2 Life support policy....................................................................................................................................................... 4
5.1 General Functions (explore using the Windows based demo software)........................................... 9
5.2 Options for stand alone operation................................................................................................................ 9
5.3 Evaluation Version – Additional Features.................................................................................................... 9
5.4 LEDs - Temperature, Current and Voltage monitoring ............................................................................ 9
5.5 Under voltage behavior .................................................................................................................................. 10
Figure 5.2: Parameterizing the positioning algorithm............................................................................................. 12
List of Tables
Table 1.1: Order codes......................................................................................................................................................... 3
Table 3.1: Pinning of supply, motor and hall connector .......................................................................................... 5
Table 3.2: Pinning of I/O connector ................................................................................................................................ 6
Table 5.1: Options for stand alone operation.............................................................................................................. 9
Table 5.2: LEDs - Temperature, Current and Voltage monitoring function..........................................................9
The TMCM-160 is a controller / driver module for general Brushless DC motor applications. It
integrates velocity and torque control as well as a hall sensor based positioning mode. The position
resolution depends on the motor, i.e. a standard 8 pole motor gives a motor axis resolution of 15
degrees. The module can be used in stand alone operation or remote controlled via a RS232 or RS485
interface (ordering option). Its small form factor (50 x 92 mm
board as a plug-on module or for panel mounting, by connecting flat ribbon cables to the two 2x13
2.54mm standard header connectors. A version with screw terminal connectors is available (TMCM-160EvalBoard).
Its integration into the TRINAMIC family of stepper motor controllers makes it easy to choose either a
stepper motor or a BLDC motor or any combination for an application.
Applications
• Constant velocity and torque limited drives
• Positioning applications with automatic ramp generation
• Remote controlled (RS232 or RS485) or stand-alone operation (0 – 10V signal)
• Plug-On module or panel mount operation
• Very compact multi-axis drives (integrate several modules on a single base board)
Motor type
• Block commutated 3 phase BLDC motors with hall sensors
• Motor power from a few Watts to 180W
• Motor velocity up to 100,000 RPM (electrical field)
• 12, 24 or 36V nominal motor voltage (or any value in between) (ask for 48V option)
• Coil current up to 3A nominal, 5A with forced cooling (up to 8.5A current for short time)
TRINAMIC Motion Control GmbH & Co. KG does not
authorize or warrant any of its products for use in life
support systems, without the specific written consent
of TRINAMIC Motion Control GmbH & Co. KG.
Life support systems are equipment intended to
support or sustain life, and whose failure to perform,
when properly used in accordance with instructions
provided, can be reasonably expected to result in
personal injury or death.
Information given in this data sheet is believed to be
accurate and reliable. However no responsibility is
assumed for the consequences of its use nor for any
infringement of patents or other rights of third
parties, which may result form its use.
Pins 18 to 26 for
RS232 via DSUB
male and
nullmodem cable
Standard connector for
Supply and Motor / Hall Sensors
26
H1
GND
22
User I/O
GND
GND
18
VS
VS
14
W
W
10
V
V
6
U
U
H3H2
+5V
232524
GND
GND
192120
GND
VS
151716
VS
W
111312
W
V
798
V
U
354
U
12
Optional connectors on
Evaluation board
5
H3
4
1.5mm
Connector
H2
3
H1
2
GND
1
+5V
5
4
3
2
1
Connectors each shown
as top view
U
V
W
VS
GND
Figure 3.1: Pinning
CAUTION:
Since the two connectors of the TMCM-160 are similar be careful not to connect the module
turned around. When powered up this would damage the module. Figure 3.1 depicts the connectors
and their position on the board. The supply, motor and hall connector is next to the three capacitors.
Be sure to place the connectors exactly to their opponents. A deviation of only one pin row can
damage the module also.
