TMCM-1161-CABLE

MODULES FOR STEPPER MOTORS MODULES Hardware Version V1.0 HARDWARE MANUAL + + TMCM-1161 1-Axis Stepper Controller / Driver up to 2.8 RMS / 24V DC USB, RS485, and RS232 + UNIQUE FEATURES: TRINAMIC Motion Control GmbH & Co. KG Hamburg, Germany www.trinamic.com + TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) Table of Contents 1 2 3 Features........................................................................................................................................................................... 3 Order Codes ................................................................................................................................................................... 5 Mechanical and Electrical Interfacing ..................................................................................................................... 6 3.1 TMCM-1161 Dimensions and Mounting Holes ............................................................................................. 6 3.2 Connectors of TMCM-1161 ................................................................................................................................. 7 3.2.1 Interface and Power Supply Connector ................................................................................................. 8 3.2.2 USB Connector ............................................................................................................................................. 10 3.2.3 In/Out Connector ......................................................................................................................................... 11 3.2.4 Motor Connector .......................................................................................................................................... 12 4 Reset to Factory Defaults ......................................................................................................................................... 13 5 On-board LEDs ............................................................................................................................................................. 14 6 Operational Ratings ................................................................................................................................................... 15 7 Functional Description .............................................................................................................................................. 16 8 TMCM-1161 Operational Description ..................................................................................................................... 17 8.1 Calculation: Velocity and Acceleration vs. Microstep and Fullstep Frequency ................................ 17 9 Life Support Policy ..................................................................................................................................................... 19 10 Revision History .......................................................................................................................................................... 20 10.1 Document Revision ........................................................................................................................................... 20 10.2 Hardware Revision ............................................................................................................................................ 20 11 References .................................................................................................................................................................... 20 www.trinamic.com 2 TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 3 1 Features The TMCM-1161 is a single axis controller/driver module for 2-phase bipolar stepper motors with state of the art feature set. It is highly integrated, offers a convenient handling and can be used in many decentralized applications. The module can be mounted on the back of NEMA23 (57mm flange size) and NEMA24 (60mm flange size) stepper motors and has been designed for coil currents up to 2.8A RMS and 24V DC supply voltage. With its high energy efficiency from TRINAMIC’s coolStep™ technology cost for power consumption is kept down. The TMCL™ firmware allows for both, standalone operation and direct mode. MAIN CHARACTERISTICS Motion controller Motion profile calculation in real-time On the fly alteration of motor parameters (e.g. position, velocity, acceleration) High performance microcontroller for overall system control and serial communication protocol handling Bipolar stepper motor driver Up to 256 microsteps per full step High-efficient operation, low power dissipation Dynamic current control Integrated protection stallGuard2 feature for stall detection coolStep feature for reduced power consumption and heat dissipation Encoder sensOstep magnetic encoder (max. 1024 increments per rotation) e.g. for step-loss detection under all operating conditions and positioning supervision Interfaces inputs for stop switches (left and right) and home switch 1 analog input 2 general purpose outputs (open collector with freewheeling diodes) USB, RS232, and RS485 communication interfaces Software TMCL: standalone operation or remote controlled operation, program memory (non volatile) for up to 2048 TMCL commands, and PC-based application development software TMCL-IDE available for free. Electrical and mechanical data Supply voltage: +24V DC nominal (10… 30V DC) Motor current: up to 2.8A RMS (programmable) Refer to separate TMCL Firmware Manual, too. www.trinamic.com TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 4 TRINAMICS UNIQUE FEATURES – EASY TO USE WITH TMCL stallGuard2™ stallGuard2 is a high-precision sensorless load measurement using the back EMF on the coils. It can be used for stall detection as well as other uses at loads below those which stall the motor. The stallGuard2 measurement value changes linearly over a wide range of load, velocity, and current settings. At maximum motor load, the value goes to zero or near to zero. This is the most energy-efficient