^1 USER MANUAL ^2 Geo Brick ^3 Programmable Servo Amplifier ^4 5xx-603800-xUxx ^5 February 13, 2008 Single Source Machine Control Power // Flexibility // Ease of Use 21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.
Copyright Information © 2008 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. To report errors or inconsistencies, call or email: Delta Tau Data Systems, Inc.
After removing the power source from the equipment, wait at least 10 minutes before touching or disconnecting sections of the equipment that normally carry electrical charges (e.g., capacitors, contacts, screw connections). To be safe, measure the electrical contact points with a meter before touching the equipment. The following text formats are used in this manual to indicate a potential for personal injury or equipment damage.
REVISION HISTORY REV. DESCRIPTION DATE CHG APPVD 1 UPDATED ANALOG INPUT SECTION 09/07/06 CP R. UNADKAT 2 UPDATED 6-AXIS REGEN RESISTOR INFO, P. 8 03/19/07 CP D. GENTRY 3 UPDATED PART NUMBER DEFINITION TABLE, P. 7 04/27/07 CP S. SATTARI 4 UPDATED TROUBLESHOOTING CHAPTER, P. 75 09/12/07 CP R. NADDAF 5 UPDATED TROUBLESHOOTING CHAPTER, P. 75 02/13/08 CP R.
Geo Brick User Manual Table of Contents Copyright Information.............................................................................................................................................. ii Operating Conditions ............................................................................................................................................... ii Safety Instructions.....................................................................................................................
Geo Brick User Manual J3: External Shunt Connector Pinout ................................................................................................................22 Shunt Regulation.................................................................................................................................................22 Minimum Resistance Value.................................................................................................................................
Geo Brick User Manual Preparation.........................................................................................................................................................65 Position Feedback and Polarity Test..................................................................................................................66 PWM Output and ADC Input Connection ..............................................................................................................66 PWM/ADC Phase Match ..
Geo Brick User Manual INTRODUCTION The Geo Brick combines the intelligence and capability of the Turbo PMAC2 motion controller with the latest IGBT-based drive technology, resulting in a compact, smart 4-, 6- or 8-axis servo drive package. The flexibility of the Turbo PMAC2 enables the Geo Brick to drive Brush, Brushless or AC induction motors with unsurpassed pure digital DSP performance.
Geo Brick User Manual • Eight thermal-fuse protected outputs (expandable to 16 with option) rated for 0.5A @ 24VDC each (Flexible outputs allow for sinking or sourcing of current depending on whether the common emitter or common collector is used.
Geo Brick User Manual Feedback Devices Many motors incorporate a position feedback device. Devices are incremental encoders, resolvers, and sine encoder systems. The Geo Brick is set up to accept incremental encoder feedback. Historically, the choice of a feedback device has been guided largely by cost and robustness factors. Today, feedbacks are relatively constant for the cost and picked by features such as size and feedback data.
Geo Brick User Manual must be able to achieve the desired speed with this voltage limitation. This can be determined by using the voltage constant of the motor (Kb), usually specified in volts-per-thousand rpm. The application speed is divided by 1000 and multiplied by the motor’s Kb. This is the required voltage to drive the motor to the desired velocity. Headroom of 20% is suggested to allow for good servo control. Peak Torque The peak torque rating of a motor is the maximum achievable output torque.
Geo Brick User Manual constant is known, the drive amplifier requirements can be calculated to effectively size a drive amplifier for a given motor. Some motor designs allow Kt to be non-linear, in which Kt will actually produce less torque per unit of current at higher output speeds. It is wise to de-rate the systems torque producing capability by 20% to allow headroom for servo control.