Pin
Name Function
1 to 12 U, V, W BLDC motor driver outputs
13 to 16 VS Positive power supply voltage
17 to 22 GND Power Ground
23 +5V 5V supply for motor hall sensors
24 to 26 H1, H2, H3 Hall sensor signals (5V TTL input with integrated 10K pull-up resistor
to 5V)
Table 3.1: Pinning of supply, motor and hall connector
1 5V_AREF 5V analog reference as used by the internal DAC. Max. load 0.5mA
2 AIN0 / VIN Analog input: Used for velocity control in stand alone operation by
supplying external 0 - 10V signal
3 AIN1 Additional analog input. Currently unused – leave open
5 DIRIN 5V TTL input. Tie to GND to inverse motor direction, leave open or
tie to 5V otherwise.
6 GPIO1 Starting from Version 1.02: This pin outputs a tacho impulse, i.e.
toggles on each hall sensor change
7 /MOTOR_OFF Emergency stop. Tie this pin to GND to stop the motor (same as
Motor Off switch on PCB). The motor can be restarted via the
interface, or by cycling the power supply.
8 LED_TEMP 5V TTL output: Toggling with 3Hz when temperature pre-warnin
threshold is exceeded, high when module shut down due to
overtemperature.
9 LED_CURLIM High, when module goes into current limiting mode
10, 14 +5V 5V supply as reference for external purpose
11, 12, 26 GND GND reference
20 RXD /
RS485INV
22 TXD /
RS485NI
RXD signal of module for RS232 communication (RS232 version)
Inverting RS485 signal (RS485 version)
TXD signal of module for RS232 communication (RS232 version)
Non-inverting RS485 signal (RS485 version)
All other pins Leave all other pins unconnected!
92mm*50mm*8.3mm (height measured from PCB to highest part on PCB connector side, parts on top
side not included, since these are just for evaluation purpose)
Figure 3.2: Dimensions
3.3 Connectors
Hall sensor: JST1.5mm type: S5B-ZR-SM2-TF (only on EvalBoard)
Board-Plug on connectors: 2.54 mm two-row Header
The operational ratings show the intended / the characteristic range for the values and should be
used as design values. An operation within the limiting values is possible, but shall not be used for
extended periods, because the unit life time may be shortened. In no case shall the limiting values be
exceeded.
Symbol Parameter Min Typ Max Unit
VS Power supply voltage for operation 9.0*) 14 - 36 40.0 V
IS Power supply current 0.04 I
A
MOT
PID Module idle power consumption 1.2 W
V5 5 Volt (+-8%) output external load (hall sensors plus
30 mA
other load)
V5A 5 Volt (+-8%) analog reference output external load 0.5 mA
IMC Continuous Motor current at VMF 0 – 3 5 A
IMP Short time Motor current in acceleration periods
0 – 6 8.5 A
It is not recommended to set motor current above 6A!
I
Peak coil output current for 100ms 20 A
MPP
VI Logic input voltage on digital / hall sensor inputs -0.3 VCC+
V
0.3
VO Logic output current on digital outputs (5V CMOS output) 10 mA
VIA Analog input voltage -24 0 – 10 24 V
f
Chopper frequency 20 kHz
CHOP
Ex Exactness of voltage and current measurement -8 +8 %
T
Motor output slope (U, V, W) 100 ns
SL
TO Environment temperature operating -25 +70 °C
TOF Environment temperature for operation at full specified
-25 +60 °C
current (air flow might required, depending upon motor
/ voltage)
T
Temperature of the module, as measured by the
board
<100 125 °C
integrated sensor.
Table 4.1: Operational / Limiting Ratings
*) At supply voltages below 12V, maximum motor current linearly decreases down to about 0.5A at
9V. To be sure to be outside this area when using the EVALboard, use at least 13V supply voltage,
due to voltage drop in the reverse polarity protection.
4.1 Power supply requirements
The power supply should be designed in a way, that it supplies the nominal motor voltage at the
desired maximum motor current. In no case shall the supply value exceed the upper / lower voltage
limit. To be able to cope with voltage which might be fed back by the motor, the supply should
provide a sufficient output capacitor, additionally a 39V suppressor (zener-)diode may be used.
