Stepper Motor with
Controller / Driver
0.55 - 3.1 Nm / 48 V
sensOstep™ Encoder
USB, RS485, and CAN
Step/Dir Interface
MECHATRONIC DRIVES WITH STEPPER MOTOR PANdrive
Hardware Version V1.1
HARDWARE MANUAL
+
+ +
+
PD-1160
UNIQUE FEATURES
TRINAMIC Motion Control GmbH & Co. KG
Hamburg, Germany
www.trinamic.com
PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 2
Table of Contents
1 Features ........................................................................................................................................................................... 3
2 Order Codes ................................................................................................................................................................... 5
3 Mechanical and Electrical Interfacing ..................................................................................................................... 6
3.1 PD57-1160 and PD60-1160 Dimensions ......................................................................................................... 6
3.1.1 PD57-1160 Dimensions ................................................................................................................................ 6
3.1.2 PD60-1160 Dimensions ................................................................................................................................ 7
3.2 Connectors of PD-1160 ....................................................................................................................................... 8
3.2.1 Power Connector ........................................................................................................................................... 9
3.2.1.1 Power Supply .......................................................................................................................................... 9
3.2.2 Serial Communication Connector ........................................................................................................... 10
3.2.2.1 RS485 ....................................................................................................................................................... 11
3.2.2.2 CAN ........................................................................................................................................................... 12
3.2.3 Multipurpose I/O Connector ..................................................................................................................... 13
3.2.3.1 Digital Inputs STOP_L, STOP_R, and HOME ................................................................................... 13
3.2.3.2 General Purpose Inputs IN_0 and IN_1 ......................................................................................... 14
3.2.3.3 Outputs OUT_0, OUT_1 ........................................................................................................................ 14
3.2.4 Step/Direction Connector .......................................................................................................................... 15
3.2.4.1 Step / Direction / Enable Inputs ...................................................................................................... 15
3.2.5 Encoder Connector ...................................................................................................................................... 16
3.2.5.1 Encoder Inputs ...................................................................................................................................... 16
3.2.6 Motor Connector .......................................................................................................................................... 17
3.2.7 Mini-USB Connector .................................................................................................................................... 18
4 Jumpers ......................................................................................................................................................................... 19
4.1 RS485 Bus Termination .................................................................................................................................... 19
4.2 CAN Bus Termination ....................................................................................................................................... 19
5 Reset to Factory Defaults ......................................................................................................................................... 20
6 On-board LEDs ............................................................................................................................................................. 21
7 Operational Ratings ................................................................................................................................................... 22
8 Torque Curves ............................................................................................................................................................. 24
8.1 Curves of PD57-1160 ......................................................................................................................................... 24
8.1.1 PD57-1-1160 Torque Curves ...................................................................................................................... 24
8.1.2 PD57-2-1160 Torque Curves ...................................................................................................................... 26
8.2 Curves of PD60-1160 ......................................................................................................................................... 28
8.2.1 PD60-3-1160 Torque Curves ...................................................................................................................... 28
8.2.2 PD60-4-1160 Torque Curves ...................................................................................................................... 29
9 Functional Description .............................................................................................................................................. 30
10 PD-1160 Operational Description ........................................................................................................................... 31
10.1 Calculation: Velocity and Acceleration vs. Microstep and Fullstep Frequency ................................ 31
11 Life Support Policy ..................................................................................................................................................... 33
12 Revision History .......................................................................................................................................................... 34
12.1 Document Revision ........................................................................................................................................... 34
12.2 Hardware Revision ............................................................................................................................................ 34
13 References .................................................................................................................................................................... 34
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PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 3
1 Features
The PANdrive™ PD-1160 is a full mechatronic solution with state of the art feature set. It is highly
integrated and offers a convenient handling. The PD-1160 includes a stepper motor, controller/driver
electronics, and TRINAMICs sensOstep™ encoder. It can be used in many decentralized applications and
has been designed for 0.55… 3.1Nm max. holding torque and 24 or 48 V DC nominal supply voltage. With
its high energy efficiency from TRINAMIC’s coolStep technology cost for power consumption is kept
down. The TMCL™ firmware allows for 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 (1024 increments per rotation) e.g. for step-loss detection under all
operating conditions and positioning supervision
- Interface for connection of external incremental a/b/n encoder
Interfaces
- RS485 interface
- CAN (2.0B up to 1Mbit/s) interface
- USB full speed (12Mbit/s) interface
- Step/Direction interface (optically isolated)
- 3 inputs for stop switches and home switch (+24V compatible) with programmable pull-up
- 2 general purpose inputs (+24V compatible) and 2 general purpose outputs (open collector)
- Incremental a/b/n encoder interface (TTL and open-collector signals supported directly)
Safety features
- Shutdown input – driver will be disabled in hardware as long as this pin is left open or shorted to
ground
- Separate supply voltage inputs for driver and digital logic – driver supply voltage may be switched
off externally while supply for digital logic and therefore digital logic remains active
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.
