Moons' TSM24S/Q User manual

TSM24S/Q
Integrated Step-Servo Motor
Hardware Manual
Rev. 1.0
AMP & MOONS’ Automation

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Contents
1 Introduction.................................................................................. 3
1.1 Features.............................................................................................3
1.2 Block Diagram ...................................................................................4
1.3 Safety Instructions .............................................................................5
2 Getting Started ............................................................................ 6
2.1 Installing Software .............................................................................6
2.2 Mounting the Hardware .....................................................................6
2.3 Choosing a Power Supply .................................................................7
2.3.1 Voltage ..................................................................................................7
2.3.2 Regeneration Clamp ..............................................................................7
2.3.3 Current ...................................................................................................8
3 Installation/Connections ............................................................ 10
3.1 Connecting the Power Supply .........................................................10
3.2 Connecting the TSM24S/Q Communications.................................. 11
3.2.1 Connecting to the PC using RS-232 ....................................................11
3.2.2 Connecting to a Host using RS-485 .....................................................12
3.3 Inputs and Outputs ..........................................................................14
3.3.1 Connector Pin Diagram ........................................................................14
3.3.2 STEP & DIR Digital Inputs....................................................................15
3.3.3 X3/X4/X5/X6 Digital Input.....................................................................16
3.3.4 X7/X8 Digital Input................................................................................17
3.3.5 AIN Input...............................................................................................17
3.3.6 Programmable Output Y1/Y2/Y3..........................................................18
3.3.7 Programmable Output Y4.....................................................................19
4 Troubleshooting ......................................................................... 20
5 Reference Materials .................................................................. 21
5.1 Mechanical Outlines ........................................................................21
5.2 Technical Specications...................................................................22
8.3 Torque-Speed Curves......................................................................23
8.4 SCL Command Reference ..............................................................24
6 Contacting MOONS’ .................................................................. 26

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1 Introduction
Thank you for selecting the MOONS’ TSM24S/Q Integrated Motor.The
TSM line of integrated step-servo motors combines servo technology with
an integrated motor to create a product with exceptional feature and broad
capability. We hope our commitment to performance, quality and economy
will result in a successful motion control project.
1.1 Features
• Programmable, Digital servo driver and motor in an integrated package
• Operates from a 12 to 70 volt DC power supply
• Control Modes:
Torque Control
* Analog input
* SCL commanded
Velocity Control
* Digital input Control Velocity
* Analog velocity
* SCL Commanded Velocity (Jogging)
Position Control
* Digital Signal type
Step & Direction
CW & CCW pulse
A/B Quadrature
* Analog Position
* Serial Commanded Position
Q Programming(Q Verision only)
* Stand alone operation
• Communications:
RS-232 or RS-485
• 5000 line (20,000 counts/rev) encoder feedback
• Available torque:
TSM24□-3□G: Up to 2.4N•m Continuous(3.0 N•m Boost)
• I/O:
8 optically isolated digital inputs, with adjustable bandwidth digital noise rejection lter, 5 to 24
volts
4 optically isolated digital output, 30V/100 mA max.
1 analog input for speed and position control, 0 to 5 volts
Differential encoder outputs (A±, B±, Z±), 26C31 line driver, 20 mA sink or source max
• Technological advances:
Full servo control, Closed loop
Efcient, Accurate, Fast, Smooth
Intelligent, Compact

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1.2 Block Diagram
A+
A -
B+
B -
Z+
Z-
Line
Driver
Encoder Outputs
Block Diagram
MOSFET
PWM
Power
Amplifier
12 - 70 VDC
External
Power Supply
Voltage
Temp
Detect
Over
Current
Detect
motor
encoder
5 Volt DC
Power Supply
DSP
Driver
Controller
3.3VDC
Internal
Logic
Supply
TSM24S/Q
I/O Connector
+
+5VDC (100mA max)
GND
Status
AIN
Optical
Iso
RS-232 or RS-485
Comm
Conn Power
Conn
GND
+5V
RS-232
RXD,+5V,TXD,GND,GND
or
RS-485
RX+,RX-,TX+,TX-,GND
-
X1
X2
X3
X4
X5
X6
X7
X8
Y1
Y2
Y3
Y4
Optical
ISO

