pads on bottom of pcb (see figure 4)
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3. Switch power supply ON again (or connect USB again if applicable)
4. Wait until the on-board red and green LEDs start flashing fast (this might take a while)
5. Switch power supply OFF again (and disconnect USB cable if applicable)
6. Remove short between pads
7. After switching power supply ON again (and / or connecting USB cable) all permanent settings have
been restored to factroy defaults
Short these two pads
Figure 4: Reset to factory default settings
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7
17 / 34
I/Os
The I/O connector (8pin JST PH series) offers one analog input, two non-isolated digital inputs with integrated pull-ups (programmable) and two optically isolated inputs. All inputs can be used for different
purposes explained in more detail in the following subsections.
7.1
Analog input IN0
The PD42-x-1240 offers one analog input. The analog input voltage range is approx. 0..+10V. For voltages above +10V saturation takes place but, up-to 30V higher voltages are tolerated without destroying
the input. For analog to digital conversion the integrated ADC of the on-board microcontroller is used.
Resolution of this converter is 12bit (0..4095).
+5V
microcontroller
+3V3
2k2
IN0
0..10V
V
22k
10k
microcontroller
100nF
TMCM-1240
pull-up
disabled
Figure 5: Analog input IN0
The analog input can be used as digital input, also. There is an integrated pull-up to +5V which can be
switched on of off in software. When using this input as anlog input the pull-up should be usually switched
off.
7.2
Digital inputs IN1 and IN2
The PD42-x-1240 offers two digital inputs IN1 and IN2 which accept signals between 0 and 30V with voltages above approx. 2.9V recognized as logical ’1’ and below 1V as logical ’0’. Both inputs offer intergated
pull-ups to +5V which can be switched on or off in software (always together). When using the inputs with
low-side switches (connected to GND), pull-ups usually should be switched on (default). In case high-side
switches are used the pull-ups must be switched off. For push-pull signals the pull-ups may be either
switched on or off.
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+5V
microcontroller
+5V...24V
+3V3
+5V
2k2
or
10k
IN1
IN2
or
22k
microcontroller
33pF
TMCM-1240
pull-up
disabled
pull-up
enabled
Figure 6: Digital inputs IN1 and IN2
7.3
HOME/STOP_L/STOP_R switch inputs
The PD42-x-1240 offers two optically isolated inputs which can be used as left (STOP_L) and right (STOP_R)
stop switch inputs. When enabled in software the STOP_L switch input will stop motor movement in
negative direction (step counter decreasing) while activated. Likewise the STOP_R switch input will stop
motor movement in positive direction (step counter increasing) while activated.
+3V3
+24V_ISO
2k2
GND_ISO
microcontroller
ISO_COM
680
or
STOP_L,
STOP_R
6k8
TMCM-1240
+24V_ISO
GND_ISO
Figure 7: Stop switch inputs
A separated / isolated supply may be used for the switches - as indicated in the drawing (+24V_ISO and
related GND_ISO) - but, same supply as for the PD42-x-1240 can be used, also, of course.
7.4
External incremental encoder input
The PD42-x-1240 offers an integrated hall-sensor based magnet encoder. In addition, an external incremental A/B encoder may be connected to the two digital inputs IN1 and IN2. Encoder with push-pull
signals (e.g. +5V TTL) and open-drain output signals are supported (single-ended). For open-drain outputs the internal pull-ups should be activated in software (default mode).
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+5V
microcontroller
+3V3
+5V
2k2
ENC_A,
ENC_B
or
10k
22k
microcontroller
33pF
TMCM-1240
pull-up
enabled
Figure 8: External encoder input
7.5
Step/Direction inputs
The PD42-x-1240 may be used as driver with an external motion controller. In this case the Step/Direction
output signals of the external motion controller may be connected to the optically isolated Step/Dir inputs
of the PD42-x-1240. Please note that these signals should be 24V signals. For lower voltage signals a
simple small signal transistor maybe inserted as level converter.
+3V3
+24V_ISO
2k2
microcontroller
ISO_COM
680
STEP,
DIR
6k8
TMCM-1240
GND_ISO
Figure 9: Step/Direction input
Due to limitations of the opto-isolators the maximum step frequency of these inputs is limited to around
20kHz. For higher motor speed the step interpolator of the driver stage should be activated or the microstep resolution reduced (default 256 microsteps per fullstep).
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8
Communication
8.1
RS485
For remote control and communication with a host system the PD42-x-1240 provides a two wire RS485
bus interface. For proper operation the following items should be taken into account when setting up an
RS485 network:
1. BUS STRUCTURE:
The network topology should follow a bus structure as closely as possible. That is, the connection
between each node and the bus itself should be as short as possible. Basically, it should be short
compared to the length of the bus.