Geo Brick User Manual 6 Introduction
Geo Brick User Manual SPECIFICATIONS Part Number Geo Brick Drive Part Number Definition Communication Options G B L 4 -C 0 - 5 0 0 - 0 0 0 Note: To use PMAC-NC software, DPRAM is required 0: No Options, Default D: DPRAM option, size 32K x 16-bit wide (required for NC software) M: ModBus Ethernet Communication Protocol (Software) option R: RS232 port on 9-pin D-sub Connector S: DPRAM and Modbus Options Combined E: DPRAM & RS232 Options Combined N: RS232 & ModBus Options Combined T: Modbus, DPRAM & RS232
Geo Brick User Manual Communication Options • Option D – small DPRAM 8K x 16-bit wide required for use with NC software • Option M – Modbus Communication Protocol • Option R – RS232 port on 9-pin D-sub Connector • Option S – DPRAM and Modbus Options Combined • Option E – DPRAM and RS232 Options Combined • Option N – RS232 and Modbus Options Combined • Option T – Modbus, DPRAM and RS232 Combined Environmental Specifications Description Unit Operating Temperature °C Rated Storage Temperature Humidity Sh
Geo Brick User Manual 6-axis Configuration GBL6-xx-5Fx-xxx 1-4 axis 5-6 axis Model Output Continuous Current (rms/axis) Output Peak Current for 2 seconds (rms/axis) Rated Input Power (KVA) @ 240VAC Output Power (Watts per axis) (based on modulation depth of 60% RMS) Total Power Dissipation (Watts) Recommended PWM Frequency Mean/Max (kHz) AC Input Line Voltage (VAC rms) DC Input Line Voltage (VDC) Logic Power (VDC, A) Continuous Regen Power rating (Watts) Peak Regen Power rating(Watts) Recommended Regen Re
Geo Brick User Manual Recommended Fusing and Wire Gauge Model Recommended Fuse (FRN/LPN) GBL4-xx-50x-xxx 15 GBL4-xx-80x-xxx 25 GBL6-xx-5Fx-xxx 35 GBL6-xx-8Fx-xxx 40 GBL8-xx-552-xxx 25 GBL8-xx-882-xxx 45 GBL8-xx-582-xxx 35 GBL8-xx-852-xxx 35 * See local and national code requirements Recommended Wire Gauge* 12 AWG 10 AWG 8 AWG 8 AWG 10 AWG 8 AWG 8 AWG 8 AWG Wire Sizes Geo Drive electronics create a DC bus by rectifying the incoming AC electricity.
Geo Brick User Manual RECEIVING AND UNPACKING Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the Geo Brick Drive is received, there are several things to be done immediately: 1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered the drive. 2. Remove the control from the shipping container and remove all packing materials.
Geo Brick User Manual Note: If Ethernet communications are used, Delta Tau Systems strongly recommends the use of RJ45 CAT5e or better shielded cable. Newer network cards have the Auto-MDIX feature that eliminates the need for crossover cabling by performing an internal crossover when a straight cable is detected during the auto-negotiation process.
Geo Brick User Manual MOUNTING The location of the drive 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.
Geo Brick User Manual 4-axis Low/Medium Power Drive GBL4-xx-50x-xxx and GBL4-xx-80x-xxx (x stands for the different options that can be ordered) Mounting Dimensions Width Depth Height Weight 114mm / 4.50in. 178mm/ 7.00in. 391mm/ 15.40in. 4.4Kgs (9.6lbs) Geo Brick amplifier 4-axis 24V D C I N P U T ( J2) +24 VD C 24VD C R ET GENE RA LP URP OS EI / O J ( 7) GENE RA LP URP OS EI / O J ( 6) LI MIT I NPU TS 5-8( J5) LI MIT I NPU TS 1-4( J4) E X T SHUNT ( J3) R EG EN R EG EN + 13 .375 3.
Geo Brick User Manual 6-axis: 4-axis Low/Medium Power plus 2-axis High Power (15A/30A) Drive GBL6-xx-5Fx-xxx and GBL6-xx-8Fx-xxx (x stands for the different options that can be ordered) Mounting Dimensions Width Depth Height Weight 203mm / 8.00in. 178mm /7.00in. 391mm / 15.40in. Call Factory Geo Brick Amplifier 6-axis 24 V D C I N P U( T J2) +24VD C 24VD C R ET G ENE RAL PU RP OSE I O / ( J7) G ENE RAL PU RP OSE I O / ( J6) LI M T I N I PU TS 5-8 ( J5) LI M T I N I PU TS 1-4 ( J4) 13 .