- Ready for CANopen
Electrical and mechanical data
- Supply voltage: common supply voltages +12 V DC / +24 V DC / +48 V DC supported (+9 V… +51 V DC)
- Motor current: up to 2.8 A RMS (programmable)
- 0.55… 3.1Nm max. holding torque (depends on motor)
- With NEMA23 (57mm motor flange size) or NEMA24 (60mm motor flange size) stepper motor
Refer to separate TMCL Firmware Manual, too.
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PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 4
Load
[Nm]
stallGuard2
Initial stallGuard2
(SG) value: 100%
Max. load
stallGuard2 (SG) value: 0
Maximum load reached.
Motor close to stall.
Motor stalls
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
0 50 100 150 200 250 300 350
Efficiency
Velocity [RPM]
Efficiency with coolStep
Efficiency with 50% torque reserve
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.
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.
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Figure 1.2 Energy efficiency example with coolStep
PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 5
Order code
Description
Size (mm3)
PD57-1-1160
PANdrive with 0.55Nm max./holding torque
60 x 60 x 58
PD57-2-1160
PANdrive with 1.01Nm max./holding torque
60 x 60 x 68
Order code
Description
Size (mm3)
PD60-3-1160
PANdrive with 2.10Nm max./holding torque
60 x 60 x 82
PD60-4-1160
PANdrive with 3.10Nm max./holding torque
60 x 60 x 103
Order code
Description
PD-1160-CABLE
Cable loom for PD-1160:
- 1x cable loom for power connector (length 200mm)
- 1x cable loom for communication connector (length 200mm)
- 1x cable loom for multipurpose I/O connector (length 200mm)
- 1x cable loom for S/D connector (length 200mm)
- 1x cable loom for encoder connector (length 200mm)
- 1x USB type A connector to mini-USB type B connector cable (length 1.5m)
2 Order Codes
The PD-1160 is currently available with two different stepper motor series (NEMA23 / 57mm flange size or
NEMA24 / 60mm flange size):
With NEMA 23 / 57mm flange size motor:
The length of the PANdrives is specified without the length of the axis. For the overall length of the
product please add 24mm.
Table 2.1 Order codes (PD57-1160)
With NEMA 24 / 60mm flange size motor:
The length of the PANdrives is specified without the length of the axis. For the total length of the
product add 24mm.
Table 2.2 Order codes (PD60-1160)
A cable loom set is available for this module:
Table 2.3 Cable loom order codes
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PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 6
Length
56.4±138.1±0.025
1.6
5
6,35-0.013
24±1
20±0.5
R 0.5
38.1±0.025
47.14±0.2
4-ø4.6
56.4±1
56.4±1
6.35-0.013
60
60
47.14±0.2
17
60
4.5
Model
Length (mm)
PD57-1-1160
41
PD57-2-1160
51
3 Mechanical and Electrical Interfacing
3.1 PD57-1160 and PD60-1160 Dimensions
3.1.1 PD57-1160 Dimensions
The PD57-1160 includes the TMCM-1160 stepper motor controller/driver module, the magnetic encoder
based on sensOstep technology and a NEMA23 bipolar stepper motor. Currently, there is a choice
between two NEMA 23/57mm bipolar stepper motors with different lengths and different holding
torques.
Figure 3.1 Dimensions of PD57-1160
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PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 7
Length
5
9
38.1±0.025
1.6
24±1
8-0.013
20±0.5
7.5±0.2
60±0.5
17
60
4.5
60
47.14±0.2
60
38.1±0.025
8
47.14±0.2
4-ø4.5
Model
Length (mm)
PD60-3-1160
65
PD60-4-1160
86
3.1.2 PD60-1160 Dimensions
Currently, there is a choice between two NEMA 24/60mm bipolar stepper motors with different lengths
and different holding torques.
Figure 3.2 Dimensions of PD60-1160
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PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 8
USB
Serial
communication
Multi-purpose
I/O
Motor
Power
Encoder
14
1
8
1
4
1
5
1
5
1
4
Step /
Direction
Label
Connector type
Mating connector type
Power
Connector
JST B4B-EH-A
(JST EH series, 4pins, 2.5mm pitch)
Connector housing: JST EHR-4
Contacts: JST SEH-001T-P0.6
Wire: 0.33mm2, AWG 22
Serial
communication
Connector
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
Multi-purpose
I/O Connector
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
Step/Direction
Connector
JST B4B-PH-K-S
(JST EH series, 4pins, 2mm pitch)
Connector housing: JST PHR-4
Contacts: JST SPH-002T-P0.5S
Wire: 0.22mm2, AWG 24
Encoder
Connector
JST B5B-PH-K-S
(JST EH series, 5pins, 2mm pitch)
Connector housing: JST PHR-5
Contacts: JST SPH-002T-P0.5S
Wire: 0.22mm2, AWG 24
Motor
Connector
JST B4B-EH-A
(JST PH series, 4pins, 2.5mm pitch)
Connector housing: JST EHR-4
Contacts: JST SEH-001T-P0.6
Wire: 0.33mm2, AWG 22
Mini-USB
Connector
Molex 500075-1517
Mini USB Type B vertical receptacle
Any standard mini-USB plug
3.2 Connectors of PD-1160
The PD-1160 offers seven connectors including the motor connector which is used for attaching the
motor coils to the electronics. In addition to the power connector there are two connectors for serial
communication (mini-USB connector and 5pin connector for RS485 and CAN) and three connectors for
Step/Direction, multipurpose input/output signals, and for an external encoder.