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1.3 Safety Instructions
Only qualied personnel should transport, assemble, install, operate, or maintain this equipment.
Properly qualied personnel are persons who are familiar with the transport, assembly, installation,
operation, and maintenance of motors, and who meet the appropriate qualications for their jobs.
To minimize the risk of potential safety problems, all applicable local and national codes regulating
the installation and operation of equipment should be followed. These codes may vary from area
to area and it is the responsibility of the operating personnel to determine which codes should be
followed, and to verify that the equipment, installation, and operation are in compliance with the
latest revision of these codes.
Equipment damage or serious injury to personnel can result from the failure to follow all applicable
codes and standards. MOONS’ does not guarantee the products described in this publication
are suitable for a particular application, nor do they assume any responsibility for product design,
installation, or operation.
• Read all available documentation before assembly and operation. Incorrect handling of the
products referenced in this manual can result in injury and damage to persons and machinery.
All technical information concerning the installation requirements must be strictly adhered to.
• It is vital to ensure that all system components are connected to earth ground. Electrical safety
is impossible without a low-resistance earth connection.
• This product contains electrostatically sensitive components that can be damaged by incorrect
handling. Follow qualied anti-static procedures before touching the product.
• During operation keep all covers and cabinet doors shut to avoid any hazards that could
possibly cause severe damage to the product or personal health.
• During operation, the product may have components that are live or have hot surfaces.
• Never plug in or unplug the Integrated Motor while the system is live. The possibility of electric
arcing can cause damage.
Be alert to the potential for personal injury. Follow recommended precautions and safe operating
practices emphasized with alert symbols. Safety notices in this manual provide important
information. Read and be familiar with these instructions before attempting installation, operation,
or maintenance. The purpose of this section is to alert users to the possible safety hazards
associated with this equipment and the precautions necessary to reduce the risk of personal injury
and damage to equipment. Failure to observe these precautions could result in serious bodily
injury, damage to the equipment, or operational difculty.

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2 Getting Started
The following items are needed:
• a 12 - 70 Volt DC power supply, see the section below entitled “Choosing a Power Supply” for
help in choosing the right one
• a small at blade screwdriver for tightening the connectors (included)
• a PC running Microsoft Windows 2000, XP, Vista, or Windows 7
• a MOONS’ programming cable (included with RS-232 Models; RS-485 converters are
available from MOONS’)
2.1 Installing Software
Before utilizing the TSM24S/Q Integrated Step-Servo Motor and Step-Servo Quick Tuner Software
in an application, the following steps are necessary:
• Install the Step-Servo Quick Tuner software from the MOONS’ website.
• Connect the drive to the PC using the programming cable. When using RS-485, it must be
setup in a 4-Wire conguration (see “Connecting to a host using RS-485” below.)
• Connect the drive to the power supply. See instructions below.
• Launch the software by clicking Start...Programs...MOONS’.
• Apply power to the drive.
• The software will recognize the drive and display the model and rmware version. At this point,
it is ready for use.
2.2 Mounting the Hardware
As with any step motor, the TSM24S/Q must be mounted so as to provide maximum heat sinking
and airow. Keep enough space around the Integrated Motor to allow for airow.
• Never use the drive where there is no airow or where other devices cause the
surrounding air to be more than 40°C (104°F).
• Never put the drive where it can get wet.
• Never use the drive where metal or other electrically conductive particles can
inltrate the drive.
• Always provide airow around the drive.