Geo Brick User Manual 8-axis Low/Medium Power Drive GBL8-xx-552-xxx, GBL8-xx-582-xxx, GBL8-xx-852-xxx and GBL8-xx-882-xxx (x stands for the different options that can be ordered) Mounting Dimensions Width Depth Height Weight 203mm/ 8.00in. 178mm./ 7.00in. 392mm./ 15.40in. 9.0 kgs (19.
Geo Brick User Manual SYSTEM WIRING OPTIONAL EMI FILTER GARxx SHUNT RESISTOR EARTH BLOCK WHT Twisted Wires J2 LOGIC J3 SHUNT MCR EARTH FRAME Motor A 1-8 BLK 24 V RET RED +24 V 24V POWER SUPPLY +24 VDC REGEN - BLK 24 VDC RET WHT BLK REGEN + MAIN POWER t e x t GND W V U 1 Motor n t e x t(Max. 8) Encoder X 1-8 Geo Brick J1 AC INPUT G L L L N 1 2 3 D t e xtt e xt t e xtt e xt Encoder n (Max.
Geo Brick User Manual Use of GFI Breakers Ground Fault Interrupter circuit breakers are designed to break the power circuit in the event that outgoing currents are not accompanied by equal and opposite returning currents. These breakers assume that if outgoing currents are not returning then there is a ground path in the load.
Geo Brick User Manual Wiring AC Input The main bus voltage supply is brought to the Geo drive through connector J1. It is acceptable to bring the single-phase power into any two of the three input pins (L1/L2/L3) on connector J1. Higher-power drive amplifiers require three-phase input power. It is extremely important to provide fuse protection or overload protection to the input power to the Geo drive amplifier. Typically, this is provided with fuses designed to be slow acting, such as FRN-type fuses.
Geo Brick User Manual 3. Conductors made up of many strands of fine conducts outperform solid or conductors with few strands at high frequencies. 4. Motor cable shields should be bounded to the back panel using 360-degree clamps at the point they enter or exit the panel. 5. Motor shields are best grounded at both ends of the cable. Again, connectors using 360-degree shield clamps are superior to connector designs transporting the shield through a single pin. Always use metal shells. 6.
Geo Brick User Manual A1-8: Motor 1 to 8 Output Connector Pinout (Low/Medium Power Units) Pin # Symbol Function Description Notes 1 GND Common W Phase1 Output Axis 1 to 8 2 3 V Phase2 Output Axis 1 to 8 4 U Phase3 Output Axis 1 to 8 DT Connector part number #014-000F04-HSG and pins part number #014-043375-001 Molex Crimper tool p/n#63811-0400 With the High Power option (15A/30A), the unit has total of six axes.
Geo Brick User Manual The regen resistors incorporate a thermal overload protection thermostat that opens when the core temperature of the resistor exceeds 225 degrees °C. This thermostat is available through the two black leads exiting the resistor. It is important that these two leads be wired in a safety circuit that stops the system from operating should the thermostat open.
Geo Brick User Manual The shunt regulator monitors the DC Bus voltage. If this voltage rises above a present threshold (Regen Turn On Voltage), the Geo Drive will turn on a power device intended to place the externally mounted regen resistor across the bus to dump the excessive energy. The power device keeps the regen resistor connected across the bus until the bus voltage is sensed to be below the Regen Turn Off voltage, at which time the power device removes the resistor connection.
Geo Brick User Manual Here also, to get energy in Joules from English mechanical units, additional conversion factors are required. To calculate the kinetic energy of a mass having a weight of W pounds, the following equation can be used: E K = 0.678 W 2 v = 0.0211Wv 2 g where: EK is the kinetic energy in joules (J) W is the weight of the moving mass in pounds (lb) g is the acceleration of gravity (32.
Geo Brick User Manual where: ELE is the lost energy in joules (J) irms is the current required for the deceleration in amperes (A), equal to the required deceleration torque divided by the motor’s (rms) torque constant KT Rpp is the phase-to-phase resistance of the motor, in ohms (Ω) td is the deceleration time in seconds (s) Capacitive Stored Energy in the Drive The energy not lost during the transformation is initially stored as additional capacitive energy due to the increased DC bus voltage.