5.1 General Functions (explore using the Windows based
demo software)
The TMCM-160 module can either be remote controlled via the PC demonstration software or a user
specific program, or it can be controlled by an analog voltage (stand alone mode). The function of the
stand alone mode can be modified by the user by writing initialization values to the on-board
EEPROM, e.g. a maximum rotation velocity, motor current limit and rotation direction. For more
detailed software information refer to the TMCM BLDC Module – Reference and Programming
Manual (7).
5.2 Options for stand alone operation
Mode Functionality Software settings
PWM control Motor PWM controlled by the analog input VIN.
Motor direction controlled by DIR in pin.
PID enforced velocity Maximum motor velocity v
velocity is scaled by VIN pin voltage and enforced
by the PID velocity regulator.
Constant velocity Desired motor velocity v set via software Remote control flag = 1
Table 5.1: Options for stand alone operation
In all modes, the motor torque is limit by the maximum current setting. The polarity of the DIR pin
can be inversed by the direction input reverse flag setting.
set via software. This
max
Remote control flag = 0
Power on velocity = 0
Remote control flag = 0
Power on velocity = v
Power on velocity = v
max
5.3 Evaluation Version – Additional Features
The evaluation version comes equipped with a screw terminal connector for the motor and for the
supply. The hall sensor connector is a 5 pin 1.5mm JST type, which directly fits to a NMB motors. An
emergency stop switch as well as indicator LEDs are included on the board. An integrated
potentiometer allows velocity setting in the stand-alone mode. To use the external 0-10V input, turn
this potentiometer to zero velocity (right turn).
5.4 LEDs - Temperature, Current and Voltage monitoring
LED / Output Action Meaning
Current Limit Blink The current limit LED blinks upon under voltage switch off
Current Limit On / Flicker Motor PWM is reduced due to exceeding the set motor current limit
Blink The power stage on the module has exceeded a critical temperature
of 100°C. (Pre-warning)
On The power stage on the module has exceeded a critical temperature
of 125°C. The motor becomes switched off, until temperature falls
below 115°C. The measurement is correct to about +/-10°C
Table 5.2: LEDs - Temperature, Current and Voltage monitoring function
TMCM-160 Manual (V1.11 / August 8th, 2007) 10
5.5 Under voltage behavior
• The motor is switched on, if the supply voltage exceeds 9.0V
• The motor is switched off, if the supply voltage falls below 8.5V
• The current reduction due to low supply voltage may inhibit starting-up of the motor
• EVALboard: Motor current is reduced to a lower value, if the voltage is below 12V. If motor load
is too high, the module goes into under voltage switch off again. This is due to the voltage drop
in the reverse polarity protection. Motor current is additionally limited at low supply voltages:
0.5A at 9V and linear increasing to 4A at 12V. To be sure to be outside this area, use at least 13V
supply voltage, due to voltage drop in the reverse polarity protection.
5.6 Demonstration Application
You can use the Demonstration application for the TMCM-160 to set the module into operation. Please
remark, that you first should as a first step switch the module to remote controlled mode. You can
use the TRINAMIC TMCL IDE to update the modules firmware and to test / set all of the modules
parameters. If your motor shows instable behavior, you have to tune the PID regulator values. In
order to do this, you need to use the TMCL IDE.
5.7 Programmable motor current limit
The motor current limiting function is meant as a function for torque limiting, and for protection of
motor, power supply and mechanics.
Whenever the pre-programmed motor current is exceeded in a chopper cycle, the TMCM-160 calculates
a reduced PWM value for the next chopper cycle. New values are calculated 100 times a second. The
response time of the current regulation can be set using the parameter “current regulation loop
delay”:
A value of zero means, that in every 100Hz period, the current correction calculation is directly
executed and the resulting PWM value is taken. A higher current loop delay acts like a filter for the
current. The higher the delay value, the slower the current loop response time. A value of 5 (default)
leads to a current regulation response time of about 60 ms. On the mechanical side, a higher value
simulates a higher dynamic mass of the motor.
t
= 1 / (1 / 3s + 1 / (10ms * (1+x
LIM
x
is the current regulation loop delay parameter, t
CRLD
The actual current regulation time may be faster, depending on the PID settings.