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2.3 Choosing a Power Supply
The main considerations when choosing a power supply are the voltage and current requirements
for the application.
2.3.1 Voltage
The TSM24S/Q is designed to give optimum performance between 24 and 48 Volts DC. Choosing
the voltage depends on the performance needed and motor/drive heating that is acceptable and/
or does not cause a drive over-temperature. Higher voltages will give higher speed performance
but will cause the TSM24S/Q to produce higher temperatures. Using power supplies with voltage
outputs that are near the drive maximum may signicantly reduce the operational duty-cycle.
The extended range of operation can be as low as 10 VDC minimum to as high as 75 VDC
maximum. When operating below 18 VDC, the power supply input may require larger capacitance
to prevent under-voltage and internal-supply alarms. Current spikes may make supply readings
erratic. The supply input cannot go below 10 VDC for reliable operation. Absolute minimum power
supply input is 10 VDC. If the Input supply drops below 10 VDC the low voltage alarm will be
triggered. This will not fault the drive.
Absolute maximum power supply input is 75 VDC at which point an over-voltage alarm and fault
will occur. When using a power supply that is regulated and is near the drive maximum voltage
of 75 VDC, a voltage clamp may be required to prevent over-voltage when regeneration occurs.
When using an unregulated power supply, make sure the no-load voltage of the supply does not
exceed the drive’s maximum input voltage of 75 VDC.
2.3.2 Regeneration Clamp
If a regulated power supply is being used, there may be a problem with regeneration. When a
load decelerates rapidly from a high speed, some of the kinetic energy of the load is transferred
back to the power supply, possibly tripping the over-voltage protection of a regulated power
supply, causing it to shut down. This problem can be solved with the use of a MOONS’ RC880
Regeneration Clamp. It is recommended that an RC880 initially be installed in an application. If
the “regen” LED on the RC880 never ashes, the clamp is not necessary.
RC880 Regen Clamp
LEDs
Green - Power
Red - Regen on

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2.3.3 Current
The maximum supply currents required by the TSM24S/Q are shown in the charts below at
different power supply voltage inputs. The TSM24S/Q power supply current is lower than the
winding currents because it uses switching ampliers to convert a high voltage and low current
into lower voltage and higher current. The more the power supply voltage exceeds the motor
voltage, the less current will be required from the power supply.
It is important to note that the current draw is signicantly different at higher speeds depending
on the torque load to the motor. Estimating how much current is necessary may require a good
analysis of the load the motor will encounter.
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0
0.5
1
1.5
2
2.5
3
3.5
0 10 20 30 40 50
Torque(N.m)
Speed(RPS)
TSM24□-3□G 24V Power
Amps
Continuous
Torque
Boost
Supply Current
Full Load
No Load
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0
0.5
1
1.5
2
2.5
3
3.5
0 10 20 30 40 50
Torque(N.m)
Speed(RPS)
TSM24□-3□G 48V Power
Amps
Continuous
Torque
Boost
Supply Current
Full Load
No Load

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0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
0
0.5
1
1.5
2
2.5
3
3.5
0 10 20 30 40 50
Torque(N.m)
Speed(RPS)
TSM24□-3□G 70V Power
Amps
Continuous
Torque
Boost
Supply Current
Full Load
No Load

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3 Installation/Connections
3.1 Connecting the Power Supply
Use 16 to 20-gauge wire to connect the TSM24 to a power supply. It contains an internal fuse
connected to the “+” terminal that is not user replaceable. If a user serviceable fuse is desired,
install a 6.3 amp fast acting fuse in line with the “+” power supply lead.
Be careful not to reverse the wires. Reversing the connection may open the internal
fuse on the drive and void the warranty.
MOONS' offers two matched power supplies for use with the TSM24S/Q.
A 24VDC, 150W(P/N MF150A24AG-V) and a 48VDC 320W(P/N MF320A48AG-V).
These power supplies have current over load capability making them ideal for use.
(To use with a switch power supplier, a RC880 regen must be connected in system)
The RC880 regeneration clamp is for use where regeneration from the motor may cause damage
to the drive. In these cases the RC880 is connected between the drive and power supply and
absorbs regenerated energy.
To Power Supply-
To Power Supply+
To Earth Ground
RC880
TSM
V-V+
V-V+
Vin
-
+
Vout
+
-
Power Supply

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3.2 Connecting the TSM24S/Q Communications
The TSM24S/Q is available with two types of serial communications, RS-232 (TSM24S/Q -3AG)
or RS-485 (TSM24S/Q -3RG). Each type requires a different hardware connection for interface to
a PC or other Host system. The RS-232 version comes with a cable that will provide the interface
to an RS-232 port through a DB9 style connector. The RS-485 version requires the user to provide
both the cabling and the RS-485 interface. Below are descriptions of how to interface both of
these serial communication types to a PC.
3.2.1 Connecting to the PC using RS-232
Locate the TSM24S/Q within 1.5 meters of the PC. Plug the DB9 connector of the communication
cable that came with the drive into the serial port of the PC. Plug the small end into the crimp style
connector on the TSM24S/Q . Secure the cable to the PC with the screws on the DB9 connector.
Note: If the PC does not have an RS-232 serial port, a USB Serial Converter will be needed.
You can contact MOONS’ to buy a USB to RS-232 converter.
The RS-232 circuitry does not have any extra electrical “hardening” and care should be taken
when connecting to the RS-232 port as hot plugging could result in circuit failure. If this is a
concern the RS-485 version should be used.
GND
TX
+5V
RX