Geo Brick User Manual Bonding The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing immunity levels. The bonding effect is to reduce the impedance between the cable shield and the back panel. Power input wiring does not require shielding (screening) if the power is fed to the enclosure via metal conduit. If metal conduit is not used in the system, shielded cable is required on the power input wires along with proper bonding techniques.
Geo Brick User Manual Motor Line Filtering Motor filtering may not be necessary for CE compliance of Geo Drives. However, this additional filtering increases the reliability of the system. Poor non-metallic enclosure surfaces and lengthy, unbonded (or unshielded) motor cables that couple noise line-to-line (differential) are some of the factors that may lead to the necessity of motor lead filtering. Motor lead noise is either common-mode or differential.
Geo Brick User Manual Connectors X1-X8: Encoder Input (1 to 8) The main encoder input channels for the Geo Brick Drive support only differential quadrature feedback. 5V supply to power the encoder is provided. • 4-axis drives with no Option 01 or Option 02 have only X1 to X4, for a total of four encoders • Option 01 adds two extra S. encoders: X5 and X6, for a total of six encoders • Option 02 adds two more S. encoders on top of Option 01: X7 and X8 for a total of eight encoder feedbacks.
Geo Brick User Manual X9-10: Analog I/O Ch5 (X9) and Ch6 (X10), (Optional) X9/10 (Female DB-9 Connector) Pin # Symbol Function Notes 1 AGND Common 2 ADC5/6+ Input 12-bit Analog Input, channel 5/6+ * 3 DAC5/6+ Output 12-bit filtered PWM analog output, channel 5/6+ 4 AE-NC-5/6 Output Amplifier Enable 5/6 Normally Closed** 5 AMPFLT5/6 Output Amplifier 5/6 fault output*** 6 ADC5/6Input 12-bit Analog Input, channel 5/6+ * 7 DAC5/6Output 12-bit filtered PWM analog output, channel 5/6+ 8 AECOM5/6 Common Ampli
Geo Brick User Manual X13: USB 2.0 Connector This connector is used in conjunction with USB A-B cable, which can be purchased from any local computer store and is provided when Option 1A is ordered. The A connector is connected to a PC or Hub device; the B connector plugs into the J9-USB port. Pin # Symbol Function 1 2 3 4 5 6 VCC DD+ GND SHELL SHELL N.C. DATADATA+ GND SHIELD SHIELD X14: RJ45, Ethernet Connector This connector is used for Ethernet communications from the Geo PMAC Drive to a PC.
Geo Brick User Manual X15: Watchdog & ABORT The X15 connector allows the user to send Ohm output from the Geo Brick Drive to the machine if a watchdog condition has occurred at the Drive. This is an important safety feature because the Geo is totally disabled when it is in watchdog condition and this output will allow the other machine’s hardware/logic to bring the drive to a safe condition. Along with the newer versions of the Geo Brick, there is a dedicated ABORT input @24VDC.
Geo Brick User Manual RS-232 (Female DB-9 Connector) PIN # 1 2 3 4 5 6 7 8 9 SYMBOL N.C. TXD RXD DSR GND DTR CTS RTS N.C FUNCTION OUTPUT INPUT BIDIRECT COMMON BIDIRECT INPUT OUTPUT DESCRIPTION NO CONNECT RECEIVE DATA SEND DATA DATA SET RDY PMAC COMMON DATA TERM RDY CLEAR TO SEND REQ. TO SEND NO CONNECT NOTES HOST TRANSMIT DATA HOST RECEIVE DATA TIED TO “DTR” TIED TO “DSR” HOST READY BIT PMAC READY BIT The baud rate for the RS-232 serial port is set by variable I54.
Geo Brick User Manual JPWR Power 4-Point Screw Terminal (Internal) JPWR (Phoenix 4-pin Screw Terminal Connector) Pin # Symbol Function Notes 1 GND Input Common 2 5V Input 5V Logic Power, current rating 3 +12V Input 12Vdc Analog Power, current rating 4 -12V Input -12Vdc Analog Power, current rating This internal connector is used to power up the logic part of the Geo Brick when the amplifier part of the unit is not attached (for Troubleshooting purposes).
