Trinamic TMCM-160 User manual

TMCM-160
Hardware
BLDC motor controller/driver module 5A/36V
with RS232 / RS485 and analog interface
V1.11
August 8th, 2007
Trinamic Motion Control GmbH & Co. KG
Sternstraße 67
D – 20357 Hamburg, Germany
www.trinamic.com

TMCM-160 Manual (V1.11 / August 8th, 2007) 2
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
Contents
1Features........................................................................................................................................................................... 3
2Life support policy....................................................................................................................................................... 4
3Outer Description ......................................................................................................................................................... 5
3.1 Pinning................................................................................................................................................................... 5
3.2 Dimensions........................................................................................................................................................... 7
3.3 Connectors ............................................................................................................................................................ 7
3.4 Application Environment .................................................................................................................................. 7
4Operational / Limiting Ratings................................................................................................................................. 8
4.1 Power supply requirements ............................................................................................................................ 8
5Functional description ................................................................................................................................................ 9
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
5.6 Demonstration Application ............................................................................................................................ 10
5.7 Programmable motor current limit ............................................................................................................. 10
5.8 Parameterizing the PID velocity regulator ................................................................................................ 11
5.9 Parameterizing the positioning algorithm ................................................................................................ 12
5.10 Restoring factory default settings................................................................................................................ 12
6Revision History.......................................................................................................................................................... 13
6.1 Documentation Revision................................................................................................................................. 13
6.2 Firmware Revision............................................................................................................................................ 13
7References .................................................................................................................................................................... 13
List of Figures
Figure 3.1: Pinning................................................................................................................................................................ 5
Figure 3.2: Dimensions........................................................................................................................................................ 7
Figure 3.3: Application Environment............................................................................................................................... 7
Figure 5.1: PID velocity regulator parameters............................................................................................................ 11
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 4.1: Operational / Limiting Ratings ...................................................................................................................... 8
Table 5.1: Options for stand alone operation .............................................................................................................. 9
Table 5.2: LEDs - Temperature, Current and Voltage monitoring function..........................................................9
Table 6.1: Documentation Revision ............................................................................................................................... 13
Table 6.2: Firmware Revision .......................................................................................................................................... 13

TMCM-160 Manual (V1.11 / August 8th, 2007) 3
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
1 Features
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 mm2) allows for integration onto a user
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-160-
EvalBoard).
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)
Highlights
• High-efficiency operation, low power-dissipation
• Typical Supply voltage 14V – 36V (ask for 48V option)
• Integrated Protection: Overload and overtemperature, reverse polarity on EVAL board.
• Supports the TRINAMIC TMCL protocol and the TMCL software environment for parameterizing
• On the fly alteration of motion parameters (e.g. position, velocity, acceleration)
Other
• Two 2-row 2.54mm connectors
• ROHS compliant
• Size: 50x92mm²
Order code Description
TMCM-160 (-option) BLDC module
TMCM-160 Evalboard BLDC evaluation module with screw terminals
TMCM-160 EvalKit BLDC evaluation module + motor + cables
Option Host interface
232 RS232 interface (standard version)
485 RS485 interface
Table 1.1: Order codes

TMCM-160 Manual (V1.11 / August 8th, 2007) 4
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
2 Life support policy
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.
© TRINAMIC Motion Control GmbH & Co. KG 2005
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.
Specifications subject to change without notice.

TMCM-160 Manual (V1.11 / August 8th, 2007) 5
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
3 Outer Description
3.1 Pinning
1
Connectors shown as top view
2
3
54 6
7
98 10
11
13 12 14
15
17 16 18
19
21 20 22
23
25 24 26
5V_AREF
AIN1
DIRIN
/MOTOR_OFF
LED_CURLIM
GND
MCLR
GND
PGC
-
-
-
-GND
-
TXD / RS485NI
RXD / RS485INV
-
PGD
+5V
GND
+5V
LED_TEMP
GPIO1
GND
AIN0 / VIN 0-10V for
velocity
Pins 18 to 26 for
RS232 via DSUB
male and
nullmodem cable
Do not use these
pins
Standard connector for
Supply and Motor / Hall Sensors Optional connectors on Evaluation board
1.5mm
Connector
1
2
3
4
5
+5V
GND
H1
H2
H3
1
2
3
4
5
GND
VS
W
V
U
User I/O
direction
Connectors each shown
as top view
12 3
5
4
67
9
8
10 11
13
12
14 15
17
16
18 19
21
20
22 23
25
24
26
U
U
V
V
W
W
VS
VS
GND
GND
GND
+5V
H3H2
H1
GND
GND
GND
VS
VS
W
W
V
V
U
U
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

TMCM-160 Manual (V1.11 / August 8th, 2007) 6
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
Pin Name Function
1 5V_AREF 5V analog reference as used by the internal DAC. Max. load 0.5mA
2 AIN0 / VIN Analo
g
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 Startin
g
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
g
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
RXD signal of module for RS232 communication (RS232 version)
Inverting RS485 signal (RS485 version)
22 TXD /
RS485NI
TXD signal of module for RS232 communication (RS232 version)
Non-inverting RS485 signal (RS485 version)
All other pins Leave all other pins unconnected!
Table 3.2: Pinning of I/O connector