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3.2.2 Connecting to a Host using RS-485
RS-485 communication allows connection of more than one drive to a single host PC, PLC, HMI
or other computer. It also allows the communication cable to be long (more than 300 meters
or 1000 feet). The use of Category 5 cable is recommended as it is widely used for computer
networks, inexpensive, easily obtained and certied for quality and data integrity.
The TSM24S/Q can be used with either Two-Wire or Four-Wire RS-485 implementation. The
connection can be point-to-point (i.e. one drive and one host) or a multi-drop network (one host
and up to 32 drives).
NOTE: To use the TSM24S/Q RS-485 version with the Step-Servo Quick Tuner software, it
must be connected in the Four-Wire conguration (see below)
RS-485 Connector Diagram
Four-Wire Conguration
Four-Wire Systems utilize separate transmit and receive wires. One pair of wires must connect the
host’s transmit signals to each drive’s RX+ and RX- terminals. The other pair connects the drive’s
TX+ and TX- terminals to the host’s receive signals. A logic ground terminal is provided on each
drive and can be used to keep all drives at the same ground potential. This terminal connects
internally to the DC power supply return (V-), so if all the drives on the RS-485 network are
powered from the same supply, only one drive’s GND terminal should be connected to the
host computer ground, others’ GND terminal must not connect the logic grounds.
Because the host in a four-wire system never needs to disable its transmitter, software is
simplied. Some converters make this process very difcult to implement and can delay
communications.
NOTE: If the PC does not have an RS-485 serial port, a converter is required.
You can contact MOONS’ to buy a USB to RS-485 converter.
RX+
RX-
TX+
TX-
GND
to PC GND
to PC RX-
to PC RX+
to PC TX-
to PC TX+
Drive #1 Drive #2 Drive #N
RX+
RX-
TX+
TX-
GND
RX+
RX-
TX+
TX-
GND
RX+
RX-
TX+
TX-
GND
120Ω
RX+
RX-

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Two-Wire Conguration
In a 2-wire system, the host must disable its transmitter before it can receive data. This must be
done quickly before a drive begins to answer a query. The TSM24S/Q includes a transmit delay
parameter that can be adjusted to compensate for a host that is slow to disable its transmitter. This
adjustment can be made over the network using the TD command, or it can be set using the Step-
Servo Quick Tuner software. It is not necessary to set the transmit delay in a four wire system.
NOTE: If the PC does not have an RS-485 serial port, a converter is required.
You can contact MOONS’ to buy a USB to RS-485 converter.
Assigning Addresses
Before the entire system is wired, each drive will need to connect individually to the host computer
so that it can be assigned a unique address.
Once the drive has been connected to the PC as described above, launch the Step-Servo Quick
Tuner software. Apply power to the drive. If a drive has already been congured, click the Upload
button so that the Step-Servo Quick Tuner settings match those of the drive. When operating the
drive in SCL mode it will need to be assigned an address. This is done on the Drive Conguration
tab where a list of address options can be seen. The numerals 0..9 or the special characters ! “ #
$ % & ‘ ( ) * + , - . / : ; < = > ? @ may be used as addresses. Make sure each drive on the network
has a unique address. On a 2-wire network, the Transmit Delay may also need to be set. Most
adapters work well with 10 milliseconds. Once the address has been assigned, click Download to
save the settings to the drive.
to PC GND
to PC TX- (A)
to PC TX+ (B)
Drive #1 Drive #2 Drive #N
RX+
RX-
TX+
TX-
GND
RX+
RX-
TX+
TX-
GND
RX+
RX-
TX+
TX-
GND
120Ω
RX+
RX-