Geo Brick User Manual J4 Limit Inputs (1-4 Axis) The Geo Brick limit and flag circuits give the flexibility to wire in standard 12V to 24V limits and flags or wire in 5V level limits and flags on a channel basis. The default is set for the standard 12V to 24V inputs, but if the resistor pack is added to the circuit, the card can read 5V inputs.
Geo Brick User Manual J5 Limit Inputs (5-8 Axis) The Geo Brick limit and flag circuits give the flexibility to wire in standard 12V to 24V limits and flags or wire in 5V level limits and flags on a channel basis. The default is set for the standard 12V to 24V inputs, but if the resistor pack is added to the circuit, the card can read 5V inputs. Note: J5 comes only with the 6- and 8-axis configuration drives as well with the Secondary Encoder options.
Geo Brick User Manual A sample of the positive limit circuit is shown below. The 4.7K resistor packs used will allow 12-24V flag inputs. If 0-5V flags are used, then a 1KΩ resistor pack (RP) can be placed in: Flags 1-4: RP39 (channel 1), RP43 (channel 2), RP 47 (channel 3), RP51 (channel 4) Flags 5-8: RP89 (channel 5), RP93 (channel 6), RP 97 (channel 7), and RP 101 (channel 8). If these resistor packs are not added, all flags (±Limits, Home, and User) will be referenced from 12-24V.
Geo Brick User Manual J6: General Purpose I/O J6 General Purpose I/O (Female DB-37 Connector) Pin # Symbol 19 18 37 17 36 Function 16 35 15 34 14 33 13 32 12 31 10 11 30 29 9 28 8 27 7 26 5 6 25 24 4 23 3 22 2 21 1 General purpose I/O is available on the Geo Brick Drive. All I/O is electrically isolated from the drive. Inputs can be configured for sinking or sourcing applications. All Inputs are 12-24VDC. All Outputs are 24V nominal operation, 0.5A maximum current.
Geo Brick User Manual Suggested M-Variable Addressing for the General Purpose I/O (J6) Notes 38 12 13 14 15 16 17 18 19 30 31 32 33 34 35 36 37 Sinking Address M0-> Y:$78800,0,1 Input 1 Data Line, J6 Pin 1 M1-> Y:$78800,1,1 Input 2 Data Line, J6 Pin 20 M2-> Y:$78800,2,1 Input 3 Data Line, J6 Pin 2 M3-> Y:$78800,3,1 Input 4 Data Line, J6 Pin 21 M4-> Y:$78800,4,1 Input 5 Data Line, J6 Pin 3 M5-> Y:$78800,5,1 Input 6 Data Line, J6 Pin 22 M6-> Y:$78800,6,1 Input 7 Data Line, J6 Pin 4 M7-> Y:$78800,7,1 Inp
Geo Brick User Manual J7: Extra General Purpose I/O (Optional) J7 General Purpose I/O (Female DB-37 Connector) Pin # Symbol 19 18 37 17 36 Function 16 35 15 34 14 33 13 32 12 31 10 11 30 29 9 28 8 27 7 26 5 6 25 24 4 23 3 22 2 21 1 General purpose I/O is available on the Geo Brick Drive. All I/O is electrically isolated from the drive. Inputs can be configured for sinking or sourcing applications. All Inputs are 12-24VDC. All Outputs are 24V nominal operation, 0.