point of operation for the motor. Load [Nm] stallGuard2 Initial stallGuard2 (SG) value: 100% Max. load stallGuard2 (SG) value: 0 Maximum load reached. Motor close to stall. Motor stalls Figure 1.1 stallGuard2 load measurement SG as a function of load coolStep™ coolStep is a load-adaptive automatic current scaling based on the load measurement via stallGuard2 adapting the required current to the load. Energy consumption can be reduced by as much as 75%. coolStep allows substantial energy savings, especially for motors which see varying loads or operate at a high duty cycle. Because a stepper motor application needs to work with a torque reserve of 30% to 50%, even a constant-load application allows significant energy savings because coolStep automatically enables torque reserve when required. Reducing power consumption keeps the system cooler, increases motor life, and allows reducing cost. 0,9 Efficiency with coolStep 0,8 Efficiency with 50% torque reserve 0,7 0,6 0,5 Efficiency 0,4 0,3 0,2 0,1 0 0 50 100 150 200 250 300 350 Velocity [RPM] Figure 1.2 Energy efficiency example with coolStep www.trinamic.com TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 5 2 Order Codes Order code TMCM-1161-opiton Description Single axis bipolar stepper motor controller / driver electronics with integrated sensOstep encoder and coolStep feature Size (mm3) 60 x 60 x 12 Table 2.1 TMCM-1161 order codes The following options are available: Firmware option -TMCL Description Module pre-programmed with TMCL firmware Order code example: TMCM-1161-TMCL Table 2.2 Firmware options A cable loom set is available for this module: Order code TMCM-1161-CABLE Description Cable loom for TMCM-1161 1x cable loom for interface connector 1x cable loom for In/Out connector 1x cable loom for motor connector 1x USB type A connector to mini-USB type B connector cable Table 2.3 Cable loom order code Please note that the TMCM-1161 is available with NEMA23 and NEMA24 stepper motors, too. Please refer to the PD-1161 documents for more information about these products. www.trinamic.com TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 6 3 Mechanical and Electrical Interfacing 3.1 TMCM-1161 Dimensions and Mounting Holes The dimensions of the controller/driver board are approx. 60mm x 60mm x 12mm in order to fit on the back of a 60mm stepper motor. Maximum component height (height above PCB level) without mating connectors is around 8mm above PCB level and 2.5mm below PCB level. There are four mounting holes for M3 screws for mounting the board either to a NEMA23 (two mounting holes at opposite corners) or a NEMA24 (other two mounting holes at opposite corners) stepper motor. 60 56.75 49.5 10.5 4.59 46.25 60 45.95 13.75 10.5 14.05 3.25 55.41 Figure 3.1 Dimensions of TMCM-1161 and position of mounting holes www.trinamic.com TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 7 3.2 Connectors of TMCM-1161 The TMCM-1161 offers four connectors including the motor connector which is used for attaching the motor coils to the electronics. There are two connectors for serial communication (one for USB and one for RS232/RS485) and one connector for I/O signals and switches. 1 Interface 1 USB In/Out 1 Motor 1 Figure 3.2 Overview connectors Label Interface / Power Motor In/Out USB Connector type JST B6B-EH-A, 2.5mm pitch connector header, vertical JST B4B-EH-A, 2.5mm pitch connector header, vertical JST B8B-EH-A, 2.5mm pitch connector header, vertical Mini-USB type B vertical female www.trinamic.com Mating connector type JST EHR-6, female crimp connector housing; crimp contacts JST SEH-001T-P0.6 JST EHR-4, female crimp connector housing; crimp contacts JST SEH-001T-P0.6 JST EHR-8, female crimp connector housing; crimp contacts JST SEH-001T-P0.6 Mini-USB type B, male TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 8 3.2.1 Interface and Power Supply Connector Pin 1 2 3 4 5 6 Label GND VCC RS485A+ RS485BRS232_TxD RS232_RxD Description Module and signal ground 10… 30V DC power supply / nom. 24V DC RS485 non-inverted bus signal RS485 inverted bus signal RS232 transmit data from module RS232 receive data to module Table 3.1 Connector for power supply and interfaces 3.2.1.1 Power Supply When using supply voltages near the upper limit, a regulated power supply is mandatory. The power supply should be designed in a way, that it supplies the nominal motor voltage at the desired maximum motor power. To ensure reliable operation of the unit, the power supply has to have a sufficient output capacitor and the supply cables should have a low resistance, so that the chopper operation does not lead to an increased power supply ripple directly at the unit. Power supply ripple due to the chopper operation should be kept at a maximum of a few 100mV. HINTS FOR POWER SUPPLY CABLES - Keep power supply cables as short as possible. Use large diameters for power supply cables. CAUTION! Add external power supply capacitors! It is recommended to connect an electrolytic capacitor of significant size (2200µF or larger recommended) to the power supply lines next to the TMCM-1161 especially if the distance to the power supply is large (i.e. more than 2-3m)! Rule of thumb for size of electrolytic capacitor: In addition to power stabilization (buffer) and filtering this added capacitor will also reduce any voltage spikes which might otherwise occur from a combination of high inductance power supply wires and the ceramic capacitors. In addition it will limit slewrate of power supply voltage at the module. The low ESR of ceramic-only filter capacitors may cause stability problems with some switching power supplies. Do not connect or disconnect motor during operation! Motor cable and motor inductivity might lead to voltage spikes when the motor is disconnected / connected while energized. These voltage spikes might exceed voltage limits of the driver MOSFETs and might permanently damage them. Therefore, always disconnect power supply before connecting / disconnecting the motor. Keep the power supply voltage below the upper limit of 30V! Otherwise the driver electronics will seriously be