^1 USER MANUAL ^2 Brick Controller ^3 Programmable Multi-Axis Controller ^4 5XX-603869-XUXX ^5 February 14, 2015 DELTA TAU Data Systems, Inc. NEW IDEAS IN MOTION … Single Source Machine Control ……………………………………………..…...………………. Power // Flexibility // Ease of Use 21314 Lassen St. Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.
Brick Controller User Manual Copyright Information © 2015 Delta Tau Data Systems, Inc. All rights reserved. This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses are unauthorized without written permission of Delta Tau Data Systems, Inc. Information contained in this manual may be updated from time-to-time due to product improvements, etc., and may not conform in every respect to former issues.
Brick Controller User Manual Safety Instructions Qualified personnel must transport, assemble, install, and maintain this equipment. Properly qualified personnel are persons who are familiar with the transport, assembly, installation, and operation of equipment. The qualified personnel must know and observe the following standards and regulations: IEC364resp.
Brick Controller User Manual REVISION HISTORY REVISION DESCRIPTION DATE CHANGE APPROVED 1 MANUAL CREATION 05/02/07 C.P S.M 2 X15 WATCHDOG DESCRIPTION, P. 10 TB1 CURRENT REQUIREMENTS, P. 11 10/31/08 C.P S.M 3 ADDED AUXILIARY BOARD INFO IN APPENDIX A 07/24/09 C.P S.S 4 CORRECTED M5061 ENTRY, P. 27 09/29/09 C.P M.Y 5 MANUAL REFORMATTING. ADDED MORE TECHNICAL INFO. E.G. WIRING DIAGRAMS, SPECIAL FEEDBACK ECT… 11/7/11 M.Y R.N 6 AMPLIFIER CONNECTION WIRING 12/27/11 R.N R.
Brick Controller User Manual Table of Contents INTRODUCTION ................................................................................................................... 10 Documentation ..........................................................................................................................10 Downloadable Turbo PMAC Script ............................................................................................11 SPECIFICATIONS ...................................................
Brick Controller User Manual X1-X8: Encoder Feedback, EnDat 2.1/2.2 .................................................................................61 Configuring EnDat ........................................................................................................................... 61 EnDat Control Registers Setup Example ........................................................................................... 65 X1-X8: Encoder Feedback, BiSS C/B ...............................................
Brick Controller User Manual Setting up the Analog Output (J9) ................................................................................................... 130 Setting up Pulse and Direction Output PFM (J9) ............................................................................ 132 Setting up the Handwheel Port (J9) ................................................................................................ 134 Serial Port (RS232) ............................................................
Brick Controller User Manual Absolute Position Reporting over MACRO ..............................................................................186 MACRO Configuration Power-Up Sequence ...........................................................................187 TROUBLESHOOTING ........................................................................................................ 188 Serial Number and Board Revisions Identification ...................................................................
Brick Controller User Manual INTRODUCTION The Brick Motion Controller is a fully scalable automation controller utilizing the intelligence and capability of its embedded Turbo PMAC2. With the ability to store motion programs locally and built-in PLC execution, it is programmable for virtually any kind of automation application. This allows for complete machine motion and logic control.
Brick Controller User Manual Downloadable Turbo PMAC Script Caution Some code examples require the user to input specific information pertaining to their system hardware. When user information is required, a commentary ending with –User Input is inserted. This manual contains downloadable code samples in Turbo PMAC script. These examples can be copied and pasted into the editor area in the Pewin32pro2.
Brick Controller User Manual SPECIFICATIONS Part Number Brick Controller Model Number Definition A B C D E F G H I BC 4 - C 0 - F 0 0 - 0 0 0 - 0 0 0 0** 0 ** ** ** B A C CPU Options - Turbo PMAC 2 Processor Number of Axes BCA-BB-CDD-EFG-HHHI0 4 : Four Axes (Default) 8 : Eight Axes BCA-BB-CDD-EFG-HHHI0 BCA-BB-CDD-EFG-HHHI0 Axes 1 to 4 Options C0: 80Mhz, 8Kx24 Internal, 256Kx24SRAM, 1MB Flash (Default) C3: 80Mhz, 8Kx24 Internal, 1Mx24SRAM, 4MB Flash F3: 240Mhz, 192Kx24 Internal, 1Mx24SR
Brick Controller User Manual Options CPU Options C0: C3: F3: 80MHz Turbo PMAC2 CPU (standard) 8Kx24 internal memory, 256Kx24 SRAM , 1MB flash memory 80MHz Turbo PMAC2 CPU 8Kx24 internal memory, 1Mx24 SRAM, 4M flash memory 240MHz Turbo PMAC2 CPU 192Kx24 internal memory, 1Mx24 SRAM, 4M flash memory Encoder Feedback Digital Quadrature Sinusoidal HiperFace Resolver Note SSI EnDat 2.1 / 2.
Brick Controller User Manual Environmental Specifications Description Operating Temperature Storage Temperature Humidity Operating Altitude Air Flow Clearances Operating Environment SPECIFICATIONS Specifications 0 to 45°C -25°C to +70°C 10% to 90% non-condensing ~3300 Feet (1000 m) ~3 inches (76.
Brick Controller User Manual RECEIVING AND UNPACKING Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the Brick Controller is received, there are several things to be done immediately: Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered the drive. Remove the Brick Controller from the shipping container and remove all packing materials.
Brick Controller User Manual MOUNTING The location of the Brick Controller is important. Installation should be in an area that is protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and other contaminants. Exposure to these can reduce the operating life and degrade performance of the drive.
Brick Controller User Manual Connector Locations Top View Encoder #1 Encoder #5 AMP 1 Encoder #2 Encoder #6 General Purpose I/O AMP 2 Limits & Flags USB MACRO Ethernet AMP 3 Abort & WD RS232 Encoder #3 Encoder #7 AMP 4 AMP 7 Encoder #4 Encoder #8 AMP 5 AMP 8 24VDC Logic Power Analog I/O Analog I/O AMP 6 Alt. Enc.
Brick Controller User Manual Mounting Dimensions For both BC4-xx-xxx-xxx-xxxxx and BC8-xx-xxx-xxx-xxxxx: Width Depth 3.50 inches (88.90 mm) 7.20 inches (182.88 mm) 14.65" (372.11 mm) Height 15.00 inches (381 mm) 15.00" (381.00 mm) 2.50" (63.50 mm) 3x M4 13.5" (342.90 mm) 7.20" (182.88 mm) 3.50" (88.
Brick Controller User Manual PINOUTS AND SOFTWARE SETUP Installation of electrical control equipment is subject to many regulations including national, state, local, and industry guidelines and rules. General recommendations can be stated but it is important that the installation be carried out in accordance with all regulations pertaining to the installation.
Brick Controller User Manual Older Models TB1: 3-pin Female Mating: 3-pin Male Pin # Symbol Function 1 +24VDC Input 2 CHGND Ground 3 +24VDC RET Common DC Power Supply 1 2 +24VDC COM 3 Description Notes Logic power input + ±5% Chassis ground Machine Chassis Logic power return - Power Supply Return Phoenix PCB Edge Connector Phoenix part #: ZEC 1,5/ 3-ST-5,0 C2 R1,3 (18883051) Delta Tau part #: 014-188305-001 (For Internal Use) PinOuts and Software Setup 20
Brick Controller User Manual +5V ENC PWR (Alternate Encoder Power) Typically, feedback devices are powered up through the X1-X8 connectors on the Brick Controller using the internal +5VDC power supply. In some cases, feedback devices consume power excessively and risk of surpassing the internal power supply limitation. This connector provides an alternate mean to power-up the feedback devices (+5V only) if the total encoder budget exceeds the specified thresholds.
Brick Controller User Manual Wiring the Alternate (+5V) Encoder Power Pin# Symbol Description Note 1 5VEXT Input 5V from external power supply 2 5VINT Output Tie to pin#1 to use internal power supply 3 GND Common Mating Connector: Adam-Tech part number 25CH-E-03 Pins part number 25CTE-R Crimping tool: Molex EDP #11-01-0208 Only two of the three available pins should be used at one time. Do not daisy-chain the internal 5V power supply with an external one.
Brick Controller User Manual Functionality, Safety Measures There are a couple of safety and functionality measures to take into account when an external encoder power supply is utilized: Power sequence: encoders versus controller/drive It is highly recommended to power up the encoders before applying power to the Brick Controller Encoder Power Loss (i.e.
Brick Controller User Manual X1-X8: Encoder Feedback, Digital A Quad B 8 X1-X8: D-sub DA-15F Mating: D-sub DA-15M 7 15 6 14 5 13 4 12 3 11 2 10 1 9 Pin# Symbol Function Description 1 CHA+ Input Encoder A+ 2 CHB+ Input Encoder B+ 3 CHC+ / AENA+ Input Encoder Index+ / Stepper amp enable + 4 ENCPWR Output Encoder Power 5V 5 CHU+ / DIR+ In/Out Halls U+ / Direction Output + for Stepper 6 CHW+/ PUL+ In/Out Halls W+ / Pulse Output + for Stepper 7 2.5V Output 2.
Brick Controller User Manual Channel A Channel B Typically, these signals are 5V TTL/CMOS level whether they are single-ended or differential. Differential signals can enhance noise immunity by providing common mode noise rejection. Modern design standards virtually mandate their use in industrial systems.
Brick Controller User Manual Setting up Quadrature Encoders Digital Quadrature Encoders use the 1/T incremental entry in the encoder conversion table. Position and velocity pointers should, by default, be valid and in most cases no software setup is required, activating (Ixx00=1) the corresponding channel is sufficient to see encoder counts in the position window when the motor/encoder shaft is moved by hand.
Brick Controller User Manual Encoder Loss Detection, Quadrature Designed for use with differential line-driver outputs (encoders), the encoder loss circuitry monitors each quadrature input pair with an exclusive-or XOR gate. In normal operation mode, the two quadrature inputs should be in opposite logical states – that is one high and one low – yielding a true output from the XOR gate. Single-Ended Quadrature Encoders are not supported for encoder loss.
Brick Controller User Manual Encoder Loss Example PLC: A 4-axis Brick Controller is setup to kill all motors upon the detection of one or more encoder loss.
Brick Controller User Manual Step and Direction PFM Output (To External Stepper Amplifier) The Brick Controller has the capability of generating step and direction (Pulse Frequency Modulation) output signals to external stepper amplifiers. These signals are accessible at the encoder connectors. The step and direction outputs are RS422 compatible and could be connected in either differential or singleended configuration for 5V (input signal) amplifiers.
Brick Controller User Manual X1-X8: Encoder Feedback, Sinusoidal 8 X1-X8: D-sub DA-15F Mating: D-sub DA-15M 7 15 6 14 5 13 Pin # Symbol Function Notes 1 Sin+ Input Sine+ 2 Cos+ Input Cosine+ 3 CHC+ Input Index+ 4 EncPwr Output Encoder Power 5 Volts 5 CHU+ In/Out U Hall 6 CHW+ In/Out W Hall 7 2.5 Volts Output Reference Power 2.
Brick Controller User Manual Setting up Sinusoidal Encoders The Sinusoidal position feedback is set up through the Encoder Conversion Table (ECT) as a high resolution interpolation entry. Encoder Conversion Table Setup Example, Channel 1 1. 2. 3. 4. Channel # 1 2 3 4 Conversion Type: High res.