Geo Brick User Manual Suggested M-Variable Addressing for the optional General Purpose I/O (J7) Notes 40 12 13 14 15 16 17 18 19 30 31 32 33 34 35 36 37 Sinking Address M16-> Y:$78803,0,1 Input 16 Data Line, J7 Pin 1 M17-> Y:$78803,1,1 Input 17 Data Line, J7 Pin 20 M18-> Y:$78803,2,1 Input 18 Data Line, J7 Pin 2 M19-> Y:$78803,3,1 Input 19 Data Line, J7 Pin 21 M20-> Y:$78803,4,1 Input 20 Data Line, J7 Pin 3 M21-> Y:$78803,5,1 Input 21 Data Line, J7 Pin 22 M22-> Y:$78803,6,1 Input 22 Data Line, J7 Pin
Geo Brick User Manual Sample J6/J7, I/O Wiring Diagrams 20 2 21 3 4 5 6 22 23 24 25 7 8 26 27 9 28 10 29 11 12 30 13 31 14 32 15 33 34 18 36 19 37 4 5 6 7 8 21 22 23 24 25 26 9 27 10 28 11 8 Output 02 GPO3- Output 03 GPO4- Output 04 Output 05 GPO6- GPIN01 GPIN02 GPIN03 GPIN04 GPIN05 GPIN06 GPIN07 GPIN08 GPIN09 GPIN10 GPIN11 GPIN12 GPIN13 GPIN14 GPIN15 GPIN16 IN_COM_01-08 IN_COM_09-16 29 24 26 9 27 10 28 Output 08 Output 01 13 31 GPO2+ Output 02 14 32 GP
Geo Brick User Manual Setting up Quadrature Encoders Digital quadrature encoders are the most common position sensors used with Geo Drives. Interface circuitry for these encoders comes standard on board-level Turbo PMAC controllers, UMAC axisinterface boards, Geo drives, and QMAC control boxes. Signal Format Quadrature encoders provide two digital signals that are a function of the position of the encoder, each nominally with 50% duty cycle, and nominally one-quarter cycle apart.
Geo Brick User Manual Encoder Loss Setup Geo Brick controller has encoder-loss detection circuitry for each encoder input. Designed for use with encoders with differential line-driver outputs, the circuitry monitors each input pair with an exclusive-or (XOR) gate. If the encoder is working properly and connected to the Geo Brick, the two inputs of the pair should be in opposite logical states – one high and one low – yielding a true output from the XOR gate.
Geo Brick User Manual Setting Up Digital Hall Sensors Many motor manufactures now give the consumer the option of placing both Hall effect sensors and quadrature encoders on the end shaft of brushless motors. This will allow the controller to estimate the rotor magnetic field orientation and adjusts the command among the motor phases properly without rotating the motor at power-up. If this is not done properly, the motor or amplifier could be damaged.
Geo Brick User Manual GBL_Hall effect wiring X1-X8 1 Function U V W T 5V GND Pin # 2 5 13 6 14 4 12 3 4 5 6 7 8 9 10 11 12 13 14 Shield ENCPWRn GND CHUn+ CHVn+ CHWn+ CHTn+ 15 Note: In the case of magnetic hall sensors, the feedback signals often come back to the controller in the same cable as the motor power leads.
Geo Brick User Manual boundary points if all commutation is done from the commutation sensors. If mounting the hall-effect sensors manually, take care to align the boundaries at these points. The simplest way is to force the motor to the zero degree point with a current offset (as described below) and adjust the sensor while watching its outputs to get a boundary as close as possible to this point.
Geo Brick User Manual Hall Sensors at 0o, 120 o, and 240o P179=I179 #1o0 P129=I129 ; store previous offsets before test ; Open loop command of zero magnitude Six Step Method I129=0 ; 0oelec. I129=3000; 60oelec. I129=3000; 120oelec. I129=0 ; 180oelec. I129=-3000 ; -120oelec. I129=-3000 ; -60oelec. I129=0 ; 0oelec.
Geo Brick User Manual UVW Value: U V W 1 3 2 6 4 5 -30 30 90 150 -150 -90 1 0 1 0 1 0 Cycle: HEZ @ +60 degrees electrical The offset can be computed using the mapping test shown above. In the example, the Hall Effect Zero (HEZ) point was found to be between +30oe and +90oe, so it is called +60oe. The offset value can be computed as: Offset = HEZ %360 o * 64 360 o The offset computed here should be rounded to the nearest integer.
Geo Brick User Manual Record whether the Hall Effects are setup as standard or reversed and move on to the next step of setting up the Controller setup parameters for Hall Effect Power on Phasing. Software Settings for Hall Effect Phasing The variables used for Hall Effect Phasing are Ixx81 & Ixx91. These variables are the Power on-phasing setup registers. To enable a Hall Effect Phasing on power up you must configure Ixx81/Ixx91 properly and then enable the power on feature by setting Ixx80=1.