Attention:
Please be careful, when programming a high value into the current regulation loop
delay register or if you want to work above the modules’ rated motor current: The
motor current could reach a very high peak value upon mechanical blocking of the
motor. If the short time current is not limited to a maximum of about 20A, this could
destroy the unit.
• The current measurement can not detect currents below about 200-300mA. If the current limit is
set to a too low value, the motor may become continuously switched off.
• The current limiting function is not meant as a protection against a hard short circuit.
• The maximum motor current should never be set above the rated short time motor current,
because the current regulator can not operate correctly, if the current limit is set too close to the
measurement range limits.
The motion control commands (TMCL_ROL, TMCM_ROR, TMCL_MVP) use a PID regulator for velocity
control. The PID regulator has to be parameterized with respect to a given motor in a given
application. The default parameter set of the PID regulator covers a range of motors suitable for the
TMCM-160 module, and typically works stable up to 15000 rpm maximum motor velocity. However, for
slower motors, the response time with this parameter set may become quite slow.
The PID regulator uses four basic parameters: The P, I and D values, as well as a timing control value.
The timing control value (PID regulation loop delay) determines, how often the PID regulator is
evoked. It is given in multiple of 10ms:
t
PIDDELAY
x
calculations
The PID parameters are divisors, e.g. use a higher value, to get less influence from the parameter. To
parameterize for a given motor, first modify the P parameter, starting from a high value and going to
a lower value, until fastest response with minimum oscillation is given.
After that, do the same for the I parameter. Now, modify the D parameter in the same way. It will
damp part of the oscillations of the other parameters, too.
As a thumb-rule, you can set the P-parameter to a starting value, such that:
P-param = (Maximum actual RPM of the motor at 100% PWM) * 0.15
The module uses the internally calculated velocity value (1/4 of electrical RPM value) as input into the
PID regulator (see schematic).
The module supports a positioning based on the motor’s hall sensor information. Please refer to the
schematic for the required set of parameters.
You can optimize the parameter set in your application to get a good positioning accuracy and a fast
positioning speed:
1. Select the maximum positioning speed as desired
2. Choose a minimum positioning speed, that allows a fast stop of the motor
3. Set the MVP_slow_down_distance in a way, that the motor slows down to the min_pos_speed in
this area (dotted line)
4. Choose the active brake velocity as allowable for your application
5. Set MVP_target_reached_distance to the value, which gives a stop as near as possible to the
target position
MVP_target_reached_distance
MVP_slow_down_distance
|velocity|
velocity enforced by
PID regulator
actual motor velocity
Velocity enforced by
max_pos_speed
min_pos_speed
active_brake_velocity
PID regulator
Motor off in this area
Motor braked in this
area if hard_stop_flag
set
position
target position
(set via MVP)
Figure 5.2: Parameterizing the positioning algorithm
5.10 Restoring factory default settings
The module stores user settings in an on-board EEPROM. You can restore the factory values, by setting
and storing a 255 to the current limit parameter. Upon next power on, all EEPROM values are loaded
with the default settings. However, this also clears the temperature measurement calibration, which
should be recalibrated before operating the device near its temperature limits.
1.09 Appl. Env. Added application environment and optical changes
1.10 HW change Reverse protection on EVALboard only
1.11 Pinning Clarification of pinning to avoid module damage
Table 6.1: Documentation Revision
6.2 Firmware Revision
Version Comment Description
1.01 Initial Version Bug in current regulation algorithm: Instable operation with settings
above 4.6A
1.02 Added RS485,
Tacho output
1.03 Invert Hall Added possibility for inversion for hall sensor signals
1.04 Disable Stop
switch
1.05 RS485 Corrected sent back address
1.06 Corrected
position
counter
Added baud rate switching
Added RS485 interface
Fixed current regulation bug
GPIO1 provides for a hall sensor derived tacho signal
Analog control input now uses 10 bit resolution for PWM / velocity
control
Corrected velocity readout when motor is turned by external force
Added disable stop switch function
In older firmware versions, the position counter sometimes looses a
step, which may add up during longer motions to 1/1000 of total
count.