Brick Controller User Manual The equivalent Turbo PMAC script code for 8-channel entries // Channel 1 I8000=$FF8000 I8001=$078B00 I8002=$000000 // Channel 2 I8003=$FF8008 I8004=$078B02 I8005=$000000 // Channel 3 I8006=$FF8010 I8007=$078B04 I8008=$000000 // Channel 4 I8009=$FF8018 I8010=$078B06 I8011=$000000 // Channel 5 I8012=$FF8100 I8013=$078B08 I8014=$000000 // Channel 6 I8015=$FF8108 I8016=$078B0A I8017=$000000 // Channel 7 I8018=$FF8110 I8019=$078B0C I8020=$000000 // Channel 8 I8021=$FF8118 I8022=$078
Brick Controller User Manual Encoder Count Error (Mxx18) The Brick Controller has an encoder count error detection feature. If both the A and B channels of the quadrature encoder change state at the decode circuitry (post-filter) in the same hardware sampling clock (SCLK) cycle, an unrecoverable error to the counter value will result (lost counts). Suggested M-Variable Mxx18 for this channel is then set and latched to 1 (until reset or cleared).
Brick Controller User Manual Encoder Loss Detection, Sinusoidal Encoder loss detection with Sinusoidal encoders can be performed using the encoder conversion table. The ECT can be set up to compute the sum of the squares of the sine and cosine terms (including user introduced biases).
Brick Controller User Manual X1-X8: Encoder Feedback, Resolver 8 X1-X8: D-sub DA-15F Mating: D-sub DA-15M 7 15 6 14 5 13 Pin # Symbol Function Notes 1 Sin+ Input Sine+ 2 Cos+ Input Cosine+ 3 CHC+ Input Index+ 4 EncPwr Output Encoder Power 5 Volts 2.5 Volts Output Reference Power 2.
Brick Controller User Manual Resolver Excitation Magnitude Revolvers’ excitation magnitude is a global setting used for all available Resolver channels. It has 15 possible settings: #define ResExcMag M8000 ResExcMag->Y:$78B11,0,4 ; Resolver Excitation Magnitude MACRO definition ; Resolver Excitation Magnitude register Excitation Peak-Peak Magnitude [Volts] 1 1.6 2 2.5 3 3.3 4 4.2 5 5.0 6 6.0 7 6.9 8 7.7 Excitation Peak-Peak Magnitude [Volts] 9 8.5 10 9.5 11 10.4 12 11.
Brick Controller User Manual Resolver Data Registers The Resolver raw data is found in the Resolver Data registers Channel 1 2 3 4 Register Y:$78B00 Y:$78B02 Y:$78B04 Y:$78B06 Channel 5 6 7 8 Register Y:$78B08 Y:$78B0A Y:$78B0C Y:$78B0E Encoder Conversion Table Processing A dedicated 3-line Encoder Conversion Table entry is used for Resolver feedback. Due to the noisy nature of Resolvers, implementing a tracking filter to the result is highly recommended.
Brick Controller User Manual Calculating The Tracking Filter Gains The tracking filter gains are system dependent, and need to be fine-tuned. This can be done by gathering and plotting filtered versus unfiltered data while moving the motor shaft manually. Best case scenario is super-imposing the filtered data on top of the unfiltered with minimum ripple and overshoot.
Brick Controller User Manual I8042=$000000 ; I8043=$D8352B ; I8044=$400 ; I8045=$80000 ; I8046=$0 ; I8047=$1 ; // Channel 7 I8048=$F78B0C ; I8049=$478B10 ; I8050=$000000 ; I8051=$D83533 ; I8052=$400 ; I8053=$80000 ; I8054=$0 ; I8055=$1 ; // Channel 8 I8056=$F78B0E ; I8057=$478B10 ; I8058=$000000 ; I8059=$D8353B ; I8060=$400 ; I8061=$80000 ; I8062=$0 ; I8063=$1 ; // End Of Table I8064=$000000 ; SIN/COS Bias word Tracking filter from conversion location $352B Maximum change in counts/cycle Proportional gain
Brick Controller User Manual Resolver Power-On PLC Example Setting up a resolver with 10V excitation magnitude and 10 KHz excitation frequency: // Clock Settings: 10KHz Phase & Servo I7100=5895 ; Servo IC1 I7101=0 I7102=0 I6800=5895 ; MACRO IC0 I6801=0 I6802=0 I7000=5895 ; Servo IC0 I7001=0 I7002=0 I10=838613 ; Servo Time Interrupt #define ResExcMag M8000 #define ResExcFreq M8001 ResExcMag->Y:$78B11,0,4 ResExcFreq->Y:$78B13,0,4 ResExcMag=11 ResExcFreq=0 ; Excitation Magnitude ; Excitation Frequency ; Exci
Brick Controller User Manual X1-X8: Encoder Feedback, HiperFace Caution The majority of HiperFace devices requires 7-12VDC power. This has to be supplied externally and NOT wired into the brick unit. Pins#4 and #12 are unused in this case, leave floating.
Brick Controller User Manual Setting up HiperFace On-Going Position The HiperFace on-going position is set up through the Encoder Conversion Table as a high resolution interpolation entry Encoder Conversion Table Setup Example, Channel 1 1. 2. 3. 4. Channel # 1 2 3 4 Conversion Type: High res.
Brick Controller User Manual And the equivalent Turbo PMAC code for setting up all 8 channels: // Channel 1 I8000=$FF8000 I8001=$078B00 I8002=$000000 // Channel 2 I8003=$FF8008 I8004=$078B02 I8005=$000000 // Channel 3 I8006=$FF8010 I8007=$078B04 I8008=$000000 // Channel 4 I8009=$FF8018 I8010=$078B06 I8011=$000000 // Channel 5 I8012=$FF8100 I8013=$078B08 I8014=$000000 // Channel 6 I8015=$FF8108 I8016=$078B0A I8017=$000000 // Channel 7 I8018=$FF8110 I8019=$078B0C I8020=$000000 // Channel 8 I8021=$FF8118 I802
Brick Controller User Manual Setting up HiperFace Absolute Power-On Position Setting up the absolute position read with HiperFace requires the programming of two essential control registers: Global Control Registers Channel Control Registers The resulting data is found in: HiperFace Data Registers PinOuts and Software Setup 44
Brick Controller User Manual Global Control Registers X:$78BnF (default value: $812004) where n=2 for axes 1-4 n=3 for axes 5-8 Axes 1-4 Axes 5-8 Global Control Register X:$78B2F X:$78B3F The Global Control register is used to program the serial encoder interface clock frequency SER_Clock and configure the serial encoder interface trigger clock. SER_Clock is generated from a two-stage divider clocked at 100 MHz as follows: M N SER_Clock [KHz] Baud Rate Global Register Setting 129 2 192.
Brick Controller User Manual Channel Control Registers X:$78Bn0, X:$78Bn4, X:$78Bn8, X:$78BnC Channel 1 Channel 2 Channel 3 Channel 4 where: n=2 for axes 1-4 n=3 for axes 5-8 X:$78B20 X:$78B24 X:$78B28 X:$78B2C Channel 5 Channel 6 Channel 7 Channel 8 X:$78B30 X:$78B34 X:$78B38 X:$78B3C Each channel has its own Serial Encoder Command Control Register defining functionality parameters.
Brick Controller User Manual HiperFace Data Registers The HiperFace absolute power-on data is conveyed into 4 memory locations; Serial Encoder Data A, B, C, and D. The Serial Encoder Data A register holds the 24 bits of the encoder position data. If the data exceeds the 24 available bits in this register, the upper overflow bits are LSB justified and readable in the Serial Encoder Data B, which also holds status and error bits. Serial Encoder Data C, and D registers are reserved and always read zero.
Brick Controller User Manual Setting up HiperFace Encoders Example An 8-axis Brick Controller is connected to eight HiperFace encoders, serial data is programmed to 9600 (M=129, N=2) baud rate for all eight channels: =0 Rising Edge =1 Falling Edge =0 Trigger on Phase =1 Trigger on Servo 0 clock Edge 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 0 0 0 0 0 0 0 1 0 0 Description: Bit #: Binary: $4 for HiperFace Typically =0 M Divisor 0 Hex ($): 0 0 0 N Div
Brick Controller User Manual The Global and Channel Control registers have to be initialized on power-up. Following, is an example PLC showing the initialization of all eight channels: //=========================== NOTES ABOUT THIS PLC EXAMPLE ================================// // This PLC example utilizes: - M5990 through M5999 // - Coordinate system 1 Timer 1 // Make sure that current and/or future configurations do not create conflicts with // these parameters.
Brick Controller User Manual Channels 1 through 4 are driving HiperFace encoders with 12-bit (4096) single-turn resolution and 12bit (4096) multi-turn resolution for a total number of data bits of 24 (12+12).
Brick Controller User Manual #define #define #define #define #define Ch4STRes Ch5STRes Ch6STRes Ch7STRes Ch8STRes Ch1STRes=12 Ch2STRes=12 Ch3STRes=12 Ch4STRes=12 Ch5STRes=16 Ch6STRes=16 Ch7STRes=16 Ch8STRes=16 P7006 P7008 P7010 P7012 P7014 #define #define #define #define #define Ch1MTRes=12 Ch2MTRes=12 Ch3MTRes=12 Ch4MTRes=12 Ch5MTRes=12 Ch6MTRes=12 Ch7MTRes=12 Ch8MTRes=12 #define ChAbsSel ChAbsSel=$FF P7016 ; ; ; ; ; ; ; ; Ch1 Ch2 Ch3 Ch4 Ch5 Ch6 Ch7 Ch8 Ch4MTRes Ch5MTRes Ch6MTRes Ch7MTRes Ch8MT
Brick Controller User Manual STData=0 MTData=0 If (STRes!>24) ; Single Turn Res<=24 //===========SINGLE TURN DATA===========// Two2STDec=exp(STRes*ln(2)) Two2STHex=Two2STDec-1 STData=SerialRegA&Two2STHex //===========MULTI TURN DATA============// Two2MTDec=exp(MTRes*ln(2)) Two2MTHex=Two2MTDec-1 If (MTRes=0) LowerMTBits=0 UpperMTBits=0 Two2MTDec=0 Two2MTHex=0 MTData=0 Else LowerMTBits=24-STRes STTemp1=exp(LowerMTBits*ln(2)) STTemp2=0 UpperMTBits=MTRes-LowerMTBits MTTemp1=exp(LowerMTBits*ln(2)) MTTemp2=exp(U
Brick Controller User Manual Encoder Count Error (Mxx18), HiperFace The Brick Controller has an encoder count error detection feature. If both the A and B channels of the quadrature encoder change state at the decode circuitry (post-filter) in the same hardware sampling clock (SCLK) cycle, an unrecoverable error to the counter value will result (lost counts). Suggested M-Variable Mxx18 for this channel is then set and latched to 1 (until reset or cleared).
Brick Controller User Manual Encoder Loss Detection, Hiperface Encoder loss detection with HiperFace encoders can be performed using the encoder conversion table. The ECT can be set up to compute the sum of the squares of the sine and cosine terms (including user introduced biases).
Brick Controller User Manual X1-X8: Encoder Feedback, SSI 8 X1-X8: D-sub DA-15F Mating: D-sub DA-15M Pin # Symbol Function 4 EncPwr Output 5 Data- Input 6 Clock- Output 12 GND Common 13 Clock+ Output 14 Data+ Input 7 15 6 14 5 13 4 12 3 11 2 10 1 9 Notes 1 2 3 Encoder Power 5 Volts only Data- packet Serial Encoder Clock- 7 8 9 10 11 Common Ground Serial Encoder Clock+ Data+ Packet 15 Note Some SSI devices require 24V power which has to be brought in externally.
