Trinamic PD-1141 User manual

MECHATRONIC DRIVE WITH STEPPER MOTOR PANdrive
TRINAMIC Motion Control GmbH & Co. KG
Hamburg, Germany
www.trinamic.com
Hardware Version V1.2
HARDWARE MANUAL
++PD-1141
+ +
UNIQUE FEATURES
Stepper Motor with
Controller / Driver
0.27 - 0.49 Nm / 24 V DC
USB, RS485, and S/D Interface

PD-1141 Hardware Manual (Rev. 1.04 / 2013-JUL-23) 2
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Table of Contents
1Features........................................................................................................................................................................... 3
2Order Codes ................................................................................................................................................................... 5
3Mechanical and Electrical Interfacing..................................................................................................................... 6
3.1 Dimensions ........................................................................................................................................................... 6
3.2 Stepper Motor Specifications ........................................................................................................................... 7
3.3 Connectors of PD-1141....................................................................................................................................... 8
3.3.1 Power and RS485 Connector ..................................................................................................................... 9
3.3.1.1 Power Supply .......................................................................................................................................... 9
3.3.1.2 RS485 ....................................................................................................................................................... 10
3.3.2 Multipurpose I/O Connector..................................................................................................................... 11
3.3.2.1 Digital Inputs IN_0, IN_1, IN_2 ........................................................................................................ 12
3.3.2.2 Analog Input AIN_1............................................................................................................................. 13
3.3.2.3 Outputs OUT_0, OUT_1 ........................................................................................................................ 13
3.3.3 Step/Direction Connector .......................................................................................................................... 14
3.3.3.1 Step / Direction / Enable inputs....................................................................................................... 14
3.3.4 Motor Connector.......................................................................................................................................... 15
3.3.5 Mini-USB Connector .................................................................................................................................... 16
4Reset to Factory Defaults......................................................................................................................................... 17
5On-Board LED .............................................................................................................................................................. 17
6Operational Ratings ................................................................................................................................................... 18
7Torque Curves ............................................................................................................................................................. 19
7.1.1 PD42-1-1141 Torque Curves...................................................................................................................... 19
7.1.2 PD42-2-1141 Torque Curves...................................................................................................................... 19
7.1.3 PD42-3-1141 Torque Curves...................................................................................................................... 20
8Functional Description.............................................................................................................................................. 21
9PD-1141 Operational Description........................................................................................................................... 22
9.1 Calculation: Velocity and Acceleration vs. Microstep and Fullstep Frequency ................................ 22
10 Life Support Policy..................................................................................................................................................... 24
11 Revision History.......................................................................................................................................................... 25
11.1 Document Revision ........................................................................................................................................... 25
11.2 Hardware Revision ............................................................................................................................................ 25
12 References .................................................................................................................................................................... 25

PD-1141 Hardware Manual (Rev. 1.04 / 2013-JUL-23) 3
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1Features
The PANdrive™PD-1141 is a full mechatronic solution with state of the art feature set. It is highly
integrated and offers a convenient handling. The PD-1141 includes a stepper motor and controller/driver
electronics. It can be used in many decentralized applications and has been designed for 0.27… 0.49 Nm
max. holding torque and 24V DC nominal supply voltage. With its high energy efficiency from TRINAMICs
coolStep technology cost for power consumption is kept down. The TMCL™ firmware allows for standalone
operation and direct mode.
MAIN CHARACTERISTICS
Motion controller
-Motion profile calculation in real-time
-On the fly alteration of motor parameters (e.g. position, velocity, acceleration)
-High performance microcontroller for overall system control and serial communication protocol
handling
Bipolar stepper motor driver
-Up to 256 microsteps per full step
-High-efficient operation, low power dissipation
-Dynamic current control
-Integrated protection
-stallGuard2 feature for stall detection
-coolStep feature for reduced power consumption and heat dissipation
-ready for dcStep
Interfaces
-RS485 2-wire communication interface
-USB full speed (12Mbit/s) device interface
-Step/Direction/Enable interface (optically isolated) for external control of driver circuit
-4 multipurpose inputs:
-3x general-purpose digital inputs
(Alternate functions: STOP_L / STOP_R / HOME switch inputs)
-1x dedicated analog input
-2 general purpose outputs
-2x open-drain 100 mA max.
Software
-TMCL: standalone operation or remote controlled operation,
program memory (non volatile) for up to 1024 TMCL commands, and
PC-based application development software TMCL-IDE available for free.
Electrical and mechanical data
-Supply voltage: +24 V DC nominal (9… 28 V DC)
-Motor current: up to 1.1 A RMS / 1.7 A peak (programmable)
-0.27… 0.49 Nm max. holding torque (depends on motor)
Refer to separate TMCL Firmware Manual, too.

