AHS Antriebstechnik TSP10 User manual

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Manual
Stepper motor drive
TSP10
AHS Antrie
bstechnik GmbH
Fichtenweg 17
64319 Pfungstadt
Phone: [phone]
Fax: [phone]

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Previous issues:
Issue
Remarks
2013-08-22 First edition
2014-01-09 Small technical changes
2014-02-05 Type code
2014-08-20 Change Firmware 2.0 (AHS+1648.GSD)
© AHS Antriebstechnik GmbH, 2013
No part of this documentation may be reproduced, processed or distributed in any form without written
consent of AHS Antriebstechnik GmbH.
Errors excepted!
Changes of the documentation and the product's technology reserved!
The current issue of this manual is available online at http://www.ahs-antriebstechnik.de/home.html.
Windows® is a registered trademark of Microsoft corporation.

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Table of contents
1 General ............................................................................................................... 5
1.1 About this manual...............................................................................................................5
1.2 Characteristics and modes of operation ..............................................................................5
1.3 Warning and note icons ......................................................................................................6
2 Safety ................................................................................................................. 7
2.1 Important safety notes ........................................................................................................7
2.2 Intended use ......................................................................................................................8
2.3 Standards and directives ....................................................................................................8
2.4 CE conformity ....................................................................................................................9
3 Product identification ...................................................................................... 10
3.1 Name plate....................................................................................................................... 10
3.2 Scope of supply ................................................................................................................ 11
3.3 Accessories...................................................................................................................... 11
4 Technical data ................................................................................................. 12
4.1 Electric data ..................................................................................................................... 12
4.2 Mechanical data ............................................................................................................... 13
5 Mechanical installation ................................................................................... 14
5.1 Switchboard assembly...................................................................................................... 14
5.2 Cooling and permissible motor current .............................................................................. 17
6 Electric installation ......................................................................................... 19
6.1 Connections ..................................................................................................................... 20
6.2 Connections ..................................................................................................................... 21
6.3 Supply voltage.................................................................................................................. 22
6.4 Motor connection .............................................................................................................. 25
6.5 Signal inputs and outputs ................................................................................................. 27
6.6 Serial interface ................................................................................................................. 32
7 Parameter setting ............................................................................................ 33
7.1 Motor current .................................................................................................................... 34
7.2 Step resolution/idle current reduction ................................................................................ 35
8 Operation lights ............................................................................................... 36
9 Mode of operation: Step and direction ............................................................ 37
9.1 Signal connection ............................................................................................................. 38
9.2 Signal Timing ................................................................................................................... 40
10 Mode of operation: Executing profiles ............................................................ 41
10.1 Input and output signals ................................................................................................... 42
10.2 Configuration .................................................................................................................... 43
10.2.1 Settings ................................................................................................................... 44

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10.2.2 Input functions ......................................................................................................... 47
10.2.3 Output signals .......................................................................................................... 49
10.2.4 Profiles .................................................................................................................... 51
10.2.5 Sample profiles ........................................................................................................ 54
10.2.6 Homing .................................................................................................................... 57
11 Commissioning ................................................................................................. 66
11.1 Commissioning with step and direction signal ................................................................... 67
11.2 Startup with profiles .......................................................................................................... 68
12 Fault recovery .................................................................................................. 70
12.1 Disconnection after fault, fault list ..................................................................................... 70
12.2 Faulty response ................................................................................................................ 71
13 Maintenance and cleaning............................................................................... 73
14 Repair and disposal ......................................................................................... 73
14.1 Dismantling ...................................................................................................................... 73
14.2 Repair .............................................................................................................................. 74
14.3 Disposal ........................................................................................................................... 74
15 Ordering code .................................................................................................. 75
16 Index ................................................................................................................ 76