Brick Controller User Manual Global Control Registers X:$78BnF (Default value: $630002) where: n=2 for axes 1-4 n=3 for axes 5-8 Global Control Register X:$78B2F X:$78B3F Axes 1-4 Axes 5-8 The Global Control register is used to program the serial encoder interface clock frequency SER_Clock and configure the serial encoder interface trigger clock. SER_Clock is generated from a two-stage divider clocked at 100 MHz: M N Clock Frequency 49 0 2.0 MHz 99 0 1.0 MHz 99 1 500.0 KHz 99 2 250.
Brick Controller User Manual Channel Control Registers X:$78Bn0, X:$78Bn4, X:$78Bn8, X:$78BnC Channel 1 Channel 2 Channel 3 Channel 4 where: n=2 for axes 1-4 n=3 for axes 5-8 X:$78B20 X:$78B24 X:$78B28 X:$78B2C Channel 5 Channel 6 Channel 7 Channel 8 X:$78B30 X:$78B34 X:$78B38 X:$78B3C Each channel has its own Serial Encoder Command Control Register defining functionality parameters.
Brick Controller User Manual SSI Data Registers The SSI data is conveyed into 4 memory locations; Serial Encoder Data A, B, C, and D. The Serial Encoder Data A register holds the 24 bits of the encoder position data. If the data exceeds the 24 available bits in this register, the upper overflow bits are LSB justified and readable in the Serial Encoder Data B, which also holds the parity error flag. Serial Encoder Data C, and D registers are reserved and always read zero.
Brick Controller User Manual SSI Control Registers Setup Example Channel 1 is driving a 25-bit (13-bit Singleturn, 12-bit Multiturn) SSI encoder. The encoder outputs binary data with no parity, and requires a 1 MHz serial clock.
Brick Controller User Manual Field Parity Type Trigger Mode Trigger Enable Gray / Binary Data Ready / Senc Mode Protocol Bits Value =0 =0 =1 =0 =1 =25 Notes Channel Control Word Hex 0x00 Continuous trigger (typical) Enable Binary Enable serial driver Hex 0x19 $001419 Control Registers Power-On PLC The global and channel control words have to be executed once on power-up: //=========================== NOTES ABOUT THIS PLC EXAMPLE ================================// // This PLC example utilizes: - M5990
Brick Controller User Manual X1-X8: Encoder Feedback, EnDat 2.1/2.2 8 X1-X8: D-sub DA-15F Mating: D-Sub DA-15M Pin # Symbol Function 4 EncPwr Output 5 Data- Input 6 Clock- Output 12 GND Common 13 Clock+ Output 14 Data+ Input 7 15 6 14 5 13 4 12 3 11 2 10 1 9 Notes 1 2 3 Encoder Power 5 Volts Data- packet Serial Encoder Clock- 7 8 9 10 11 Common Ground Serial Encoder Clock+ Data+ Packet 15 Note Some EnDat devices require 24V power which has to be brought in externally.
Brick Controller User Manual Global Control Registers X:$78BnF (default value: $002003) where n=2 for axes 1-4 n=3 for axes 5-8 Axes 1-4 Axes 5-8 Global Control Register X:$78B2F X:$78B3F The Global Control register is used to program the serial encoder interface clock frequency. SENC_CLK is the serial data clock transmitted from the Brick to the encoder. It is used by the encoder to clock in data transmitted from the Brick, and clock out data from the encoder: M N Serial Clock Frequency 0 0 4.
Brick Controller User Manual Channel Control Registers X:$78Bn0, X:$78Bn4, X:$78Bn8, X:$78BnC Channel 1 Channel 2 Channel 3 Channel 4 where: n=2 for axes 1-4 n=3 for axes 5-8 X:$78B20 X:$78B24 X:$78B28 X:$78B2C Channel 5 Channel 6 Channel 7 Channel 8 X:$78B30 X:$78B34 X:$78B38 X:$78B3C Each channel has its own Serial Encoder Command Control Register defining functionality parameters.
Brick Controller User Manual EnDat Data Registers The EnDat data is conveyed into 4 memory locations; EnDat Data A, B, C, and D. The EnDat Data A register holds the 24 bits of the encoder position data. If the data exceeds the 24 available bits in this register, the upper overflow bits are LSB justified and readable in the EnDat Data B register, which also holds error flags. The error bit flag is always returned by the encoder, except for a Reset command.
Brick Controller User Manual EnDat Control Registers Setup Example Channel 1 is driving a 37-bit (25-bit Singleturn, 12-bit Multiturn) EnDat 2.2 encoder. The encoder requires a 4 MHz serial clock.
Brick Controller User Manual Field Value Notes Command code =$38 Hex 0x38 for EnDat 2.
Brick Controller User Manual X1-X8: Encoder Feedback, BiSS C/B 8 X1-X8: D-sub DA-15F Mating: D-Sub DA-15M Pin # Symbol Function 4 EncPwr Output 5 Data- Input/Output 6 Clock- Output 12 GND Common 13 Clock+ Output 14 Data+ Input/Output 7 15 6 14 5 13 4 12 3 11 2 10 1 9 Notes 1 2 3 Encoder Power 5 Volts Data- packet, SLOSerial Encoder Clock-, MO- 7 8 9 10 11 Common Ground Serial Encoder Clock+ , MO+ Data+ Packet, SLO+ 15 Note Some BiSS devices require 24V power which has to
Brick Controller User Manual Global Control Registers X:$78BnF (default value: $18000B) where n=2 for axes 1-4 n=3 for axes 5-8 Global Control Register X:$78B2F X:$78B3F Axes 1-4 Axes 5-8 The Global Control register is used to program the serial encoder interface clock frequency SER_Clock and configure the serial encoder interface trigger clock. SER_Clock is generated from a two-stage divider clocked at 100 MHz as follows: M N Clock Frequency 49 0 2.0 MHz 99 0 1.0 MHz 99 1 500.0 KHz 99 2 250.
Brick Controller User Manual Channel Control Registers X:$78Bn0, X:$78Bn4, X:$78Bn8, X:$78BnC Channel 1 Channel 2 Channel 3 Channel 4 where: n=2 for axes 1-4 n=3 for axes 5-8 X:$78B20 X:$78B24 X:$78B28 X:$78B2C Channel 5 Channel 6 Channel 7 Channel 8 X:$78B30 X:$78B34 X:$78B38 X:$78B3C Each channel has its own Serial Encoder Command Control Register defining functionality parameters.
Brick Controller User Manual W [09] [08:06] [05:00] 0 0x0 R/W W This write-only bit is used to enable the output drivers for SENC_MODE the SENC_SDO, SENC_CLK, SENC_ENA pins for each respective channel. Reserved Reserved and always reads zero. Status Bits 000 0x00 Position Bits This bit field is used to define the number of status bits in the encoder data. The valid range of settings is 0 – 6 (000 – 110). The status bits are assumed to always follow after the position data and before the CRC.
Brick Controller User Manual BiSS Control Registers Setup Example Channel 1 is driving an 18-bit Renishaw resolute BiSS-C encoder. The encoder requires a 1 MHz serial clock, and has 2 status bits.
Brick Controller User Manual Field CRC Mask BiSS Type Trigger Mode Trigger Enable Data Ready / Senc Mode Status Bits Protocol Bits Value =33 =0 =0 =1 =1 =2 =18 Notes Channel Control Word Hex 0x21 typical for Renishaw for BiSS-C Continuous trigger (typical) Enable $211492 Enable serial driver Binary 010 Binary 010010 Control Registers Power-On PLC The Global and Channel Control words have to be executed once on power-up //=========================== NOTES ABOUT THIS PLC EXAMPLE ==========================
Brick Controller User Manual Setting up SSI | EnDat | BiSS With the Brick Controller, the absolute serial encoder data is brought in as an unfiltered parallel Y-word into the Encoder Conversion Table (ECT) where it is processed for the PMAC to use for on-going position in the motor servo-loop, and power-on absolute position. In general, encoder data is left-shifted 5 bits in the ECT to provide fractional data.
Brick Controller User Manual Setup Summary Encoder Conversion Table Processing: Process Technique 1 Technique 2 Technique 3 ECT for Position From serial register A, 5-bit shift From serial register A, no shift From serial register A, 5-bit shift ST is the Singleturn resolution (in bits) for rotary encoders. Similarly, this would be the protocol resolution (in bits) for linear scales.
Brick Controller User Manual Technique 1 Example Channel 1 is driving a 25-bit (13-bit Singleturn, 12-bit Multiturn) rotary serial encoder, or a linear scale with similar protocol resolution (13 bits, 1 micron). Encoder Conversion Table - for position (Technique 1) Conversion Type: Parallel pos from Y word with no filtering Width in Bits: Singleturn/absolute resolution in bits (e.g.
Brick Controller User Manual Counts Per User Units (Technique 1) With technique 1, the user should expect to see 2ST counts per revolution for rotary encoders, and 1/Resolution counts per user unit for linear scales in the motor position window. 25-bit rotary encoder (13-bit Singleturn): 213= 8,192 cts/rev 1-micron linear scale: 1/0.
Brick Controller User Manual In this mode, PMAC reads and reports 18 bits from the first serial data register: Serial Data Register B (Ch1 Y:$78B21) 47 Serial Data Register A (Ch1 Y:$78B20) 18 bits 23 0 With this setting of Ixx80=2, the actual position is reported automatically on Power-up. Otherwise, a #1$* command is necessary to read and report the absolute position. With absolute serial encoders (no multi-turn data), the power-on position format is set up for unsigned operation.
Brick Controller User Manual Technique 2 Example Channel 1 is driving a 37-bit (25-bit Singleturn, 12-bit Multiturn) rotary serial encoder, or a linear scale with similar protocol resolution (25 bits, 10 nanometer). Encoder Conversion Table – for position (Technique 2) Conversion Type: Parallel pos from Y word with no filtering Width in Bits: Singleturn/absolute resolution in bits (e.g.
Brick Controller User Manual At this point, you should be able to move the motor/encoder shaft by hand and see ‘motor’ counts in the position window Note Counts Per User Units (Technique 2) With technique 2, the user should expect to see 2ST-5= 2ST/32 counts per revolution for rotary encoders, and 1/(32*Resolution) counts per user unit for linear scales in the motor position window. Examples: 37-bit rotary encoder (25-bit Singleturn): 225/32= 1,048,576 cts/rev 10-nanometer linear scale: 1/(32*0.
Brick Controller User Manual Absolute Power-On Position Read (Technique 2) With technique 2, the absolute power-on position can be read directly from the serial data registers. But, proper scaling (5-bit right shift, in a PLC) is required to conform to the unshifted on-going position.
Brick Controller User Manual With absolute serial encoders (no multi-turn data), the power-on position format is set up for unsigned operation. Note The upper two fields in Ixx95 are the only relevant ones. Bits 0 through 15 are reserved and should always be set to 0.
Brick Controller User Manual Technique 3 Example Channel 1 is driving a 32-bit (20-bit Singleturn, 12-bit Multiturn) rotary serial encoder, or a linear scale with similar protocol resolution (20 bits, 0.1 micron). Encoder Conversion Table - for position (Technique 3) Conversion Type: Parallel pos from Y word with no filtering Width in Bits: Singleturn/absolute resolution in bits (e.g.
Brick Controller User Manual At this point, you should be able to move the motor/encoder shaft by hand and see ‘motor’ counts in the position window. Note Counts Per User Units (Technique 3) With technique 3, the user should expect to see 2ST counts per revolution for rotary encoders, and 1/Resolution counts per user unit for linear scales in the motor position window. Examples: 32-bit rotary encoder (20-bit Singleturn): 220= 1,048,576 cts/rev 0.1-micron linear scale: 1/0.