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TRINAMICS UNIQUE FEATURES –EASY TO USE WITH TMCL
stallGuard2™stallGuard2 is a high-precision sensorless load measurement using the back EMF on the
coils. It can be used for stall detection as well as other uses at loads below those which
stall the motor. The stallGuard2 measurement value changes linearly over a wide range
of load, velocity, and current settings. At maximum motor load, the value goes to zero or
near to zero. This is the most energy-efficient point of operation for the motor.
Load
[Nm]
stallGuard2
Initial stallGuard2
(SG) value: 100%
Max. load
stallGuard2 (SG) value: 0
Maximum load reached.
Motor close to stall.
Motor stalls
Figure 1.1 stallGuard2 load measurement SG as a function of load
coolStep™coolStep is a load-adaptive automatic current scaling based on the load measurement via
stallGuard2 adapting the required current to the load. Energy consumption can be
reduced by as much as 75%. coolStep allows substantial energy savings, especially for
motors which see varying loads or operate at a high duty cycle. Because a stepper motor
application needs to work with a torque reserve of 30% to 50%, even a constant-load
application allows significant energy savings because coolStep automatically enables
torque reserve when required. Reducing power consumption keeps the system cooler,
increases motor life, and allows reducing cost.
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
0 50 100 150 200 250 300 350
Efficiency
Velocity [RPM]
Efficiency with coolStep
Efficiency with 50% torque reserve
Figure 1.2 Energy efficiency example with coolStep

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2Order Codes
The PD-1141 is currently available with three NEMA 17 stepper motors.
The length of the PANdrives is specified without the length of the axis. For the overall length of the
product please add 24 mm.
Order code
Description
Size (mm3)
PD42-1-1141-option
PANdrive 0.27Nm max. holding torque
42 x 42 x 46.5
PD42-2-1141-option
PANdrive 0.35Nm max. holding torque
42 x 42 x 51
PD42-3-1141-option
PANdrive 0.49Nm max. holding torque
42 x 42 x 60
Table 2.1 PD-1141 order codes
The following options are available:
Firmware option
Description
Order code example:
-TMCL
Module pre-programmed with TMCL firmware
PD42-1-1141-TMCL
Table 2.2 PD-1141 firmware options
A cable loom set is available for this module:
Order code
Description
PD-1141-CABLE
Cable loom for PD-1141:
-1x cable loom for power and RS485 connector (length 200mm)
1x cable loom for multipurpose I/O connector (length 200mm)
-1x cable loom for S/D connector (length 200mm)
-1x USB type A connector to mini-USB type B connector cable (length 1.5m)
Table 2.2 Cable loom order codes

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3Mechanical and Electrical Interfacing
3.1 Dimensions
The PD-1141 includes the TMCM-1141 stepper motor controller/driver module and a NEMA17 bipolar
stepper motor. Currently, there is a choice between three NEMA 17/42mm bipolar stepper motors with
different lengths and different holding torques.
Length
42±1
2
22-0.05
24±1
20
5
4.5
13 max
37
22
42±1
42±1
5
42±1
34
2xM3
42±1
37
34
3
FRONT VIEW REAR VIEW
Figure 3.1 PD-1141 dimensions
Model
Length of motor
PD42-1-1141
33.5±1 mm
PD42-2-1141
38±1 mm
PD42-3-1141
47±1 mm