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1 General
1.1 About this manual
This manual contains information on the installation and use of the stepper motor control TSP10. It
addresses specialist staff which has the following knowledge or training:
Transport: knowledge of how to handle construction elements susceptible to electrical
discharge
Mounting: electro-technical training, knowledge of the safety directives
Commissioning: good knowledge in the areas of electrical engineering and propulsion technology
Observe the national accident prevention instructions.
1.2 Characteristics and modes of operation
The stepper motor controls of the TSP10 are compact microstepping subassemblies to control 2-
phase stepper motors.
Operating voltage: 24... 74 V DC
Motor current: 0.2... 7 Arms
Modes of operation of the basic device TSP10-BA:
· control with step and direction signal
· start of programmed motion tasks by digital inputs (indexing function)
Set the device parameters either by two rotary switches at the top side of the device or use the
TopSuite set-up program.
The contact jack for the serial RS232 interface is located in the face of the device. A computer and a
Windows® operating system are necessary to use the TopSuite set-up program.
All digital inputs and outputs are opto-isolated.
A two-colour LED indicates the device status by colours and flashing signals.
The devices of the TSP10 are intended for switchboard mounting.
Heat is removed by the back or lateral supporting surface of the case.
If the back surface is used for mounting, you may fasten a heat sink at the lateral supporting surface.
This improves the dissipation of heat.

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1.3 Warning and note icons
The following warning and note icons are used in this manual:
Icon Meaning
Warning against a hazard which may cause heavy injury or death.
Observe instructions to avoid hazards!
Warning against a hazard which may cause slight injury.
Observe instructions to avoid hazards!
Note on a situation or unsafe procedure which may damage the
product or objects nearby.
Observe instructions on safe operation of the product!
This is no warning icon against a dangerous or injurious situation.
This icon indicates notes on use and other very useful information.

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2 Safety
This chapter provides important instructions on the safe and intended use of the stepper motor control
TSP10.
In your function as a machine manufacturer you are responsible for integrating the stepper motor
control TSP10 in your machine. AHS Antriebstechnik GmbH is not liable for any damage which may
originate from wrong or unintended use of the stepper motor control TSP10.
Hence, follow strictly the instructions given in this manual to avoid damage to body or property and to
apply the stepper motor control TSP10 correctly and efficiently.
2.1 Important safety notes
High electric voltage may cause hazardous electric shock to people.
· Never use the stepper motor control unless the case and all cable shields are grounded.
· Never use the stepper motor control while the case is opened. Construction elements and
wires in the device are live.
· Do not touch the connections of the supply voltage connector if power is on.
· Do not touch the connections of the motor connector if power is on.
These contacts are live even if there is no motor connected.
Unintentional movements of the driving mechanism may damage people or
objects.
· Assess the risk of your machine and take suitable measures to make sure that unintentional
movements will not cause damage to persons or objects.
· To safely shutdown the driving mechanism, always interrupt or switch off the supply voltage.
Switching the stepper motor control off by the enable input is not a safe method of interrupting
during emergency failures.
Connecting or separating live wires and connections may lead to arcing.
This damages wires and contacts and may injure people.
· Connect or disconnect electric contacts only when the supply voltage is switched off.
The stepper motor control contains construction elements which are
susceptible to electrical discharge and may be damaged by improper use.
· Observe ESD preventive measures according to DIN EN 61340-5.

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2.2 Intended use
The stepper motor controls TSP10 may be used only according to points (1) to (7) below.
(1) The stepper motor controls of the TSP10 are intended for installation in electrical plants or
machines and may be commissioned only as integrated components of plants or machines.
(2) The stepper motor controls of the TSP10 may be used only in plants or machines that comply
with applying national directives or standards.
(3) The manufacturer of these plants or machines have to assess the risk and make sure that
unintentional movements of the driving mechanism do not damage people or objects.
(4) To safely shutdown the driving mechanism, always interrupt or switch off the supply voltage of
the stepper motor control. Switching the stepper motor control TSP10 off by the enable input
is not a safe method of interrupting during emergency failures.
(5) Use the stepper motor controls TSP10 only to drive suitable stepper motors. The output
current of the stepper motor control may not be higher than the rated motor current.
(6) Use only copper wire to establish electric connections of the stepper motor controls TSP10.
The cross sections of the conductors are defined in the EN 60204 standard or in table 310-16
of the NEC (columns 60 °C or 75 °C for AWG cross sections).
(7) Observing these operating instructions is a part of the intended use. Observe esp. data on
supply voltage, ambient conditions and safe operation.
No other use of the stepper motor controls of the TSP10 is considered compliant with the
requirements given in points (1) to (7).
AHS Antriebstechnik GmbH assumes no liability for damages which may result from use which is not
compliant with the requirements.
2.3 Standards and directives
TSP10 Step motor drives are components intended to be built into machines or plants for industrial
purpose.
The units meet the following standard:
EN 61800-3 Adjustable speed electrical power drive systems
Part 3: EMC requirements and special test methods

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2.4 CE conformity
TSP10 Step motor drives are components that are intended to be built into electrical plant and
machines for industrial use. The manufacturer of the machine is responsible that the machine or plant
fulfills the requirements of the EMC directive.