Brick Controller User Manual Absolute Power-On Position Read (Technique 3) With Technique 3, the absolute power-on read can be performed using PMAC’s automatic settings (Ixx80, Ixx10 and Ixx95).
Brick Controller User Manual With absolute serial encoders (no multi-turn data), the power-on position format is set up for unsigned operation. Note The upper two fields in Ixx95 are the only relevant ones. Bits 0 through 15 are reserved and should always be set to 0. Note Note Some serial encoders use an external (not from the Brick) source for power. Make sure that this power is applied prior to performing an absolute read on power-up.
Brick Controller User Manual X1-X8: Encoder Feedback, Yaskawa Sigma II & III X1-X8: D-sub DA-15F Mating: D-sub DA-15M Pin # Symbol Function 4 EncPwr Output 5 SDI Input GND Common SDO Output 8 7 15 6 14 5 13 4 12 3 11 2 10 1 9 Notes 1 2 3 Encoder Power 5 Volts Serial Data In 6 7 8 9 10 11 12 Common Ground 13 14 Serial Data Out 15 Note Use an encoder cable with high quality shield. Connect the shield to chassis ground, and use ferrite core in noise sensitive environment.
Brick Controller User Manual Molex 2.00 mm (.079") Pitch Serial I/O Connector, Receptacle Kit, Wire-to-Wire. Part Number: 0542800609 Pin # Function Wire Color code 1 +5VDC RED 2 GND BLACK 3 BAT+ Orange 4 BATOrange/Black (Orange/White) 5 SDO Blue 6 SDI Blue/Black (Blue/White) All Yaskawa Sigma II & Sigma III protocols, whether incremental or absolute and regardless of the resolution, are supported. Note This option allows the Brick to connect to up to eight Yaskawa devices.
Brick Controller User Manual Global Control Registers X:$78BnF (default value: $002003) where n=2 for axes 1-4 n=3 for axes 5-8 Global Control Register X:$78B2F X:$78B3F Axes 1-4 Axes 5-8 With the Yaskawa option, the Global Control Register is pre-set and need not be changed.
Brick Controller User Manual Channel Control Registers X:$78Bn0, X:$78Bn4, X:$78Bn8, X:$78BnC Channel 1 Channel 2 Channel 3 Channel 4 where: n=2 for axes 1-4 n=3 for axes 5-8 X:$78B20 X:$78B24 X:$78B28 X:$78B2C Channel 5 Channel 6 Channel 7 Channel 8 X:$78B20 X:$78B34 X:$78B38 X:$78B3C Bits 10, 12, and 13 are the only fields to be configured in the Channel Control Registers with the Yaskawa option. The rest is protocol information. This has to be done in a startup PLC to execute once on power up.
Brick Controller User Manual Yaskawa Feedback Channel Control Power-On Example PLC (Motors 1-8) This code statement can be added to your existing initialization PLC.
Brick Controller User Manual Yaskawa Sigma II 16-Bit Absolute Encoder Y:$78B21 [23-12] [11-0] [23-20] Multi-Turn Position (16-bits) Channel 1 Channel 2 Channel 3 Channel 4 Y:$78B20 [19-4] Absolute Single Turn Data (16-bits) Yaskawa Data Registers Y:$78B20 Channel 5 Y:$78B24 Channel 6 Y:$78B28 Channel 7 Y:$78B2C Channel 8 [3:0] Y:$78B30 Y:$78B34 Y:$78B38 Y:$78B3C The on-going servo and commutation position data is setup using a 2-line Entry in the Encoder Conversion Table.
Brick Controller User Manual I8007=$020004 ; Width and Bias, total of 32-bits LSB starting at bit#4 I8008=$278B30 I8009=$020004 ; Entry 5 Unfiltered parallel pos of location Y:$78B30 ; Width and Bias, total of 32-bits LSB starting at bit#4 I8010=$278B34 I8011=$020004 ; Entry 6 Unfiltered parallel pos of location Y:$78B34 ; Width and Bias, total of 32-bits LSB starting at bit#4 I8012=$278B38 I8013=$020004 ; Entry 7 Unfiltered parallel pos of location Y:$78B38 ; Width and Bias, total of 32-bits LSB st
Brick Controller User Manual Absolute Power-On Position Read (Yaskawa 16-bit) Channel 1 example PLC, 16-bit Absolute Sigma II Encoder End Gat Del Gat Close #define #define #define #define STD0_15 MTD0_3 MTD4_15 MTD0_15 M7000 M7001 M7002 M7003 ; ; ; ; Single-turn Data 0-15 (16-bits) Multi-Turn Data 0-3 (4-bits) Multi-Turn Data 4-15 (12-bits) Multi-Turn Data 0-15 (16-bits) STD0_15->Y:$78B20,4,16 MTD0_3->Y:$78B20,20,4 MTD4_15->Y:$78B21,0,12 MTD0_15->* #define Mtr1ActPos M162 Mtr1ActPos->D:$00008B ; #1 Ac
Brick Controller User Manual Yaskawa Sigma II 17-Bit Absolute Encoder Y:$78B21 [23-13] [12-0] [23-21] Multi-Turn Position (16-bits) Channel 1 Channel 2 Channel 3 Channel 4 Y:$78B20 [20-4] Absolute Single Turn Data (17-bits) Yaskawa Data Registers Y:$78B20 Channel 5 Y:$78B24 Channel 6 Y:$78B28 Channel 7 Y:$78B2C Channel 8 [3:0] Y:$78B30 Y:$78B34 Y:$78B38 Y:$78B3C The on-going servo and commutation position data is setup using a 2-line Entry in the Encoder Conversion Table.
Brick Controller User Manual Encoder Conversion Table Setup (Motors 1-8) The ECT automatic entry is equivalent to: I8000=$278B20 I8001=$021004 ; Entry 1 Unfiltered parallel pos of location Y:$78B20 ; Width and Bias, total of 33-bits LSB starting at bit#4 I8002=$278B24 I8003=$021004 ; Entry 2 Unfiltered parallel pos of location Y:$78B24 ; Width and Bias, total of 33-bits LSB starting at bit#4 I8004=$278B28 I8005=$021004 ; Entry 3 Unfiltered parallel pos of location Y:$78B28 ; Width and Bias, total of 3
Brick Controller User Manual Absolute Power-On Position Read (Yaskawa 17-bit) Channel 1 example PLC, 17-bit Absolute Sigma II Encoder End Gat Del Gat Close #define #define #define #define FirstWord SecondWord STD0_16 MTD0_15 M7000 M7001 M7002 M7003 ; ; ; ; Yaskawa Data Register1, 1st word Yaskawa Data Register1, 2nd word Single-Turn Data 0-16 (17-bits) Multi-Turn Data 0-15 (16-bits) FirstWord->Y:$78B20,0,24 SecondWord->Y:$78B21,0,4 STD0_16->* MTD0_15->* #define Mtr1ActPos M162 Mtr1ActPos->D:$00008B ;
Brick Controller User Manual Yaskawa Sigma III 20-Bit Absolute Encoder [23-16] Y:$78B21 [15-0] Multi-Turn Position (16-bits) Channel 1 Channel 2 Channel 3 Channel 4 Y:$78B20 [23-4] Absolute Single Turn Data (20-bits) Yaskawa Data Registers Y:$78B20 Channel 5 Y:$78B24 Channel 6 Y:$78B28 Channel 7 Y:$78B2C Channel 8 [3:0] Y:$78B30 Y:$78B34 Y:$78B38 Y:$78B3C The on-going servo and commutation position data is setup using a 2-line Entry in the Encoder Conversion Table.
Brick Controller User Manual Encoder Conversion Table Setup (Motors 1-8) The ECT automatic entry is equivalent to: I8000=$278B20 I8001=$024004 ; Entry 1 Unfiltered parallel pos of location Y:$78B20 ; Width and Bias, total of 36-bits LSB starting at bit#4 I8002=$278B24 I8003=$024004 ; Entry 2 Unfiltered parallel pos of location Y:$78B24 ; Width and Bias, total of 36-bits LSB starting at bit#4 I8004=$278B28 I8005=$024004 ; Entry 3 Unfiltered parallel pos of location Y:$78B28 ; Width and Bias, total of 3
Brick Controller User Manual Absolute Power-On Position Read (Yaskawa 20-bit) Channel 1 example PLC, 20-bit Absolute Sigma III Encoder End Gat Del Gat Close #define #define #define #define FirstWord SecondWord STD0_19 MTD0_15 M1000 M1001 M1002 M1003 ; ; ; ; Yaskawa Data Register1, 1st word Yaskawa Data Register1, 2nd word Single-Turn Data 0-19 (20-bits) Multi-Turn Data 0-15 (16-bits) FirstWord->Y:$78B20,0,24 SecondWord->Y:$78B21,0,4 STD0_19->* MTD0_15->* #define Mtr1ActPos M162 Mtr1ActPos->D:$00008B ;
Brick Controller User Manual Yaskawa Sigma II 13-Bit Incremental Encoder [23-11] Y:$78B21 [10-0] 23 Incremental Compensation (11-bits) Channel 1 Channel 2 Channel 3 Channel 4 Y:$78B20 [22-11] [10:4] Incremental Position in Single Turn (13-bits) Yaskawa Data Registers Y:$78B20 Channel 5 Y:$78B24 Channel 6 Y:$78B28 Channel 7 Y:$78B2C Channel 8 3 2 1 0 U V W Z Y:$78B30 Y:$78B34 Y:$78B38 Y:$78B3C The on-going servo and commutation position data is setup using a 2-line Entry in the Encoder Conve
Brick Controller User Manual Encoder Conversion Table Setup (Motors 1-8) The ECT automatic entry is equivalent to: I8000=$278B20 I8001=$00D006 ; Entry 1 Unfiltered parallel pos of location Y:$78B20 ; Width and Bias, total of 13-bits LSB starting at bit#6 I8002=$278B24 I8003=$00D006 ; Entry 2 Unfiltered parallel pos of location Y:$78B24 ; Width and Bias, total of 13-bits LSB starting at bit#6 I8004=$278B28 I8005=$00D006 ; Entry 3 Unfiltered parallel pos of location Y:$78B28 ; Width and Bias, total of 1
Brick Controller User Manual Yaskawa Sigma II 17-Bit Incremental Encoder [23-11] Y:$78B21 [10-0] 23 Incremental Compensation (11-bits) Channel 1 Channel 2 Channel 3 Channel 4 Y:$78B20 [22-6] [5:4] Incremental Position in Single Turn (17-bits) Yaskawa Data Registers Y:$78B20 Channel 5 Y:$78B24 Channel 6 Y:$78B28 Channel 7 Y:$78B2C Channel 8 3 2 1 0 U V W Z Y:$78B30 Y:$78B34 Y:$78B38 Y:$78B3C The on-going servo and commutation position data is setup using a 2-line Entry in the Encoder Convers
Brick Controller User Manual Encoder Conversion Table Setup (Motors 1-8) The ECT automatic entry is equivalent to: I8000=$278B20 I8001=$011006 ; Entry 1 Unfiltered parallel pos of location Y:$78B20 ; Width and Bias, total of 17-bits LSB starting at bit#6 I8002=$278B24 I8003=$011006 ; Entry 2 Unfiltered parallel pos of location Y:$78B24 ; Width and Bias, total of 17-bits LSB starting at bit#6 I8004=$278B28 I8005=$011006 ; Entry 3 Unfiltered parallel pos of location Y:$78B28 ; Width and Bias, total of 1
Brick Controller User Manual Yaskawa Incremental Encoder Alarm Codes Yaskawa Incremental encoder Alarm Registers Channel 1 Y:$78B22,8,8 Channel 5 Y:$78B32,8,8 Channel 2 Y:$78B26,8,8 Channel 6 Y:$78B36,8,8 Channel 3 Y:$78B2A,8,8 Channel 7 Y:$78B3A,8,8 Channel 4 Y:$78B2E,8,8 Channel 8 Y:$78B3E,8,8 - Alarm Type Session Flag Session Flag - Clear Action Power cycle Power cycle - Warning - - Bit# Error Name Type 8 Fixed at “1” - 9 Encoder Error 10 Fixed at “0” 11 Position Error 12 13 Fixed at
Brick Controller User Manual Homing with Yaskawa Incremental Encoders Hardware capture is not available with serial data encoders, software capture (Ixx97=1) is required. Setting Ixx97 to 1 tells Turbo PMAC to use the register whose address is specified by Ixx03 for the trigger position. The disadvantage is that the software capture can have up to 1 background cycle delay (typically 2-3 msec), which limits the accuracy of the capture.