TMCM-160 Manual (V1.11 / August 8th, 2007) 7
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
3.2 Dimensions
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
3.4 Application Environment
TMCM-160
HALL sensors
RS-232
or
RS-485
BLDC
Motor
5V Power Supply
14..36V DC
programmable
Motion
Controller
3-ph
MOSFET
Driver
Stage
„classic“ analog
control
Figure 3.3: Application Environment

TMCM-160 Manual (V1.11 / August 8th, 2007) 8
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
4 Operational / Limiting Ratings
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
VSPower supply voltage for operation 9.0*) 14 - 36 40.0 V
ISPower supply current 0.04 IMOT A
PID Module idle power consumption 1.2 W
V55 Volt (+-8%) output external load (hall sensors plus
other load)
30 mA
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
It is not recommended to set motor current above 6A!
0 – 6 8.5 A
IMPP Peak coil output current for 100ms 20 A
VILogic input voltage on digital / hall sensor inputs -0.3 VCC+
0.3
V
VOLogic output current on digital outputs (5V CMOS output) 10 mA
VIA Analog input voltage -24 0 – 10 24 V
fCHOP Chopper frequency 20 kHz
ExExactness of voltage and current measurement -8 +8 %
TSL Motor output slope (U, V, W) 100 ns
TOEnvironment temperature operating -25 +70 °C
TOF Environment temperature for operation at full specified
current (air flow mi
g
ht required, dependin
g
upon motor
/ voltage)
-25 +60 °C
Tboard Temperature of the module, as measured by the
integrated sensor.
<100 125 °C
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.

TMCM-160 Manual (V1.11 / August 8th, 2007) 9
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
5 Functional description
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 analo
g
input VIN.
Motor direction controlled by DIR in pin.
Remote control flag = 0
Power on velocity = 0
PID enforced velocity
Maximum motor velocity vmax set via software. This
velocity is scaled by VIN pin volta
g
e and enforced
by the PID velocity regulator.
Remote control flag = 0
Power on velocity = vmax
Constant velocity Desired motor velocity v set via software Remote control flag = 1
Power on velocity = v
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.
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
Temperature
Warning
Blink The power sta
g
e on the module has exceeded a critical temperature
of 100°C. (Pre-warning)
Temperature
Warning
On The power sta
g
e 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
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
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.
tLIM = 1 / (1 / 3s + 1 / (10ms * (1+xCRLD)))
xCRLD is the current regulation loop delay parameter, tLIM the resulting time for an 1/e response.
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.

TMCM-160 Manual (V1.11 / August 8th, 2007) 11
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
5.8 Parameterizing the PID velocity regulator
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:
tPIDDELAY = xPIDRLD * 10ms
xPIDRLD is the PID regulation loop delay parameter, tPIDDELAY is the resulting delay between two PID
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).
actual RPM
(1/4 electrical
RPM)
target RPM
(1/4 electrical
RPM)
Clip
4095
32 / P-param
sum Clip
32767
32 / I-param
last
32 / D-param
actual PWM
0-1023
new PWM
CLK: 100Hz /
PIDloopdelay
CLK: 100Hz /
PIDloopdelay
Figure 5.1: PID velocity regulator parameters
Default values:
P-param = 2400
I-Param = 150
D-Param = 600
xPIDRLD = 2

TMCM-160 Manual (V1.11 / August 8th, 2007) 12
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
5.9 Parameterizing the positioning algorithm
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
|velocity|
position
target position
(set via MVP)
max_pos_speed
min_pos_speed
MVP_target_reached_distance
Motor off in this area
active_brake_velocity Motor braked in this
area if hard_stop_flag
set
MVP_slow_down_distance
Velocity enforced by
PID regulator
velocity enforced by
PID regulator
actual motor velocity
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.

TMCM-160 Manual (V1.11 / August 8th, 2007) 13
Copyright © 2006, TRINAMIC Motion Control GmbH & Co. KG
6 Revision History
6.1 Documentation Revision
Version Comment Description
1.07 New Version Revised Version
1.08
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 settin
g
s
above 4.6A
1.02 Added RS485,
Tacho output
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
1.03 Invert Hall Added possibility for inversion for hall sensor signals
Corrected velocity readout when motor is turned by external force
1.04 Disable Stop
switch
Added disable stop switch function
1.05 RS485 Corrected sent back address
1.06 Corrected
position
counter
In older firmware versions, the position counter sometimes looses a
step, which may add up durin
g
lon
g
er motions to 1/1000 of total
count.
Table 6.2: Firmware Revision
7 References
[TMCL] TMCL Manual, www.trinamic.com
TMCM BLDC Module Reference and Programming Manual, www.trinamic.com