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3 Product identification
All versions of the stepper motor controls TSP10 are uniquely identified by the type name (order
name).
Please, find further details in the chapter 15 Ordering code.
After powering on, the firmware version of the stepper motor control TSP10 is indicated as a flashing
code. e.g., 1x flash, break, 2x flash = version 1.2
Since all stepper motor controls TSP10 are equipped with a serial RS232
interface, the firmware version can be displayed by the set-up program
TopSuite as well.
Type name and other data are shown on the name plate of the device.
3.1 Name plate
The name plate is at the side of the case.
The name plate shown in the picture belongs to the standard version of the basic device.
1
Type name (order name)
2
Version of the stepper motor control
3
Operating voltage
4
Maximum output current (rms, peak)
5
Serial number

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3.2 Scope of supply
The stepper motor controls TSP10 are delivered with mating connectors to connect the supply voltage
and the motor wires.
Supply voltage: Phoenix Contact FKCT 2,5/4-ST
Motor connector: Phoenix Contact FKCT 2,5/5-ST
3.3 Accessories
Cable for serial interface (article AHS No. KAB-TSP-232)
Heatsink (article AHS No. HS-TSP)

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4 Technical data
4.1 Electric data
Supply
v
oltage
24 - 74 VDC
Motor
c
urrent
Number of selectable values
0.2 to 7.0 Arms
16 *
M
otor
c
urrent @
a
mbient
t
emperature
without heat sink
with heat sink
3.2 A at 25 °C
1.6 A at 45 °C
7.0 A at 25 °C
3.5 A at 45 °C
Permissible
h
ea
t
si
n
k
t
emperature
Max. 60 °C (forced cooling may be
necessary)
Permissib
le
a
mbient
t
emperature
Operation
Storage
0 °C to +50 °C
–55 °C to +70 °C
H
umidity
10-90 %, non-condensing
Chopper f
requency of
power
stage
20 kHz
I
nput
s
ignals
Step
Direction
Enable
DE1 ... DE10 (customisable)*
Input
i
nterface
RS232
O
utput
s
ignals
Enabled
DA1 ... DA4 (customisable)*
Idle
c
urrent
r
eduction
off (motor current always on 100%)
after 0.1 s at 50%
after 1... 3000 ms (adjustable) *
at 0... 100% (adjustable)*
Max.
i
nput
f
requency
500 kHz
Adjustable
s
tep
r
esolution
200 bis 10000*
P
reset
n
umbers of steps
200, 400, 500, 800, 1000, 2000, 5000,
10000
O
perating
l
ights
Two-Colour-LED
F
ault
p
rotection
Short circuit (phase to phase, phase to
zero conductor) and over temperature
* set additional values via the RS232 interface

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4.2 Mechanical data
The case of the stepper motor control TSP10 consists of two parts which are joined and screwed
together. A part of the case is designed as a heatsink bracket including cut-outs to mount the TSP10
in the switchboard.
Case material: Aluminium
Overall weight: 500 g
The exact dimensions of the stepper motor control TSP10 are given in the dimensional drawing.
all dimensions in mm

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5 Mechanical installation
Powerful magnetic fields may affect parts in the TSP10. This may damage
the stepper motor control or the connected motor.
· Mount any devices which generate magnetic fields far enough away from the TSP10 and/or
shield magnetic fields.
5.1 Switchboard assembly
The stepper motor control TSP10 is usually fastened with M4 screws on a mounting surface of the
switchboard. The cut-outs for the screws are arranged in such a way that the TSP10 may be mounted
at the back of the device or at its side.
Observe the following requirements for assembly:
· The mounting surface should be level and able to carry sufficient load to bear the device’s 500 g
of weight.
· Powerful shocks, vibrations or impacts may not affect the stepper motor control TSP10.
· Mount the device vertically aligned. Horizontal alignment impairs the cooling.
· Leave at least 10 cm of space above and below the device and at least 2.5 cm on either side.
· Do not cover the airing drillings of the TSP10 case.
· Arrange the cooling/airing of the switchboard in such a way that the case temperature of the
TSP10 does not rise above 60 °C.
· The inside temperature of the switchboard (ambient temperature for the TSP10) may not rise
above 50 °C.