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3.3 Inputs and Outputs
The TSM24S/Q has three types of inputs:
• High speed digital inputs for step & direction commands or encoder following, 5 to 24 volt logic
• Low speed digital input for other signals, 5 to 24 volt logic
• Analog input for analog speed and positioning modes
All drives include 8 digital inputs and 1 analog input
• X1/STEP & X2/DIR are high-speed digital inputs for commanding position. Quadrature signals
from encoders can also be used. When not being used for the Step & Direction function these
inputs can be used for CW & CCW step, (start/stop)/direction (oscillator mode), or general
purpose input
• X3 & X4 are low speed software programmable input and can be used for Motor Enable/
Disable and Alarm/Fault Reset function, or general purpose input
• X5/X6/X7/X8 are low speed software programmable input and can be used for CW/CCW Jog,
CW/CCW Limit, Speed 1/Speed 2 (oscillator mode), or general purpose input
• AIN is an analog input for a velocity or position command signal. It can accept 0-5 volts and
has gain, ltering, offset and dead-band settings.
3.3.1 Connector Pin Diagram
A-
B-
Z-
Y4-
YCOM
Y2
X8-
X7-
GND
+5V
X6
X4
DIR-
STEP-
A+
B+
Z+
Y4+
Y3
Y1
X8+
X7+
AIN
XCOM
X5
X3
DIR+
STEP+
27 28
1 2

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3.3.2 STEP & DIR Digital Inputs
The TSM24 drives include two high-speed inputs: X1/STEP and X2/DIR. They accept 5 to 24 volt
single-ended or differential signals, up to 2 MHz. Typically these inputs connect to an external
controller that provides step & direction command signals. You can also connect a master encoder
to the high-speed inputs for “following” applications. Or you can use these inputs with Wait
Input(WI), Feed to Sensor(FS), Seek Home(SH) and other SCL or Q commands.
The diagrams below show how to connect the STEP & DIR Inputs to various commonly used
devices.
+5v to +24v out
DIR
STEP
DIR+
DIR-
STEP+
STEP-
Indexer
with
Sinking
Outputs
Connecting to Indexer with Sinking Outputs
TSM24
DIR
COM
STEP
Indexer
with
Sourcing
Outputs
DIR+
DIR-
STEP+
STEP-
Connecting to Indexer with Sourcing Outputs
TSM24
DIR+
DIR-
STEP+
DIR+
DIR-
STEP+
STEP-
STEP-
Indexer
with
Differential
Outputs
Connecting to Indexer with Differential Outputs
Many high-speed indexers have differential outputs
TSM24
DIR+
DIR-
STEP+
STEP-
5 - 24
volt DC
Power
Supply
Using Mechanical Switches
+direction switch
run/stop switch
(closed = run)
TSM24

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3.3.3 X3/X4/X5/X6 Digital Input
While the STEP and DIR inputs are designed for high-speed digital input operation, the X3/X4/
X5/X6 input are designed for low speed digital input operation between 5 and 24 volts optically
Isolated Single-ended input. They can be used with sourcing or sinking signals, 5 to 24 volts. This
allows connection to PLCs, sensors, relays and mechanical switches. Because the input circuits
are isolated, they require a source of power. If you are connecting to a PLC, you should be able
to get power from the PLC power supply. If you are using relays or mechanical switches, you will
need a 5-24 V power supply.
What is COM?
“Common” is an electronics term for an electrical connection to a common voltage. Sometimes
“common” means the same thing as “ground”, but not always. In the case of the TSM24 drives, if
you are using sourcing (PNP) input signals, then you will want to connect COM to ground (power
supply -). If you are using sinking (NPN) signals, then COM must connect to power supply +.
Note: If current is owing into or out of an input, the logic state of that input is low or
closed. If no current is owing, or the input is not connected, the logic state is high or
open.
The diagrams below show how to connect X3/X4/X5/X6 input to various commonly used devices.
5-24VDC
0VDC
XCOM
X3
X4
X5
X6
User Control Drives
5-24VDC
XCOM
X3
X4
Drives
0VDC
+
-
NPN
Sensor
5-24VDC
XCOM
X3
Drives
+
-
PNP
Sensor
0VDC