Brick Controller User Manual X9-X10: Analog Inputs/Outputs 5 X9-X10: D-Sub DE-9F Mating: D-Sub DE-9M 4 9 3 8 1 2 7 6 Pin # Symbol Function Notes 1 AGND Ground 2 ADC+ Input 3 DAC+ Output 12-bit filtered PWM analog output, channel 5/6+ 4 BR-NC Output Brake 5-6 / Relay Normally Closed 5 AMPFLT Input Amplifier fault Input 5/6 6 ADC- Input 16-bit Analog Input, channel 5/6- 7 DAC- Output 8 BRCOM Common 9 BR-NO Output Analog Ground 16-bit Analog Input, channel 5/6+ 12-bi
Brick Controller User Manual Setting up the Analog (ADC) Inputs Differential Analog Input Signal 1 AGND ADC+ 5 9 5 ±10VDC Input Signal 9 ±10VDC Input Signal 4 ADC- 4 8 8 3 3 ADC+ 7 7 2 2 6 6 1 AGND Single Ended Analog Input Signal For single-ended connections, tie the negative ADC pin to ground. Note The analog inputs use the ADS8321 Converter device Note Note Full (16-bit) resolution is available for bipolar signals only.
Brick Controller User Manual Setting up the DAC Outputs 8 3 9 5 5 9 4 DACAnalog Device DAC+ Analog Device 4 8 3 DAC+ 7 2 7 2 6 AGND 6 AGND Single Ended DAC Output Signal 1 1 Differential DAC Output Signal The analog outputs on X9 through X12 are (12-bit) filtered PWM signals, therefore a PWM frequency in the range of 30-36 KHz and a PWM deadtime of zero are suggested for a good quality analog output signal (minimized ripple).
Brick Controller User Manual With Servo IC 0 being the clock master and using enhanced clock settings, the following are suggested Servo IC 1 clock settings which provide good analog output signals: Enhanced Servo IC 0 Clock Settings I7000=3275 I7001=0 I7002=3 I10=1863964 Suggested Servo IC 1 Clock Settings Resulting Frequencies KHz PWM PHASE SERVO I7100=816 I7101=3 I7102=3 I7104=0 9 18 4.5 Resulting Frequencies KHz PWM PHASE SERVO PWMDeadtime 36 18 4.
Brick Controller User Manual Setting up the General Purpose Relay, Brake This option provides either a general purpose relay (which can be toggled in software) OR a dedicated brake relay output tied to its’ corresponding channel amplifier-enable line. This option is built to order and is jumper configurable at the factory (E6, E7, E8 and E9). The brake relay is commonly used in synchronizing (in hardware) external events such as automatically releasing a motor brake upon enabling it (i.e. vertical axis).
Brick Controller User Manual High True Brake Output Sourcing Sinking 6 7 2 8 9 4 5 5 9 4 8 3 Logic device / BRAKE RET Brake BRAKE 3 BRAKE Logic device / Brake BRAKE RET 7 2 6 1 DC Power Supply COM 12-24V 1 DC Power Supply 12-24VDC COM Low True Brake Output Sourcing Sinking DC Power Supply 12-24VDC COM 7 5 5 9 9 4 4 8 8 3 7 Logic device / BRAKE RET Brake BRAKE 3 BRAKE Logic device / Brake BRAKE RET 2 2 6 6 1 1 DC Power Supply COM 12-24V The brake relays on X9, X10,
Brick Controller User Manual Setting up the External Amplifier Fault Input The amplifier fault signal is a bidirectional single-ended input. Its’ minus end is tied internally to the brake/relay common (pin #8) which dictates how the amplifier fault input should be connected. If the amplifier fault signal is not used, it can be treated and used as a general purpose +12~24V input by setting bit 20 of Ixx24 to 1.
Brick Controller User Manual X13: USB 2.0 Connector This connector is used to establish USB (A-B type cable) communication between the host PC and the Brick Controller. This type of USB cable can be purchased at any local electronics or computer store. It may be ordered from Delta Tau as well. Pin # Symbol Function 1 VCC N.C. 2 DData3 D+ Data+ 4 Gnd GND 5 Shell Shield 6 Shell Shield Caution The electrical ground plane of the host PC connected through USB must be at the same level as the Brick Controller.
Brick Controller User Manual X15: Watchdog & ABORT (TB2) X15 has two essential functions: A 24VDC Abort Input (mandatory for normal operation) which can be used in various applications to halt motion when necessary (i.e. opening machine door, replacing tool). A watchdog relay output allowing the user to bring the machine to a stop in a safe manner in the occurrence of a watchdog. These functions are disabled on Brick Controllers with Turbo PMAC firmware version 1.946 or earlier.
Brick Controller User Manual The hardware Abort input functionality differs slightly from the software global Abort (^A) command. The following table summarizes the differences: Motor(s) Status Before Abort Action Software Global Abort ^A Action Hardware Abort Trigger Action (Removing 24VDC) Killed (Open-Loop mode) Closes the position-loop on all active (Ixx0=1) motors No Action is taken. Motors remain killed Amplifier Enabled (i.e.
Brick Controller User Manual J4: Limits, Flags, EQU [Axis 1- 4] J4 is used to wire axis/channels 1 through 4 over travel limit switches, home and user flags, and EQU output. The limits and flags can be ordered either 5V or 12-24V. The EQU output is always 5V. Per axis/channel, there are 2 limit inputs, 2 flag inputs, and 1 EQU output: - Positive limit. Negative limit - Home flag.
Brick Controller User Manual J5: Limits, Flags, EQU [Axis 5- 8] J5 is used to bring in axis/channels 5 through 8 over travel limit switches, home and user flags, and EQU output. The limits and flags can be ordered either 5V or 12-24V. The EQU output is always 5V. Per axis/channel, there are 2 limit inputs, 2 flag inputs, and 1 EQU output: - Positive limit. Negative limit - Home flag.
Brick Controller User Manual Wiring the Limits and Flags The Brick Controller allows the use of sinking or sourcing limits and flags. The opto-isolator IC used is a PS2705-4NEC-ND quad phototransistor output type. This IC allows the current to flow from return to flag or from flag to return.
Brick Controller User Manual Limits and Flags [Axis 1- 4] Suggested M-Variables M115->X:$078000,19 M116->X:$078000,9 M120->X:$078000,16 M121->X:$078000,17 M122->X:$078000,18 ; ; ; ; ; User 1 flag input status EQU1, ENC1 compare output value Home flag 1 input status Positive Limit 1 flag input status Negative Limit 1 flag input status M215->X:$078008,19 M216->X:$078008,9 M220->X:$078008,16 M221->X:$078008,17 M222->X:$078008,18 ; ; ; ; ; User 2 flag input status EQU2, ENC2 compare output value Home flag
Brick Controller User Manual J6: General Purpose Inputs/Outputs J6 is used to wire general purpose digital Inputs (1-16) and Outputs (1-8) to the Brick Controller.
Brick Controller User Manual J7: Additional General Purpose Inputs/Outputs J7 is used to wire general purpose digital Inputs (17-32) and Outputs (9-16) to the Brick Controller.
Brick Controller User Manual J8: Additional General Purpose Inputs/Outputs J8 is used to wire general purpose digital Inputs (33-48) and Outputs (17-24) to the Brick Controller.
Brick Controller User Manual About the Digital Inputs and Outputs All general purpose inputs and outputs are optically isolated. They operate in the 12–24 VDC range, and can be wired to be either sinking or sourcing. Inputs The inputs use the PS2505L-1NEC photocoupler. For sourcing inputs, connect the input common pin(s) to the 12–24V line of the power supply. The input devices are then connected to the common ground line of the power supply at one end, and individual input pins at the other.
Brick Controller User Manual Wiring the Digital Inputs and Outputs The inputs and outputs can be wired to be either sourcing out of or sinking into the Brick Controller: Sourcing Inputs / Outputs Sinking Inputs / Outputs PinOuts and Software Setup 20 1 21 2 22 3 23 4 24 5 25 6 26 7 27 8 28 9 27 8 26 7 25 6 24 5 23 4 22 3 21 2 20 1 COM 29 30 31 32 13 33 14 37 18 36 17 35 16 34 15 14 13 12 30 31 32 33 34 OUTPUT 8 / 16 11 29 11 OUTPUT 7 / 15 12 OUTPUT 6 / 14
Brick Controller User Manual General Purpose I/Os (J6) Suggested M-Variables // Inputs: M1->Y:$78800,0,1 M2->Y:$78800,1,1 M3->Y:$78800,2,1 M4->Y:$78800,3,1 M5->Y:$78800,4,1 M6->Y:$78800,5,1 M7->Y:$78800,6,1 M8->Y:$78800,7,1 M9->Y:$78801,0,1 M10->Y:$78801,1,1 M11->Y:$78801,2,1 M12->Y:$78801,3,1 M13->Y:$78801,4,1 M14->Y:$78801,5,1 M15->Y:$78801,6,1 M16->Y:$78801,7,1 ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input 01 02 03 04 0
Brick Controller User Manual General Purpose I/Os Additional (J8) Suggested M-Variables // Inputs: M49->Y:$78A00,0,1 M50->Y:$78A00,1,1 M51->Y:$78A00,2,1 M52->Y:$78A00,3,1 M53->Y:$78A00,4,1 M54->Y:$78A00,5,1 M55->Y:$78A00,6,1 M56->Y:$78A00,7,1 M57->Y:$78A01,0,1 M58->Y:$78A01,1,1 M59->Y:$78A01,2,1 M60->Y:$78A01,3,1 M61->Y:$78A01,4,1 M62->Y:$78A01,5,1 M63->Y:$78A01,6,1 M64->Y:$78A01,7,1 ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; Input Input Input Input Input Input Input Input Input Input Input Input Input Input Input
Brick Controller User Manual J9: Handwheel Analog I/O J9 is used to wire the additional analog inputs, Handwheel encoder, analog output, and PFM output.