Host
c:>
Slave
Slave
Slave
node
1
node
n-1
node
n
}
termination
resistor
(120 Ohm)
RS485
termination
resistor
(120 Ohm)
keep distance as
short as possible
Figure 10: RS485 bus structure with termination resistors
2. BUS TERMINATION:
Especially for longer busses and/or multiple nodes connected to the bus and/or high communication
speeds, the bus should be properly terminated at both ends. The PD42-x-1240 does not integrate
any termination resistor. Therefore, 120 Ohm termination resistors at both ends of the bus have to
be added externally.
3. NUMBER OF NODES:
The RS485 electrical interface stadard (EIA-485) allows up to 32 nodes to be connected to a single bus.
The bus transceiver used on the PD42-x-1240 units (SN65HVD1781D) offers a significantly reduced
bus load compared to the standard and allows a maximum of 255 units to be connected to a single
RS485 bus using standard TMCL firmware. Please note: usually it cannot be expected to get reliable
communication with the maximum number of nodes connected to one bus and maximum supported
communication speed at the same time. Instead, a compromise has to be found between bus cable length,
communication speed and number of nodes.
4. COMMUNICATION SPEED:
The maximum RS485 communication speed supported by the PD42-x-1240 hardware is 1Mbit/s. Factory default is 9600 bit/s. Please see separate PD42-x-1240 TMCL firmware manual for information
regarding other possible communication speeds below the upper hardware limit.
5. NO FLOATING BUS LINES:
Avoid floating bus lines while neither the host/master nor one of the slaves along the bus line is
transmitting data (all bus nodes switched to receive mode). Floating bus lines may lead to communication errors. In order to ensure valid signals on the bus it is recommended to use a resistor network
connecting both bus lines to well defined logic levels.
There are actually two options which can be recommended: Add resistor (bias) network on one side
of the bus, only (120R termination resistor still at both ends):
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Slave
Slave
node
n- 1
node
n
+5V
pull-up (680R)
RS485+ / RS485A
termination
resistor
(120R)
termination
resistor
(120R)
RS485- / RS485B
pull-down (680R)
GND
Figure 11: RS485 bus lines with resistor (bias) network on one side, only
Or add resistor network at both ends of the bus (like Profibus™ termination):
+5V
pull-up (390R)
Slave
Slave
node
n- 1
node
n
+5V
pull-up (390R)
RS485+ / RS485A
termination
resistor
(220R)
termination
resistor
(220R)
RS485- / RS485B
pull-down (390R)
GND
pull-down (390R)
GND
Figure 12: RS485 bus lines with Profibus™recommended line termination
8.2
CAN
For remote control and communication with a host system the PD42-x-1240 provides a CAN bus interface.
Please note that the CAN interface is not available in case USB is connected. For proper operation the
following items should be taken into account when setting up a CAN network:
1. BUS STRUCTURE:
The network topology should follow a bus structure as closely as possible. That is, the connection
between each node and the bus itself should be as short as possible. Basically, it should be short
compared to the length of the bus.
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Host
c:>
Slave
Slave
Slave
node
1
node
n-1
node
n
}
termination
resistor
(120 Ohm)
termination
resistor
(120 Ohm)
keep distance as
short as possible
CAN
Figure 13: CAN bus structure with termination resistors
2. BUS TERMINATION:
Especially for longer busses and/or multiple nodes connected to the bus and/or high communication
speeds, the bus should be properly terminated at both ends. The PD42-x-1240 does not integrate
any termination resistor. Therefore, 120 Ohm termination resistors at both ends of the bus have to
be added externally.
3. BUS TERMINATION:
The bus transceiver used on the PD42-x-1240 units (TJA1051T) supports at least 110 nodes under
optimum conditions. Practically achievable number of nodes per CAN bus highly depend on bus
length (longer bus -> less nodes) and communication speed (higher speed -> less nodes).
9
Motor driver current
The on-board stepper motor driver operates current controlled. The driver current may be programmed
in software with 32 effective scaling steps in hardware.