damaged! Especially, when the selected operating voltage is near the upper limit a regulated power supply is highly recommended. Please see chapter 6 also (operating values). There is no reverse polarity protection! The module will short any reversed supply voltage due to internal diodes of the driver transistors. www.trinamic.com TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 9 3.2.1.2 RS485 For remote control and communication with a host system the PD-1161 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) termination resistor (120 Ohm) keep distance as short as possible RS485 Figure 3.5: RS485 bus structure 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 PD-1161 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 RS-485 electrical interface standard (EIA-485) allows up to 32 nodes to be connected to a single bus. The bus transceiver used on the PD-1161 units (SN65HVD3082ED) has just 1/8th of the standard bus load and allows a maximum of 256 units to be connected to a single RS485 bus. 4. 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 as well defined logic levels. In contrast to the termination resistors this network is normally required just once per bus. Certain RS485 interface converters available for PCs already include these additional resistors (e.g. USB-2-485). Slave Slave node n- 1 node n +5V pull-up (1k) RS485+ / RS485A termination resistor (120 Ohm) RS485- / RS485B pull-down (1k) GND Figure 3.6: RS485 bus lines with resistor network www.trinamic.com TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 3.2.2 USB Connector Pin 1 2 3 4 5 Label VBUS DD+ ID GND Description +5V power Data – Data + not connected ground Table 3.2 Mini USB connector www.trinamic.com 10 TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 11 3.2.3 In/Out Connector Pin 1 2 3 4 5 Label GND VCC OUT_0 OUT_1 IN_0 6 STOP_L/ STEP/ IN_1 7 STOP_R/ DIR/ IN_2 8 HOME/ ENABLE/ IN_3 Description Module ground (system and signal ground) 10… 30V DC power supply / nom. 24V DC General purpose output, open collector General purpose output, open collector Analog input, 0… 10V (analog to digital converter range) Digital input, +24V compatible, programmable internal pull-up.* Functionality can be selected in software: a) Left stop switch input (connected to REF1 input of TMC429 motion controller) b) Step signal (connected to step input of TMC262 stepper driver) c) General purpose input (connected to processor) Digital input +24V compatible, programmable internal pull-up.* Functionality can be selected in software: a) Right stop switch input (connected to REF3 input of TMC429 motion controller) b) Direction signal (connected to direction input of TMC262 stepper driver) c) General purpose input (connected to processor) Digital input +24V compatible, programmable internal pull-up.* Functionality can be chosen in software: a) Home switch input (connected to processor) b) Enable signal (connected to processor) c) General purpose input (connected to processor) Table 3.3 In/Out connector * It is possible to enable / disables pull-ups (1k to 5+V) in software for all three digital inputs. Pull-ups are always enabled / disabled for all three together / at the same time. +24V OUT_0 OUT_1 OUT_0 OUT_1 GND GND Figure 3.3 Internal circuit of OUT_0/1 www.trinamic.com TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 12 PU 1kO +5V / pull-up ON 0V / pull-up OFF IN_1/2/3 10kO +3.3V 47kO IN_0 IN_1/2/3 GND GND GND Figure 3.4 Internal circuit of IN_0 1nF 22kO 22kO 100nF IN_0 GND GND Figure 3.5 Internal circuit of IN_1/2/3 3.2.3.1 Left and Right Limit Switches The TMCM-1161 can be configured so that a motor has a left and a right limit switch. The motor stops when the traveler has reached one of the limit switches. An additional home switch might be used for initialization. STOP_L HOME STOP_R Motor Left stop switch Right stop switch Traveler Figure 3.6 Limit switches and home switch 3.2.4 Motor Connector Pin Label Description 1 2 3 4 OA1 OA2 OB1 OB2 Motor Motor Motor Motor Table 3.4 Motor connector www.trinamic.com coil coil coil coil A A B B TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 13 4 Reset to Factory Defaults It is possible to reset the TMCM-1161 to factory default settings without establishing a communication link. This might be helpful in case communication parameters of the preferred interface have been set to unknown values or got accidentally lost. For this procedure two pads on the bottom side of the board have to be shortened (see figure 4.12). Please perform the following steps: 1. 2. 3. 4. 5. 6. 7. Power supply off and USB cable disconnected Short two pads as marked in Figure 4.1 Power up board (power via USB is sufficient for this purpose) Wait until the on-board red and green LEDs start flashing fast (this might take a while) Power-off board (disconnect USB cable) Remove short between pads After switching on power-supply / connecting USB cable all permanent settings have been restored to factory defaults Short these two pads Figure 4.1 Reset to factory default settings www.trinamic.com TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 14 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 slowly flashing 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 on. BEHAVIOR OF LEDS WITH STANDARD TMCL FIRMWARE Status Label Description Heartbeat Run This green LED flashes slowly during operation. Error Error This red LED lights up if an error occurs. Green LED Figure 5.1 on-board LEDs www.trinamic.com USB Red LED TMCM-1161 V1.0 Hardware Manual (Rev. 1.14 / 2013-JUL-23) 15 6 Operational Ratings The operational ratings shown below should be used as design values. In no case should the maximum values been exceeded during operation. Symbol Parameter Min Typ Max Unit VCC VUSB Power supply voltage for operation Power supply via USB connector 10 24 5 30 V DC V IUSB Current withdrawn from USB supply when USB bus powered (no other supply connected) Motor coil current for sine wave peak (chopper 0 regulated, adjustable via software) Continuous motor current (RMS) 0 Power supply current ICOIL_peak ICOIL_RMS ISUPPLY TENV 40 mA 4