Brick Controller User Manual Setting up the Analog Inputs (J9) AGND ADC5 AGND ADC6 AGND ADC7 AGND ADC8 14 ADC4 15 AGND 16 ADC3 17 AGND 2 ADC2 3 AGND 4 ADC1 18 I5081=$000000 I5082=$000001 I5083=$000002 I5084=$000003 I5085=$000004 I5086=$000005 I5087=$000006 I5088=$000007 21 ; ; ; ; ; ; ; ; ADC0 ADC1 ADC2 ADC3 ADC4 ADC5 ADC6 ADC7 Unipolar Unipolar Unipolar Unipolar Unipolar Unipolar Unipolar Unipolar 23 Unipolar Mode Bipolar Bipolar Bipolar Bipolar Bipolar Bipolar Bipolar Bipolar
Brick Controller User Manual J9 Analog Inputs Suggested M-Variables Bipolar Mode (Signed) M6991->Y:$003400,12,12,S M6992->Y:$003402,12,12,S M6993->Y:$003404,12,12,S M6994->Y:$003406,12,12,S M6995->Y:$003408,12,12,S M6996->Y:$00340A,12,12,S M6997->Y:$00340C,12,12,S M6998->Y:$00340E,12,12,S ; ; ; ; ; ; ; ; Unipolar Mode (Unsigned) ADC1 ADC2 ADC3 ADC4 ADC5 ADC6 ADC7 ADC8 M6991->Y:$003400,12,12,U M6992->Y:$003402,12,12,U M6993->Y:$003404,12,12,U M6994->Y:$003406,12,12,U M6995->Y:$003408,12,12,U M6996->Y:$00
14 1 15 16 3 16 3 15 2 14 1 2 18 19 6 21 8 9 9 21 8 20 Analog DAC Device COM 20 7 Analog DAC+ Device DAC- 7 19 6 18 5 17 Single-Ended Output 5 Differential Output 4 4 Setting up the Analog Output (J9) 17 Brick Controller User Manual 22 23 23 10 10 22 The analog output out of J9 is a (12-bit) filtered PWM signal, therefore a PWM frequency in the range of 30-36 KHz and a PWM deadtime of zero are suggested for a good quality analog output signal (minimum ripple).
Brick Controller User Manual For assistance with clock settings, use the Delta Tau Calculator: DT Calculator Forum Link J9 Analog Output Suggested M-Variable // I/O 10 & 11 Mode (PWM) M7001->Y:$78404,10,1 M7002->Y:$78404,11,1 M7001=0 ; =0 PWM, =1 PFM M7002=0 ; =0 PWM, =1 PFM // Analog Output M-variable M7000->Y:$78412,8,16,S // These I/O nodes have to be setup once on power-up.
15 15 2 2 16 16 3 3 4 4 6 19 19 20 21 8 22 21 9 10 22 COM 11 11 23 23 10 COM 9 20 PULSE+ PULSE PULSEFREQUENCY DIR+ DEVICE/ DIRAMPLIFIER 8 PULSE PULSEFREQUENCY DIR+ DEVICE/ DIRAMPLIFIER 7 7 PULSE+ 18 18 Single Ended Pulse And Direction 6 Differential Pulse And Direction 5 5 17 17 Setting up Pulse and Direction Output PFM (J9) 13 13 25 25 12 12 24 Using the Delta Tau Calculator or referring to the Turbo Software Reference Manual, the desired maximum PFM Frequenc
Brick Controller User Manual The calculated Ixx69 specifies the maximum command output value which corresponds to the maximum PFM Frequency: I6826=3 ; MACRO IC Channel 2 Output Mode Select. C PFM M8000->Y:$7841C,8,16,S ; Supplementary Channel 2* Output C Command Value ; Min=0, Max= Calculated Ixx69 M8001->X:$7841D,21 ; Invert C Output Control. 0=no inversion, 1=invert M8001=0 ; Testing the J9 PFM Output Writing directly to the suggested M-variable (i.e.
2 14 14 1 3 15 15 2 4 4 16 16 3 Brick Controller User Manual 5 17 17 Setting up the Handwheel Port (J9) 20 +5V External +5V COM Power Supply 21 23 10 24 CHB+ 11 Quadrature Encoder CHC+ 25 +5V PWR 12 CHB- 13 CHC- 13 CHC+ GND 24 CHB+ 25 Quadrature Encoder 12 GND 11 CHA+5V PWR CHA+ 23 CHA+ 10 22 22 9 9 21 8 +5V External +5V COM Power Supply 8 20 7 7 19 19 6 6 18 18 5 A quadrature encoder type device is normally brought into the handwheel port; it c
Brick Controller User Manual Serial Port (RS232) An optional serial RS-232 communication port is available on the Brick Controllers. This port can be used as a primary communication mean or employed as a secondary port that allows simultaneous communication. Pin# 1 2 3 4 5 6 7 8 9 N.C. DTR TXD CTS RXD RTS DSR N.C. GND RS-232: D-Sub DE-9F Mating: D-Sub DE-9M 5 4 9 3 8 2 7 1 6 Symbol Function Description Notes N.C.
Brick Controller User Manual AMP1-AMP8: Amplifier Connection 8 AMP1-AMP8: D-sub DA-15F Mating: D-Sub DA-15M 7 15 6 14 5 13 4 12 3 11 2 10 1 9 Pin # Schematic Symbol Function 1 DACA+ Output DAC A output + 2 DACB+ Output DAC B output + 3 AE_NC+ Output Amplifier Enable Relay Normally Close 4 AE_NO+ Output Amplifier Enable Relay Normally Open 5 AFAULT- (COM) Common 6 N.C. Not connected 7 N.C.
Brick Controller User Manual Wiring the DAC Output 9 10 2 DAC+ Analog DACDevice COM 11 12 4 13 5 14 6 15 7 8 8 15 7 14 6 13 5 12 4 11 3 DAC+ Analog COM Device 1 Differential DAC Output 3 10 2 9 1 Single Ended DAC Output DACA+ DACASine-Wave DACB+ Amplifier DACBCOM 8 15 7 14 6 13 5 12 4 11 3 10 2 9 1 Sinusoidal DAC Output PinOuts and Software Setup 137
Brick Controller User Manual Wiring the Amplifier Enable and Fault Signals The amplifier enable output signal can be either: High true using the normally open contact (pin #4) Low true using the normally closed contact (pin #3) Also, it can be either sourcing or sinking depending on the wiring scheme.
Brick Controller User Manual Older Models / Newer Models (FLT RET jumper installed) High True Amplifier Enable Output 9 12 COM DC Power 12-24V Supply AE COM AMP FLT 13 14 6 15 8 8 15 7 AE COM 7 14 6 13 AMP FLT 4 AMP ENA 11 3 10 2 AMP ENA 5 12 4 5 DC 12-24V Power Supply COM 11 3 10 2 9 1 Sinking 1 Sourcing Low True Amplifier Enable Output 9 10 2 AE COM 11 3 12 4 COM AMP FLT DC Power 12-24V Supply 14 15 8 15 7 AE COM 6 13 AMP FLT 13 14 6 7 8 PinOuts and S
Brick Controller User Manual Newer Models (FLT RET jumper removed) High True Amplifier Enable Output 9 12 4 13 COM DC Power 12-24V Supply AE COM AMP FLT+ AMP FLT- 14 15 AMP FLT COM 8 8 15 AMP ENA COM AMP FLT COM 5 AMP FLT+ AMP FLT- 11 3 10 2 AMP ENA 6 13 14 6 7 AMP ENA 7 12 4 5 DC 12-24V Power Supply COM 11 3 10 2 9 1 Sinking 1 Sourcing Low True Amplifier Enable Output 9 10 2 11 3 AE COM COM 13 5 12 4 AMP FLT+ AMP FLT- DC Power 12-24V Supply 14 AMP FLT COM 8
Brick Controller User Manual DRIVE-MOTOR SETUP The Brick Controller supports three types of outputs: Analog ±10V 12-bit Filtered PWM Analog ±10V 18-bit True DAC Pulse Frequency Modulation (PFM) The following chart summarizes the steps to implement for setting up a motor properly with the Brick Controller: Encoder / Motor wiring Factory Default Reset $$$***, Save, $$$ (recommended) Encoder Software Setup. Verify Feedback. (rotate shaft by hand) Output Type i.e.
Brick Controller User Manual Filtered PWM Output (Analog ±10V) In this mode, the ±10V analog output is obtained by passing the digital PWM signal through a 10 KHz low pass filter. This technique, although not as performing as a true digital to analog converter, is more than adequate for most servo applications. The duty cycle of the PWM signal controls the magnitude of the voltage output. This is handled internally by the PMAC, the user needs not to change any settings.
Brick Controller User Manual Clock Settings, Output Mode, Command Limit Most commonly used and suggested clock settings in this mode allowing a good compromise are a 30 KHz PWM Frequency, 10 KHz Phase, and 2.5 KHZ Servo. DT Calculator Link I7100 I7101 I7102 = 981 = 5 = 3 ; PWM Frequency 30 KHz, PWM 1-4 ; Phase Clock 10 KHz, Servo IC 1 ; Servo Clock 2.5 KHz, Servo IC 1 I7000 I7001 I7002 = 981 = 5 = 3 ; PWM Frequency 30 KHz, PWM 5-8 ; Phase Clock 10 KHz, Servo IC 0 ; Servo Clock 2.
Brick Controller User Manual I2T Protection: Ixx57, Ixx58 I2T is a software thermal model (PMAC internal calculation) used to protect motor and drive from exceeding current specifications. For a safe setup, the lower limit of continuous and peak current specifications between the motor and drive should be selected. Example: A Brick Controller driving a torque-mode amplifier that has a gain of 3 amperes/volt and a continuous current rating of 10 amperes, with a motor rated to 12 amperes continuous.
Brick Controller User Manual The open-loop test is usually performed on an unloaded motor. The open loop command output is adjustable, start off with a conservative 1 to 2 percent command output (i.e. #nO2) value and increment gradually until you see a satisfactory result.
Brick Controller User Manual Position-Loop PID Gains: Ixx30…Ixx39 The position-loop tuning is done as in any Turbo PMAC PID-Loop setup. The PMACTuningPro2 automatic or interactive utility can be used to fine-tune the PID-Loop. Satisfactory Step and Parabolic move responses would look like: Position Step Move Position Parabolic Move At this point of the setup, the motor(s) is ready to accept Jog commands.
Brick Controller User Manual True DAC Output (±10V) Clock Settings, Output Mode Default Clock settings are suitable for most applications. Output mode is set to DAC. I7100 I7101 I7102 = 6527 = 0 = 3 ; Servo IC 1 PWM Frequency 4.5 KHz, Max Phase Frequency 9 KHz ; Servo IC 1 Phase Clock 9 Khz ; Servo IC 1 Servo Clock 2.25 I7000 I7001 I7002 = 6527 = 0 = 3 ; Servo IC 0 PWM Frequency 4.5 KHz, Max Phase Frequency 9 KHz ; Servo IC 0 Phase Clock 9 Khz ; Servo IC 0 Servo Clock 2.
Brick Controller User Manual I2T Protection: Ixx57, Ixx58 I2T is a software thermal model (PMAC internal calculation) used to protect motor and drive from exceeding current specifications. For a safe setup, the lower limit of continuous and peak current specifications between the motor and drive should be selected. Example: A Brick Controller driving a torque-mode amplifier that has a gain of 3 amperes/volt and a continuous current rating of 10 amperes, with a motor rated to 12 amperes continuous.
Brick Controller User Manual The open-loop test is usually performed on an unloaded motor. The open loop command output is adjustable, start off with a conservative 1 to 2 percent command output (i.e. #nO2) value and increment gradually until you see a satisfactory result.
Brick Controller User Manual Position-Loop PID Gains: Ixx30…Ixx39 The position-loop tuning is done as in any Turbo PMAC PID-Loop setup. The PMACTuningPro2 automatic or interactive utility can be used to fine-tune the PID-Loop. Satisfactory Step and Parabolic move responses would look like: Position Step Move Position Parabolic Move At this point of the setup, the motor(s) is ready to accept Jog commands.