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3.3.4 X7/X8 Digital Input
The X7/X8 input are designed for low speed digital input operation between 5 and 24 volts
optically Isolated differential input. They are normally used for end of travel limit switches. The
diagrams below show how to connect the X7/X8 Inputs to various commonly used devices.
3.3.5 AIN Input
The TSM24S/Q drives have an analog input (AIN) which can accept a signal range of 0 to 5 volts.
The drive can be congured to operate at a speed or position that is proportional to the analog
signal. Use the Step-Servo Quick Tuner software to set the signal range, offset, dead-band and
lter frequency. The TSM24S/Q provides a +5 volt/100mA limit voltage supply that can be used to
power external devices such as potentiometers. It is not the most accurate supply for reference,
for more precise readings use an external supply that can provide the desired accuracy.
5 - 24
volt DC
Power
Supply
Connecting an NPN type Proximity Sensor to an Input
(when prox sensor activates, input goes low)
X7/X8+
X7/X8-
+
-
+
NPN
Proximity
Sensor
-output
TSM24
5 - 24
volt DC
Power
Supply
Connecting a PNP type Proximity Sensor to an Input
(when prox sensor activates, input goes low)
X7/X8+
X7/X8-
+
-
+
PNP
Proximity
Sensor
-
output
TSM24
+5v
AIN
GND
100 mA limit
Signal
Conditioning
inside drive
rotcennoCO/I
Ω
+5v OUT
AIN
GND
1 - 10k
pot TSM24
Connecting a Potentiometer
to the Analog Input

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3.3.6 Programmable Output Y1/Y2/Y3
The TSM24S/Q drives feature three optically isolated digital outputs (Y1 to Y3). Y1, Y2 and Y3
share a common terminal YCOM.
• Y1 can be set to signal a fault condition.
• Y2 can be set to indicate whether the motor is in position(dynamic).
• Y3 can be set to control a motor brake.
These outputs can also be turned on and off by program instructions like Set Output (SO). The
output can be used to drive LEDs, relays and the inputs of other electronic devices like PLCs and
counters. Diagrams of various connection types follow.
Do not connect the outputs to more than 30 volts. The current through each output terminal must
not exceed 100mA.
5-24VDC
0VDC
Y1
YCOM
Y2
Y3
User Control Drives
Y1
YCOM
Y2
Y3
Load
+
-
5-24VDC
Power Supply

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3.3.7 Programmable Output Y4
TSM24S/Q drives feature one optically isolated digital output Y4. The Y4+(collector) and Y4-
(emitter) terminals of the transistor are available at the connector. This allow the output to be
congured for current sourcing or sinking.
Y4 can be set to provide an output frequency proportional to motor speed (tach signal) or to
provide a timing output (50 pulses/rev) or to indicate whether the motor is in position(static)
Diagrams of various connection types follow.
Do not connect the output to more than 30 volts. The current through the output terminal
must not exceed 100mA.
+
-
Y4+
Y4-
5 - 24
volt DC
Power
Supply
Connecting a Sinking Output
Load
TSM24
COM
IN
Y4+
Y4-
PLC
Connecting a Sourcing Output
5 - 24VDC
Power Supply
TSM24
+
-
+
-
5 - 24
volt DC
Power
Supply
Driving a Relay
Y4+
Y4-
relay
1N4935 suppresion diode
TSM24

20
Rev. 1.0
0006302013
TSM24S/Q Hardware Manual
[phone]
4 Troubleshooting
LED Error Codes
The TSM24S/Q uses red and green LEDs to indicate status. When the motor is enabled, the
green LED ashes slowly. When the green LED is solid, the motor is disabled. Errors are indicated
by combinations of red and green ashes as shown below. This feature can be disabled for certain
warnings but not for alarms. See software manual for information on how to do this and which
warnings may be masked.
Code Error
Solid green no alarm,motor disabled
Flashing green no alarm,motor enabled
1red,1 green motor stall (optional encoder only)
2red,1 green ccw limit
2red,2 green cw limit
3 red,1 green drive overheating
3 red,2 green internal voltage out of range
3 red,3 green blank Q segment
4 red,1 green power supply overvoltage or excess regen
4 red,2 green power supply undervoltage
4 red,3 green ash memory backup error
5 red,1 green Over current/short circuit
6 red,1 green Open motor winding
6 red,2 green bad encoder signal (optional encoder only)
7red,1 green communication error
7red,2 green ash memory error