Geo Brick User Manual I191= $800000 + $400000 + $0B0000 = $CB0000 Optimizing the Hall Effect Phasing Routine for Maximum Performance Since typically there are only three Hall Sensors, the accuracy of phase referencing is good to +/-30o of the commutation cycle, which is enough to get reasonable torque and reasonable smoothness without any phasing search. However, it is recommended to more accurately update the phase position register during the home routine for a particular axis.
Geo Brick User Manual Other Cases Not all applications will be using the index pulse as part of a homing routine. It is acceptable to use another global fixed position as a fine phasing reference. As long as the position chosen is fixed with respect to the motor’s position. Use the same procedure as described above to find the phase position value at that fixed position.
Geo Brick User Manual This diagram shows the hall-effect waveforms with zero offset, defined such that the V-signal transition when the U-signal is low (defined as the zero point in the hall-effect cycle) represents the zero point in PMAC’s commutation cycle. If the hall-effect sensors do not have this orientation, bits 16 to 21 of Ixx81 can be used to specify the offset between PMAC’s zero point and the hall-effect zero point.
Geo Brick User Manual The description of Ix81 in the Software Reference shows the common values of offsets used, for all the cases where the zero point in the hall-effect cycle is at a 0o, 60o, 120o, 180o, -120o, or -60o point -- where manufacturers generally align the sensors. Example: Turbo PMAC Hall Effect Example with Ixx72=683 Hall Sensors at 30o, 150 o, and 270o For the Turbo PMAC, the Hall effect method of phasing uses two PMAC I-Variables, Ixx81 and Ixx91.
Geo Brick User Manual Setting Up the Analog Inputs (optional) The Geo Brick Drive can be ordered with up to four analog to digital converters on a 4-Axis Geo Brick Drive and can be ordered with two analog to digital converters on a 6-Axis Geo Brick Drive. There are no analog input options available for an 8-Axis Geo Brick Drive. These A to D converters can be ordered with either the 12-bit low-resolution or 16-bit hi-resolution analog option.
Geo Brick User Manual For a 6-Axis Geo Brick Drive On a 6-Axis unit, the analog inputs use channels 7 and 8 of the second gate-array and channels 5 and 6 are used for the current loop feedback. The strobe word for the current loop feedback is I7106=$3FFFFF, which will set the strobe word for all the channels on the second gate-array. This then creates a conflict in reading the analog ADC inputs because it needs a strobe word value of I7106=$1FFFFF for 12-bit option and 16-bit option.
Geo Brick User Manual At the same time, the first bit of the 24-bits in P5000 is moved to the front and set as P5003. The results of P5001 and P5003 are added together and then copied into a temporary M-variable location, M5004. The data in M5004 is 24-bits; therefore we can then set M5005 to point to the upper signed 16-bits of M5004, which will be the ADC7 16-bit signed analog input.
Geo Brick User Manual The Geo Brick analog +/-10V outputs are produced by filtering a PWM signal. This technique has been used for some time now by some other DeltaTau products (PMAC2A-PC/104) and many of our competitors. Although this technique does not contain the same levels of performance as a true Digital to Analog converter (DAC), for most servo applications it is more than adequate. Passing the PWM signal through a 10KHz low pass filter creates the +/-10V signal output.
Geo Brick User Manual Setting up for Pulse and Direction Output The following section shows how to quickly setup the key variables for a stepper motor (PFM) system. The step and direction outputs are RS422 compatible and are capable of being connected in either differential mode or single ended configurations for 5V input drivers. Below are two examples for wiring the Geo Brick drive to the stepper Amplifier. The user needs to write pin 8 to pin 4 so as to enable the Stepper output and the AENA.
Geo Brick User Manual I7m04: PFM Pulse Width Control The pulse width is specified in PFM clock cycles and has a range of 1 to 255 cycles. The default value is 15. Since the default value of PFM clock is actually set to 9.8304 MHz, the default output pulse width will be 15/9,830400 = 1.5258 µS. Note that when the PFM clock values are changed, the PFM pulse width values must be evaluated for proper stepper drive operation. The user of a typical stepper drive should not need to modify these control variables.