Brick Controller User Manual Pulse and Direction Output (PFM) The Pulse and direction (Pulse Frequency Modulation) output pins are located on the encoder (X1-X8) connectors. The stepper drive specifications dictate the choice of the maximum PFM clock frequency, and pulse width. DT Calculator Forum Link Step 1: Choose Max PFM clock by changing the PFM clock divider. Click on calculate to see results. Step 2: Choose PFM Pulse width by changing I7m04. Click on calculate to see results.
Brick Controller User Manual PFM Setup Example // Encoder Conversion I8000=$C78000 I8001=$C78008 I8002=$C78010 I8003=$C78018 // Encoder Conversion I8004=$C78100 I8005=$C78108 I8006=$C78110 I8007=$C78118 Table, for ; Entry 1 ; Entry 2 ; Entry 3 ; Entry 4 Table, for ; Entry 5 ; Entry 6 ; Entry 7 ; Entry 8 channels 1-4 incremental encoder, incremental encoder, incremental encoder, incremental encoder, channels 5-8 incremental encoder, incremental encoder, incremental encoder, incremental encoder, // Channe
Brick Controller User Manual Issuing Open-Loop Commands Activating the motor channel should be sufficient at this point to allow open loop commands. Note that an open loop command of zero magnitude (#nO0) will result in a zero frequency output, and an open loop command of 100 (#nO100) will result in the maximum calculated frequency output.
Brick Controller User Manual Implementing PID gains, Ixx30..Ixx35 In PFM mode, the PID Gains can be determined using the following empirical equations: Ixx30 660000 Ixx08 PFM CLock [MHz] Ixx31 0 Ixx32 6660 Servo Freq. [KHz] Ixx33..
Brick Controller User Manual MACRO CONNECTIVITY Introduction to MACRO MACRO Ring for Distributed Motion Control - www.macro.org MACRO stands for Motion and Control Ring Optical. It is a high bandwidth non-proprietary digital interface industrialized by Delta Tau Data Systems for distributed multi-axis systems. MACRO can be connected using either fiber optic or twisted copper pair RJ45 cables.
Brick Controller User Manual MACRO Configuration Examples The Brick Controller with its’ MACRO interface supports a wide variety of MACRO ring formations.
Brick Controller User Manual Review: MACRO Nodes and Addressing Each MACRO IC consists of 16 nodes: 2 auxiliary, 8 servo and 6 I/O nodes: Auxiliary nodes are reserved for master/slave setting and internal firmware use Servo nodes are used for motor control carrying feedback, commands, and flag information I/O nodes are user configurable for transferring general purpose data I/ O Nodes Node 15 14 13 12 11 10 9 8 Auxiliary Nodes 7 6 5 4 3 2 1 0 Servo Nodes Each I/O node consists of
Brick Controller User Manual Review: MACRO Auxiliary Commands In MACRO Auxiliary mode (Brick - Brick), master and slave data exchange (i.e. reads, writes) can be done using Macro Auxiliary MX commands. For simplicity, the following examples describe syntax commands intended to communicate with a slave unit associated with node 0. But ultimately, these commands can be used with any enabled node on the addressed slave. MACRO auxiliary commands are only valid from the master side.
Brick Controller User Manual Configuration Example 1: Brick - Brick MACRO Ring Master MACRO Ring Slave The following example describes the necessary steps for setting up a MACRO ring comprised of an 8axis Brick Controller as a master and another 8-axis Brick Controller as a slave. Alternately, it is possible to have 2 x 4-axis Brick Controllers as slaves. Their settings would be similar except for the activated nodes. And I85, in this case, can be used to assign a station number to each of the slaves.
Brick Controller User Manual 5. Clock settings considerations The MACRO ring is synchronized at phase rate. Keep in mind that the phase clock frequency must be the same on both the master and the slave. The MACRO IC must be sourcing the clock (parameter I19). A Save followed by a $$$ are required whenever I19 is changed. It is advised to have both the MACRO and servo ICs set at the same phase frequency.
Brick Controller User Manual Note about Slave Motors’ I2T I2T setting parameters, Ixx69, Ixx57 and Ixx58, should be configured properly, for complete protection, when the motor is controlled locally. I2T setting parameters, Ixx57 and Ixx58, should be set to zero on the slave side when it is in auxiliary mode, and configured for the corresponding channel over MACRO (on the master side).
Brick Controller User Manual Setting up the Master 1. Establish communication to the master using USB, Ethernet, or Serial. 2. Consider starting from factory default settings. This can be done by issuing a $$$*** followed by a Save, and a reset $$$. 3. Consider downloading the suggested M-Variables in the Pewin32Pro2 software. 4. The master’s motors can now be set up as described in the motor setup section of this manual. Typically, these are motors #1 through #8. 5.
Brick Controller User Manual 9.
Brick Controller User Manual Servo Node Addresses MACRO Motor # Address motor 1st 2 nd 3 rd 4 th 5 or 9 6 or 10 7 or 11 8 or 12 Note $78420 $78424 $78428 $7842C Register MACRO Motor # motor Address Register Servo Node 0 5th 9 or 13 $78430 Servo Node 8 Servo Node 1 th 10 or 14 $78434 Servo Node 9 th 11 or 15 $78438 Servo Node 12 th 12 or 16 $7843C Servo Node 13 Servo Node 4 Servo Node 5 6 7 8 At this point of the setup, you should be able to move the motor/encoder shaft by h
Brick Controller User Manual Configuration Example 2: Brick - Geo MACRO Drive This configuration example discusses the necessary steps for setting up a MACRO ring with an 8-axis Brick Controller as a master and up to 4 x dual axes Geo MACRO drives as slaves. For simplicity, we will cover guidelines for setting up one Geo MACRO drive in detail. The others can be configured similarly.
Brick Controller User Manual The following steps are guidelines for setting up one Geo Macro Drive slave: 1. Establish communication to the Brick Controller using USB, Ethernet, or Serial. 2. Consider starting from factory default settings. This can be done by issuing a $$$*** followed by a Save, and a reset ($$$). 3. Consider downloading the suggested M-Variables in the Pewin32Pro2 software. 4. The master’s motors can now be set up as described in the motor setup section of this manual.
Brick Controller User Manual 8. If the Geo MACRO Drive has been configured prior to this setup, then it may have been assigned a station number and/or may have some enabled nodes. You would need to know what the station number is in order to perform ASCII communication, or which nodes are enabled in order to issue MS commands.
Brick Controller User Manual 16. Activating MACRO Motors Variable I4900 reports how many servo ICs is the Brick Controller populated with. Knowing that each Servo IC services 4 axes, querying I4900 will reveal how many local channels are occupied and thus the number of the 1st available motor on the Macro Ring: If I4900 returns $1 $3 Servo ICs Local present Motors IC0 only (4-axis) 1-4 IC0, and IC1(8-axis) 1–8 First Motor# On The Ring 5 9 Activation 2-axis Slave I500,2,100=1 I900,2,100=1 17.
Brick Controller User Manual Servo Node Addresses MACRO Motor # Address motor 1st 5 or 9 $78420 Register MACRO Motor # motor Address Register Servo Node 0 5th 9 or 13 $78430 Servo Node 8 th nd 6 or 10 $78424 Servo Node 1 6 10 or 14 $78434 Servo Node 9 3rd 7 or 11 $78428 Servo Node 4 7th 11 or 15 $78438 Servo Node 12 Servo Node 5 th 12 or 16 $7843C Servo Node 13 2 4 th 8 or 12 Note MACRO Connectivity $7842C 8 At this point of the setup, you should be able to move th
Brick Controller User Manual 18.
Brick Controller User Manual The current loop feedback address Ixx82 should be set per the following table: MACRO Motor # motor 1st 5 or 9 MACRO Motor # motor Ixx82 Register Ixx82 Register $078422 Servo Node 0 5th Servo Node 1 th 9 or 13 $078432 Servo Node 8 6 10 or 14 $078436 Servo Node 9 $07843A Servo Node 12 $07843E Servo Node 13 nd 6 or 10 $078426 3rd 7 or 11 $07842A Servo Node 4 7th 11 or 15 4th 8 or 12 $07842E 8th 12 or 16 2 Servo Node 5 Commutation Cycle Siz
Brick Controller User Manual 20. Motor Phasing, Open-Loop Test Motor phasing is performed in the same manner as it would be for any digitally commutated motor. The following is a satisfactory open loop test: An erratic or inverted saw tooth response is typically (with quadrature, or sinusoidal encoders) an indication of reversed encoder direction –with respect to the output command- The encoder decode parameter MS{node},I910 can then be changed from 7 to 3 or vice versa.
Brick Controller User Manual Brick – Brick MACRO I/O Data Transfer This section describes the handling of inputs and outputs data transfer over the MACRO ring. That is transferring I/O data from the Brick slave to the Brick master.
Brick Controller User Manual Transferring the Digital (Discrete) Input and Outputs A Brick Controller can be populated with up to 48 digital inputs and 24 digital outputs (connectors J6, J7, and J8) for a total of 72 I/O points (bits) mapped as follows: Inputs Address Connector Outputs st 1 byte Y:$78800,0,8 2nd byte Y:$78801,0,8 3rd Byte Y:$78803,0,8 4th Byte Y:$78804,0,8 5th Byte Y:$78A00,0,8 6th Byte Y:$78A01,0,8 st 1 byte 2nd byte 3rd Byte J6 J7 Address Connector Y:$78802,0,8 Y:$78805,0,8 Y:
Brick Controller User Manual The proposed transfer mechanism establishes the reading of inputs and writing to outputs through bitwise assignments (single-bit definitions) from the master side. Outputs: At the master side, the user would write the desired outputs’ state (using the bitwise definitions) to pre-defined open memory registers which are copied, using a PLC code, into the 24-bit register of MACRO I/O node 2.
Brick Controller User Manual Slave Digital I/Os Transfer Example I6841=I6841|$000004 // Digital Outputs #define OutByte1 M7000 #define OutByte2 M7001 #define OutByte3 M7002 OutByte1->Y:$078802,0,8,U OutByte2->Y:$078805,0,8,U OutByte3->Y:$078A02,0,8,U // Digital Inputs #define InByte1 M7003 #define InByte2 M7004 #define InByte3 M7005 #define InByte4 M7006 #define InByte5 M7007 #define InByte6 M7008 InByte1->Y:$078800,0,8,U InByte2->Y:$078801,0,8,U InByte3->Y:$078803,0,8,U InByte4->Y:$078804,0,8,U InByte5->Y
Brick Controller User Manual Master Digital I/Os Transfer Example I6841=I6841|$000004 ; Make sure that I/O node 2 is active // Open Memory Registers #define OpenReg16Y M7000 #define OpenReg16X M7001 #define OpenReg15Y M7002 #define OpenReg15X M7003 OpenReg16Y->Y:$10FF,0,24,U OpenReg16X->X:$10FF,8,16,U OpenReg15Y->Y:$10FE,8,16,U OpenReg15X->X:$10FE,8,16,U M7000..