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3.2 Stepper Motor Specifications
MAIN CHARACTERISTICS OF THREE DIFFERENT MOTORS AVAILABLE AS PART OF THE PD-1141
Specifications
Units
QSH4218
-35-10-027
-41-10-035
-51-10-049
Rated Voltage
V
5.3
4.5
5.0
Rated Phase Current
A
1.0
1.0
1.0
Phase Resistance at 20°C
Ω
5.3
4.5
5.0
Phase Inductance (typ.)
mH
6.6
7.5
8.0
Holding Torque (typ.)
Ncm
27
35
49
oz in
38
50
69
Detent Torque
mNm
22
25
28
Rotor Inertia
g cm2
35
54
68
Weight (Mass)
Kg
0.22
0.28
0.35
Insulation Class
B
B
B
Dielectic Strength (for one minute)
VAC
500
500
500
Connection Wires
N°
4
4
4
Step Angle
°
1.8
1.8
1.8
Step angle Accuracy (max.)
%
5
5
5
Flange Size (max.)
mm
42.3
42.3
42.3
Motor Length (max.)
mm
33.5
38
47
Rear shaft hole depth
mm
5.0
5.0
5.0
Rear shaft hole diameter
mm
3.0
3.0
3.0
Axis Diameter
mm
5.0
5.0
5.0
Axis Length (typ.)
mm
24
24
24
Axis D-cut (0.5mm depth)
mm
20
20
20
Maximum Radial Force
(20 mm from front flange)
N
28
28
28
Maximum Axial Force
N
10
10
10
Ambient temperature
°C
-20…+50
-20…+50
-20…+50
Related PANdrive
PD42-1-1141
PD42-2-1141
PD42-3-1141
Table 3.1 NEMA 17 / 42mm stepper motor technical data

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3.3 Connectors of PD-1141
The controller/driver board of the PD-1141 offers five connectors including the motor connector which is
used for attaching the motor coils to the electronics. Further, there is a connector for power and for the
RS485 interface. The USB interface and the step/direction interface have their own connectors. The 8pin
multipurpose I/O connector offers four multipurpose inputs and two general purpose outputs.
Motor
14 1 5
Power and
RS485
1
8
Multi-
purpose
I/O
Step /
Direction
USB
14
Figure 3.2 Overview connectors
Label
Connector type
Mating connector type
Power and
RS485
Connector
CI0105P1VK0-LF
CVIlux CI01 series, 5 pins, 2mm pitch
Connector housing CVIlux: CI01055000-A
Contacts CVIlux: CI01T011PE0-A
or
Connector housing JST: PHR-5
Contacts JST: SPH-002T-P0.5S
Wire: 0.22mm2
Multi-purpose
I/O Connector
CI0108P1VK0-LF
CVIlux CI01 series, 8 pins, 2mm pitch
Connector housing CVIlux: CI01085000-A
Contacts CVIlux: CI01T011PE0-A
or
Connector housing JST: PHR-8
Contacts JST: SPH-002T-P0.5S
Wire: 0.22mm2
Step/Direction
Connector
CI0104P1VK0-LF
CVIlux CI01 series, 4 pins, 2mm pitch
Connector housing CVIlux: CI01045000-A
Contacts CVIlux: CI01T011PE0-A
or
Connector housing JST: PHR-4
Contacts JST: SPH-002T-P0.5S
Wire: 0.22mm2
Motor
Connector
CI0104P1VK0-LF
CVIlux CI01 series, 4 pins, 2mm pitch
Connector housing CVIlux: CI01045000-A
Contacts CVIlux: CI01T011PE0-A
or
Connector housing JST: PHR-4
Contacts JST: SPH-002T-P0.5S
Wire: 0.22mm2
Mini-USB
Connector
Molex 500075-1517
Mini USB Type B vertical receptacle
Any standard mini-USB plug
Table 3.1 Connectors and mating connectors, contacts and applicable wire