Explanation of different columns in table below:
Motor current setting in software
(TMCL)
These are the values for TMCL axis parameter 6 (motor run current) and
7 (motor standby current). They are used to set the run / standby current
using the following TMCL commands:
SAP 6, 0, // set run current
SAP 7, 0, // set standby current
(read-out value with GAP instead of SAP. Please see separate PD42-x-1240
firmware manual for further information)
Motor current IRMS
[A]
Resulting motor current based on motor current setting
Motor Current Setting
Motor current setting
in software (TMCL)
Current scaling step
(CS)
Motor current ICOIL [A]
peak
Motor current ICOIL [A]
RMS
0. . . 7
0
0.102
0.072
8. . . 15
1
0.203
0.144
16. . . 23
2
0.305
0.215
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Motor current setting
in software (TMCL)
Current scaling step
(CS)
Motor current ICOIL [A]
peak
Motor current ICOIL [A]
RMS
24. . . 31
3
0.406
0.287
32. . . 39
4
0.508
0.359
40. . . 47
5
0.609
0.431
48. . . 55
6
0.711
0.503
56. . . 63
7
0.813
0.575
64. . . 71
8
0.914
0.646
72. . . 79
9
1.016
0.718
80. . . 87
10
1.117
0.790
88. . . 95
11
1.219
0.862
96. . . 103
12
1.320
0.934
104. . . 111
13
1.422
1.005
112. . . 119
14
1.523
1.077
120. . . 127
15
1.625
1.149
128. . . 135
16
1.727
1.221
136. . . 143
17
1.828
1.293
144. . . 151
18
1.930
1.364
152. . . 159
19
2.031
2.133
160. . . 167
20
2.133
1.508
168. . . 175
21
2.234
1.580
176. . . 183
22
2.336
1.652
184. . . 191
23
2.438
1.724
192. . . 199
24
2.539
1.795
200. . . 207
25
2.641
1.867
208. . . 215
26
2.742
1.939
216. . . 223
27
2.844
2.011
224. . . 231
28
2.945
2.083
232. . . 239
29
3.047
2.154
240. . . 247
30
3.148
2.226
248. . . 255
31
3.250
2.298
Table 11: Available motor current settings
In addition to the settings in the table the motor current may be switched off completely (free-wheeling)
using axis parameter 204 (see PD42-x-1240 firmware manual).
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10
10.1
Torque curves
PD42-1-1240 Torque Curve
Figure 14: PD42-1-1240 torque vs. velocity 24V / 2A, 256µsteps
10.2
PD42-2-1240 Torque Curve
Figure 15: PD42-2-1240 torque vs. velocity 24V / 2A, 256µsteps
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10.3
PD42-3-1240 Torque Curve
Figure 16: PD42-3-1240 torque vs. velocity 24V / 2A, 256µsteps
10.4
PD42-4-1240 Torque Curve
Figure 17: PD42-4-1240 torque vs. velocity 24V / 2A, 256µsteps
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11
26 / 34
Functional Description
The PD42-x-1240 is a full mechatronic solution including a 42mm flange (NEMA17) bipolar stepper motor.
It includes the controller / driver electronics TMCM-1240 and a choice between four different NEMA 17 /
42mm flange size bipolar hybrid stepper motors with different length and torque.
The PD42-x-1240 can be controlled via USB, RS485 or CAN serial interfaces. There are three general
purpose digital inputs which can be used, also as STOP_L / STOP_R / HOME switch inputs (for reference
movements, as end switches etc. depending on firmware, mode and configuration) or for connecting
an additional external encoder (incremental A/B/N). In addition, there is one dedicated analog input for
0. . . +10V analog signals and two general-purpose outputs (one open-drain and one switchable +5V supply
output).
The PD42-x-1240 with TMCL™ firmware option is supported by the PC based software development environment TMCL-IDE for the Trinamic Motion Control Language (TMCL™). Using predefined TMCL™ high
level commands like move to position a rapid and fast development of motion control applications is guaranteed. Please refer to the PD42-x-1240 or TMCM-1240 firmware manuals for more information about
TMCL™ commands.
Communication traffic is kept low since all time critical operations, e.g. ramp calculation are performed
on board. Complete stand-alone or full remote control or anything in-between is possible. The firmware
of the module can be updated via the serial interface. As an alternative to TMCL, a CANopen firmware is
available.
The PD42-x-1240 contains the following main components:
• Microcontroller (ARM Cortex-M3™), responsible for overall control and communication
• Highly integrated advanced stepper motor controller supporting linear and unique 6-points ramps
in hardware
• Advanced stepper motor driver with stallGuard2™ and coolStep™ with MOSFET driver stage (8x
power N-MOSFETs for bipolar stepper motor)
• RS485, CAN and USB transceivers
• On-board voltage regulators (+5V and +3V3) required for supply of all on-board digital circuits
Figure 18: PD42-x-1240 block diagram
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12
Operational Ratings and Characteristics
Never Exceed the absolute maximum ratings! Keep the power supply voltage
below the upper limit of +30V! Otherwise the board electronics will seriously be
damaged! Especially, when the selected operating voltage is near the upper limit
a regulated power supply is highly recommended.
NOTICE
General Operational Ratings
Symbol
Parameter
Min
Typ
Max
Unit
10
12. . . 24
30
V
工商网监
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