The multipurpose connector offers two general purpose outputs, two general purpose inputs, two inputs
for stop switches and one for an additional home switch.
The power supply connector offers separate inputs for driver and for logic power supply plus hardware
shutdown input. Leaving the shutdown input open or tying it to ground will disable the motor driver
stage in hardware. For operation, this input should be tied to supply voltage.
Figure 3.3 Overview connectors
Table 3.1 Connectors and mating connectors, contacts and applicable wire
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PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 9
4
1
Pin
Label
Description
1
+V
Driver
Module + driver stage power supply input
2
+V
Logic
(Optional) separate digital logic power supply input
3
/SHUTDOWN
Shutdown input. Connect this input to +V
Driver
or +V
Logic
in order
to activate driver stage. Leaving this input open or connecting it
to ground will disable driver stage
4
GND
Module ground (power supply and signal ground)
Add external power supply capacitors!
It is recommended to connect an electrolytic capacitor of significant size (e.g. 2200 µF /
63V) to the power supply lines next to the PD-1160 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.
3.2.1 Power Connector
This PANdrive offers separate power supply inputs for digital logic (pin 2) and driver/power stage (pin 1).
Both supply inputs use common ground connections (pin 4). This way, power supply for the driver stage
may be switched off while still maintaining position and status information when keeping digital logic
supply active. Due to internal diode the digital logic supply has to be equal or higher than the
driver/power stage supply. Otherwise the diode between driver/power stage supply and digital logic
supply might short the separate supplies.
+U
In case power supply is provided only to the power section (pin 1) an internal diode will distribute
power to the logic section. So, when separate power supplies are not required it is possible to just use
pin 1 and 4 for powering the module. If so, pin 2 (logic supply) and pin 3 (/SHUTDOWN input) can be
connected together in order to enable the driver stage.
ENABLING THE DRIVER STAGE
Connect /SHUTDOWN input to +U
open or connecting it to ground will disable driver stage.
A 4-pin JST EH series B4B-EH connector is used as power connector on-board.
SUPPLY ONLY
DRIVER
Driver
or +U
in order to activate the driver stage. Leaving this input
Logic
Table 3.2 Connector for power supply
3.2.1.1 Power Supply
For proper operation care has to be taken with regard to the power supply concept and design. Due to
space restrictions the TMCM-1160 module includes about 20 µF / 100 V of supply filter capacitors. These
are ceramic capacitors which have been selected for high reliability and long life time.
HINTS FOR POWER SUPPLY CABLES
- Keep power supply cables as short as possible.
- Use large diameters for power supply cables.
CAUTION!
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PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 10
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 51V!
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 also chapter 7 (operating values).
There is no reverse polarity protection!
The module will short any reversed supply voltage due to internal diodes of the driver
transistors.
1
5
Pin
Label
Description
1
CAN_H
CAN bus signal (dominant high)
2
CAN_L
CAN bus signal (dominant low)
3
GND
Module ground (system and signal ground)
4
RS485+
RS485 bus signal (non inverted)
5
RS485-
RS485 bus signal (inverted)
3.2.2 Serial Communication Connector
The module supports RS485 and CAN communication via this connector.
CAN interface will be de-activated in case USB is connected due to internal sharing of hardware
resources.
A 2mm pitch 5-pin JST B5B-PH-K connector is used for serial communication.
Table 3.3 Connector for serial communication
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PD-1160 V1.1 Hardware Manual (Rev. 1.02 / 2013-JUL-23) 11
c:>
node
1
node
n
- 1
node
n
Host
Slave Slave Slave
RS485
termination
resistor
(120 Ohm)
termination
resistor
(120 Ohm)
}
keep distance as
short as possible
node
n - 1
node
n
Slave Slave
termination
resistor
(120 Ohm)
+5V
GND
pull-up (1k)
pull-down (1k)
RS485- / RS485B
RS485+ / RS485A
3.2.2.1 RS485
For remote control and communication with a host system the PD-1160 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.
Figure 6.4: 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-1160 does
offer on-board termination resistors which can be activated with the help of a jumper. The
jumper has to be removed for units not connected to one end of the bus!
3. NUMBER OF NODES:
The RS485 electrical interface standard (EIA-485) allows up to 32 nodes to be connected to a
single bus. The bus transceiver used on the PD-1160 units (SN65HVD485ED) has 1/2 of the
standard bus load and allows a maximum of 64 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 to 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).
Figure 3.5 Bus lines with resistor network
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