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3.3.1 Power and RS485 Connector
A 5pin single row connector is used for power supply and RS485 serial communication.
5
1
Pin
Label
Direction
Description
1
GND
Power (GND)
System and signal ground
2
VDD
Power (Supply)
VDD (+9 V… +28 V)
3
GND
Power (GND)
System and signal ground
4
RS485+
Bidirectional
RS485 interface, diff. signal (non-inverting)
5
RS485-
Bidirectional
RS485 interface, diff. signal (inverting)
Table 3.2 Connector for power supply and RS485
3.3.1.1 Power Supply
For proper operation care has to be taken with regard to power supply concept and design. Due to space
restrictions the PD-1141 includes about 40µF/35V of supply filter capacitors. These are ceramic capacitors
which have been selected for high reliability and long life time. The module includes a 28V suppressor
diode for over-voltage protection.
CAUTION!
Add external power supply capacitors!
It is recommended to connect an electrolytic capacitor of significant size (e.g. 470µF/35V)
to the power supply lines next to the PD-1141 especially if the distance to the power
supply is large (i.e. more than 2-3m)! In larger systems a zener diode circuitry might be
required in order to limit the maximum voltage when the motor is operated at high
velocities.
Rule of thumb for size of electrolytic capacitor:    
 
In addition to power stabilization (buffer) and filtering this added capacitor will also
reduce any voltage spikes which might otherwise occur from a combination of high
inductance power supply wires and the ceramic capacitors. In addition it will limit slew-
rate of power supply voltage at the module. The low ESR of ceramic-only filter capacitors
may cause stability problems with some switching power supplies.
Do not connect or disconnect motor during operation!
Motor cable and motor inductivity might lead to voltage spikes when the motor is
disconnected / connected while energized. These voltage spikes might exceed voltage
limits of the driver MOSFETs and might permanently damage them. Therefore, always
disconnect power supply before connecting / disconnecting the motor.
Keep the power supply voltage below the upper limit of 28V!
Otherwise the driver electronics will seriously be damaged! Especially, when the selected
operating voltage is near the upper limit a regulated power supply is highly
recommended. Please see also chapter 6 (operating values).
There is no reverse polarity protection!
The module will short any reversed supply voltage due to internal diodes of the driver
transistors.

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3.3.1.2 RS485
For remote control and communication with a host system the PD-1141 provides a two wire RS485 bus
interface. For proper operation the following items should be taken into account when setting up an
RS485 network:
1. BUS STRUCTURE:
The network topology should follow a bus structure as closely as possible. That is, the
connection between each node and the bus itself should be as short as possible. Basically, it
should be short compared to the length of the bus.
c:> node
1
node
n- 1
node
n
Host Slave Slave Slave
RS485
termination
resistor
(120 Ohm)
termination
resistor
(120 Ohm)
}
keep distance as
short as possible
Figure 3.3 Bus structure
2. BUS TERMINATION:
Especially for longer busses and/or multiple nodes connected to the bus and/or high
communication speeds, the bus should be properly terminated at both ends. The PD-1141 does
not integrate any termination resistor. Therefore, 120 Ohm termination resistors at both ends of
the bus have to be added externally.
3. NUMBER OF NODES:
The RS485 electrical interface standard (EIA-485) allows up to 32 nodes to be connected to a
single bus. The bus transceiver used on the PD-1141 units (SN65HVD3082ED) has just 1/8th of the
standard bus load and allows a maximum of 256 units to be connected to a single RS485 bus.
4. NO FLOATING BUS LINES:
Avoid floating bus lines while neither the host/master nor one of the slaves along the bus line is
transmitting data (all bus nodes switched to receive mode). Floating bus lines may lead to
communication errors. In order to ensure valid signals on the bus it is recommended to use a
resistor network connecting both bus lines to well defined logic levels. In contrast to the
termination resistors this network is normally required just once per bus. Certain RS485 interface
converters available for PCs already include these additional resistors (e.g. USB-2-485).
node
n- 1
node
n
Slave Slave
termination
resistor
(120 Ohm)
+5V
GND
pull-up (1k)
pull-down (1k)
RS485- / RS485B
RS485+ / RS485A
Figure 3.4 Bus lines with resistor network