Brick Controller User Manual Bitwise Assignments (downloaded onto the master) // J6 Outputs #define Output1 #define Output2 #define Output3 #define Output4 #define Output5 #define Output6 #define Output7 #define Output8 M7101 M7102 M7103 M7104 M7105 M7106 M7107 M7108 Output1->Y:$10FF,0,1 Output2->Y:$10FF,1,1 Output3->Y:$10FF,2,1 Output4->Y:$10FF,3,1 Output5->Y:$10FF,4,1 Output6->Y:$10FF,5,1 Output7->Y:$10FF,6,1 Output8->Y:$10FF,7,1 ; ; ; ; ; ; ; ; Output Output Output Output Output Output Output Output
Brick Controller User Manual // J8 Outputs #define Output17 #define Output18 #define Output19 #define Output20 #define Output21 #define Output22 #define Output23 #define Output24 // J8 Inputs #define Input33 #define Input34 #define Input35 #define Input36 #define Input37 #define Input38 #define Input39 #define Input40 #define Input41 #define Input42 #define Input43 #define Input44 #define Input45 #define Input46 #define Input47 #define Input48 M7117 M7118 M7119 M7120 M7121 M7122 M7123 M7124 M7163 M7164 M7
Brick Controller User Manual Transferring the X9-X12 Analog Inputs/Outputs A Brick Controller MACRO slave can be populated with up to: 4 x 16-bit analog inputs (connectors X9 through X12) 4 x 12-bit filtered PWM ±10V analog outputs (connectors X9 through X12) These inputs and outputs are typically mapped using suggested or pre-defined M-Variables at the following addresses: Analog Inputs, connectors X9-X12 M505->Y:$078105,8,16,S M605->Y:$07810D,8,16,S M705->Y:$078115,8,16,S M805->Y:$07811D,8,16,S N
Brick Controller User Manual Slave Settings I6841=I6841|$3300 ; Enable servo nodes 8,9,12,13 I544=$078433 I644=$078437 I744=$07843B I844=$07843F ; ; ; ; MacroIC0 MacroIC0 MacroIC0 MacroIC0 Node 8 Node 9 Node12 Node13 Command Command Command Command Address. Address. Address. Address.
Brick Controller User Manual Transferring the J9 Analog Inputs A Brick Controller MACRO slave with option 12 offers 8 x 12-bit analog inputs on connector J9.
Brick Controller User Manual MACRO Limits and Flags, Homing Limits and Flags MACRO Motors’ Limits and Flags are automatically copied by the Firmware. They can be accessed from the Ring Controller using the MACRO Suggested M-Variables. Note In a Brick – Brick MACRO configuration, the over-travel limits should be disabled on the slave side (Ixx24=Ixx24|$20001). They are only enabled on the master side.
Brick Controller User Manual MACRO Suggested M-Variables // Macro IC 0 Node 0 Flag Registers M150->X:$003440,0,24 ; Macro IC 0 M151->Y:$003440,0,24 ; Macro IC 0 M153->X:$003440,20,4 ; Macro IC 0 M154->Y:$003440,14,1 ; Macro IC 0 M155->X:$003440,15,1 ; Macro IC 0 M156->X:$003440,16,1 ; Macro IC 0 M157->X:$003440,17,1 ; Macro IC 0 M158->X:$003440,18,1 ; Macro IC 0 M159->X:$003440,19,1 ; Macro IC 0 Node Node Node Node Node Node Node Node Node 0 0 0 0 0 0 0 0 0 flag status flag command TUVW flags amplifier
Brick Controller User Manual // Macro IC 0 Node 9 Flag Registers M650->X:$003449,0,24 ; Macro IC 0 M651->Y:$003449,0,24 ; Macro IC 0 M653->X:$003449,20,4 ; Macro IC 0 M654->Y:$003449,14,1 ; Macro IC 0 M655->X:$003449,15,1 ; Macro IC 0 M656->X:$003449,16,1 ; Macro IC 0 M657->X:$003449,17,1 ; Macro IC 0 M658->X:$003449,18,1 ; Macro IC 0 M659->X:$003449,19,1 ; Macro IC 0 Node Node Node Node Node Node Node Node Node 9 9 9 9 9 9 9 9 9 flag status register flag command register TUVW flags amplifier enable fla
Brick Controller User Manual Absolute Position Reporting over MACRO Writing to the motor actual position (Mxx62) should only be done when the motor is killed. Caution The Brick Controller supports a wide variety of absolute encoders. When used as a MACRO slave, the simplest way to report the absolute position to the master (ring controller) is to use the MACRO auxiliary communication (read/write).
Brick Controller User Manual MACRO Configuration Power-Up Sequence Typically, in a MACRO master-slave configuration, it is desirable to power up the slave first and then the master. This ensures proper establishment of MACRO communication. If this is not desirable or possible, the following procedure should ensure that MACRO communication is properly initiated. But either way, clearing MACRO ring faults is always recommended on power up in the following order: 1. Power up slave (logic power). 2.
Brick Controller User Manual TROUBLESHOOTING Serial Number and Board Revisions Identification The following Serial Number Page provides the users with information about their Brick Controller without having to open the enclosure by simply inserting the serial number and pressing the enter key: This page will display: Description and part number of the top assembly (Brick Controller) Part numbers and revision numbers of the sub-assembly boards Top assembly original ship date Top assembly last shi
Brick Controller User Manual Boot Switch SW (Firmware Reload) – Write-Protect Disable This momentary button switch has two essential functions: 1. Putting the Brick Controller in Boostrap Mode for reloading PMAC firmware. 2.
Brick Controller User Manual Reloading PMAC firmware The following steps ensure proper firmware reload/upgrade. Step1: Power up the unit while holding the BOOT SW switch down. Step2: Release the BOOT SW switch approximately 2-3 seconds after power-up. Step3: Launch the Pewin32Pro2. Run the PMAC Devices window under Setup > Force All Windows To Device Number. Click Test for the corresponding communication method.
Brick Controller User Manual Step4: The download utility will prompt for a .BIN file. MAKE SURE you open the correct file. The PMAC firmware file for Brick Controller MUST ALWAYS be TURBO2.BIN. Note Step4: Wait until download is finished, and click done. Step5: Close all PMAC applications (i.e. Pewin32Pro2), and recycle power.
Brick Controller User Manual Changing IP Address, Gateway IP, Gateway Mask In order to change any of these addresses, the BOOT SW switch has to be held down prior to pressing the corresponding Store button.
Brick Controller User Manual Enabling ModBus A Brick unit ordered initially with the ModBus option is normally enabled by factory. However, ModBus is a field upgradeable option. The user needs to provide Delta Tau (or their local distributor) with the MAC ID of the Brick unit. This is found in the lower left hand side of the Ethernet 100 Base T utility. Upon purchase of the ModBus Option, a .BIN file is obtained from Delta Tau for this purpose.
Brick Controller User Manual Reloading Boot and Communication Firmware The boot and firmware .IIC files are required for this procedure. They are normally obtained directly from Delta Tau, or downloaded from the PMAC forum Webpage. The following steps ensure proper configuration: Downloading the wrong boot or communication files will severely corrupt the functionality of the communication processor.
Brick Controller User Manual Reset Switch SW (Factory Reset) This momentary switch button is used to reset the Brick Controller back to factory default settings, global reset. Issuing a SAVE after power up (with the reset switch held down) will permanently erase any user configured parameters. Caution Reset SW instructions: Power down the unit then power back up while holding the Reset SW switch down. Release the Reset SW once the unit is powered up.
Brick Controller User Manual APPENDIX A DB- Connector Spacing Specifications X1-8: DB-15 Connectors for encoder feedback 3.115±.05 1.541±.015 8 7 6 15 14 5 4 13 12 3 2 11 10 8 1 9 7 15 6 14 5 13 4 12 3 11 2 10 1 9 X9-12: DB-9 Connectors for Analog I/O 2.45±.05 1.213+.015 5 4 9 3 8 2 7 1 6 5 4 9 3 8 2 7 1 6 Screw Lock Size for all DB-connectors .18 7 #4-40 FEMALE SCREWLOCK QTY 2 per connector Steel, Zinc Plated Appendix A .235 DIA .
Brick Controller User Manual APPENDIX B Schematics AMP1-AMP8: Amplifier Fault / Amplifier Enable diagrams FLT RET Jumpers Newer models of the Brick Controller (December 2013) introduced jumpers (FLT RET) which allow the isolation of the amplifier fault input from the amplifier enable common. Hence allowing true differential amplifier fault input signals.
Brick Controller User Manual Newer Models (December 2013) J6 and J7: General Purpose I/O Inputs Opto Gnd Plane MMBZ33VALT1 1 3 D35 2 MMBZ33VALT1 MMBZ33VALT1 8 6 4 2 2 1 2 1 7 5 3 1 D58 8 6 4 2 D57 2 MMBZ5V6ALT1 MMBZ5V6ALT1 1 D56 2 D55 1 2 3 4 5 6 7 8 ACI1A ACI1B ACI2A ACI2B ACI3A ACI3B ACI4A ACI4B C1 E1 C2 E2 C3 E3 C4 E4 PS2705-4 C240 C243 .1uf RP160 2.
Brick Controller User Manual Outputs: J6 & J7 (603793 – 109 and earlier) Outputs: J6 & J7 (603793 – 10A and later) Appendix B 199
Brick Controller User Manual J4: Limit Inputs for Axis 1-4 U 39 16 15 14 13 12 11 10 9 C1 E1 AC1 AC1 C2 E2 AC2 AC2 C3 E3 AC3 AC3 C4 E4 AC4 AC4 1 2 1 3 5 7 3 4 5 6 7 8 PS2 7 05 - 4 C 16 0 C 16 2 .1 .1 C 16 1 C 16 3 .1 .1 14 13 12 11 10 9 C1 E1 AC1 AC1 C2 E2 AC2 AC2 C3 E3 AC3 AC3 C4 E4 AC4 AC4 1 2 1 3 5 7 4 .7KSIP8 I 1 R P3 9 3 5 7 2 4 6 8 5 6 7 8 PS2 7 05 - 4 C 16 4 C 16 6 .1 .1 C 16 5 C 16 7 .1 .
Brick Controller User Manual J5: Limit Inputs for Axis 5-8 U 59 16 15 14 13 12 11 10 9 C1 E1 AC1 AC1 C2 E2 AC2 AC2 C3 E3 AC3 AC3 C4 E4 AC4 AC4 1 2 1 3 5 7 3 4 5 6 7 8 PS2 7 05 - 4 C 20 0 C 20 2 .1 .1 C 20 1 C 20 3 .1 .1 14 13 12 11 10 9 C1 E1 AC1 AC1 C2 E2 AC2 AC2 C3 E3 AC3 AC3 C4 E4 AC4 AC4 1 2 1 3 5 7 4 .7KSIP8 I 1 R P8 9 3 5 7 2 4 6 8 5 6 7 8 PS2 7 05 - 4 C 20 4 C 20 6 .1 .1 C 20 5 C 20 7 .1 .
Brick Controller User Manual APPENDIX C Absolute Serial Encoders Limitation with Turbo PMAC The following is a summary of certain limitations which could be encountered with higher resolution absolute serial encoders, and a description of related registers with respect to the proposed setup techniques. Note that techniques 1 and 3 are processed in the Encoder Conversion Table (ECT) using the standard 5-bit shift, whereas technique 2 is processed with no shift.
Brick Controller User Manual Maximum “Actual” Open-Loop Velocity In open-loop mode, the actual velocity register is limited by the Encoder Conversion Table to 24 bits. Furthermore, it requires two samples (servo cycles) to compute the velocity. Therefore, the maximum value which the actual velocity register can withhold is: When performing an open-loop move/test with higher resolution serial encoders, care must be taken not to exceed this threshold.
Brick Controller User Manual Maximum “Commanded” Closed-Loop Velocity In closed-loop mode, the commanded (desired) velocity register is limited to: In terms of motor counts per millisecond, the maximum commanded velocity will be the same with or without shifting but since the number of counts per revolution “unshifted” is 32 times less, then the maximum programmable velocity is 32 times greater.