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This illustration shows how to mount the TSP10 at the back of the device.
The measures given indicate how much space should be left.
The shaded area may be occupied by other devices or the switchboard wall.

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This illustration shows how to mount the TSP10 at the side of the device.
The measures given indicate how much space should be left.
The shaded area may be occupied by more devices or the switchboard wall.

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5.2 Cooling and permissible motor current
The stepper motor control TSP10 shuts down when overheating.
This may damage the machine.
· Observe the following notes on how to cool the stepper motor control TSP10.
· Design your machine to avoid damage from automatic shutdown of the stepper motor control.
When designing your machine, consider in general the automatic shutdown
of the stepper motor control.
The motor will also shut down, for example, if the motor current exceeds the
permissible peak value.
The thermal loss from the stepper motor control TSP10 is mainly a function of the motor current and
the chosen current reduction.
This means that the highest permissible motor current is a function of the cooling of the TSP10.
A part of the case is turned into a heatsink bracket to dissipate thermal loss. The cut-outs to mount the
TSP10 in the machine are in this part of the case.
The TSP10 may be mounted at the back wall or the side wall of the device.
In addition, the top and bottom of the case are provided with airing holes to permit cool air to flow
through the TSP10.
If the TSP10 is mounted on a mounting plate, the surface for dissipating the thermal loss is larger.
The cooling surface may be enlarged by applying the heatsink by AHS Antriebstechnik GmbH as well
(chapter 3.3 Accessories). Screw the heatsink at the side of the case. Mount the TSP10 in this case
at the back side of the case.
This results in many options for cooling the stepper motor control.
Heat transfer to the mounting plate or the heatsink is improved by the use of
thermal pad or paste.
Coating layers on the mounting plate may block the heat transfer. Remove
any coating from the mounting surface, if possible.

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A few examples follow on how the highest permissible motor current depends on the cooling. The
stated motor currents are effective values.
Assembly without cooling plate and heat sink
Ambient temperature Highest permissible
motor current
Free convection 25 °C 3.2 A
45 °C 1.6 A
With fan 25 °C 7.0 A
45 °C 3.5 A
Assembly on co
oling plate *
Ambient temperature Highest permissible
Motor current
Free convection 25 °C 5.0 A
45 °C 2.5 A
With fan 25 °C 7.0 A
45 °C 5.0 A
* Size the cooling plate (mounting plate) in the switchboard in such a way that the temperature of the
TSP10 case does not rise above 60 °C.
Assembly with heat sink
Ambient temperature Highest permissible
Motor current
Free convection 25 °C 7.0 A
45 °C 3.5 A
With fan 25 °C 7.0 A
45 °C 7.0 A
Check the temperature of the TSP10 case by direct measuring with a
temperature sensor while the plant is running. In addition, you may display
the device temperature in the parameterization programme TopSuite. This
measured value is used for shutdown because of overheating.

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6 Electric installation
Connecting or separating live wires and connections may lead to arcing.
This damages wires and contacts and may injure people.
· Connect or disconnect electric contacts only when the supply voltage is switched off.
Improper installation of the stepper motor control may destroy the stepper
motor control or connected devices, or people may be injured by electric
shock.
· The stepper motor control may be installed only by specialist staff trained in electrical
engineering.
The stepper motor control TSP10 has four terminals to connect external components:
· supply voltage (X3)
· motor connection (X4)
· signal inputs and outputs (X2)
· RS232 interface (X1)
The following paragraphs specify the connector configuration and the typical wiring.
The stated wire cross sections, the implementation of the wiring and methods of grounding and
shielding are complying with the general state-of-the-art and are sufficient for most applications.
Special applications, operating conditions and system configurations or
standards and regulations may require to connect the TSP10 in a manner not
described in the following paragraphs. In particular standards and regulations
will then override the information given here.

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6.1 Connections
Front side Bottom side
No.
Connection
Position and construction
1
RS
-
232 interface
X1, front side, Sub-D-Socket 9p
2
Signal inputs and outputs
X2, front side, Sub-D-Socket 25p
3
Supply voltage
X3, bottom side, FKCT 2,5/4-ST
4
Motor connection
X4, bottom side, FKCT 2,5/5-ST
1
2
3
4
1
2
3
4
5