Geo Brick User Manual Ixx30: Motor xx Proportional Gain To create a closed loop position response with a natural frequency of approximately 25 Hz and a damping ratio of 1, use the following calculation: Ixx30 = 660 ,000 Ixx08 * PFMCLK ( MHz ) Example: PFMCLK is set to default of 9.83 MHz, and Ixx08 is set to default of 96. Ixx30 = 660,000 / (96 * 9.83) = 700. Ixx31 Motor x Derivative Gain Derivative Gain is set to 0 because the motor system behaves like a velocity-loop servo drive.
Geo Brick User Manual Example: User wants channels 5 to 8 to be used with stepper motors. First the user needs to wire the Stepper drive, and so as to enable the Stepper output pin 8 needs to be shorted to pin 4 (+5V) for X5 to X8. Assume for this example that all the stepper motors that will be used do not have encoders for feedback. For this example, the factory defaults for the other variables will allow the PFM outputs to be commanded with a low true Amplifier Fault and ±Limits plugged in.
Geo Brick User Manual DIRECT PWM COMMUTATION CONTROLLER SETUP The Geo Brick drive must have the proper controller setup to command the amplifier/motor system. This section summarizes the key variables for Turbo PMAC2 controllers that would have to be modified for use with the amplifier. The Delta Tau setup software such as Turbo Setup will help set these parameters for the system automatically.
Geo Brick User Manual DC BRUSH MOTOR DRIVE SETUP WITH TURBO PMAC Commutation Phase Angle: Ixx72 Ixx72 controls the angular relationship between the phases of a multiphase motor. When Turbo PMAC is closing the current loop digitally for Motor xx, the proper setting of this variable is dependent on the polarity of the current measurements.
Geo Brick User Manual • Ixx73 = 0, Ixx74 = 0: These default settings ensure that Turbo PMAC will not try to do a phasing search move for the motor. A failed search could keep Turbo PMAC from enabling this motor. • Ixx77 = 0 to command zero direct (field) current. • Ixx78 = 0 for zero slip in the commutation calculations.
Geo Brick User Manual Before testing any of Turbo PMAC’s software features for digital current loop and direct PWM interface, it is important to know whether the hardware interface is working properly. PMAC’s M-Variables are used to access the input and output registers directly. The examples shown here use the suggested MVariable definitions for Motor 1.
Geo Brick User Manual Position Feedback and Polarity Test If the PWM command values observed in the Watch window are not zero, set them to zero with the command: M102=0 M104=0 M107=0 The motor can be turned (or pushed) freely by hand now. As the motor is turned, monitor the M101 value in the Watch window. Look for the following: • It should change as the motor is moved. • It should count up in one direction, and count down in the other direction.
Geo Brick User Manual PWM/ADC Phase Match Command values from Turbo PMAC’s Phase A PWM outputs should cause a roughly proportionate response of one sign or the other on Turbo PMAC’s Phase A ADC input (whatever the phase is named in the motor and drive). The same is true for Phase B.
Geo Brick User Manual Setting I2T Protection It is important to set the I2T protection for the amplifier/motor system for Turbo PMAC2 direct PWM commutation. Normally, an amplifier has internal I2T protection because it is closing the current loop. When Turbo PMAC2 is closing the current loop, the amplifier cannot protect itself or the motor from over heating.
Geo Brick User Manual Calculating Minimum PWM Frequency The minimum PWM frequency requirement for a system is based on the time constant of the motor. Calculate the minimum PWM frequency to determine if the amplifier will properly close the current loop. Systems with very low time constants need the addition of chokes or in-line inductive loads to allow the PMAC to properly close the current loop of the system. In general, the lower the time constant of the system, the higher the PWM frequency must be.
Geo Brick User Manual Amplifier Only Special online commands With the Geo Brick Amplifiers a new version of firmware was created to help the user identify the unit easier. If the user uses the “TYPE” on-line command and PMAC responds and there is a word AMP, then your drive has the latest Amplifier firmware. New TYPE and CID commands on detection of a TURBO2 type AMP TYPE TURBO2, AMP,Xn CID 603793 All of the "AMP" commands, i.e., commands that begin with "AMP" are read only commands.
Geo Brick User Manual AMPSID Function: Report serial electronic identification number Scope: Global Syntax: AMPSID This command causes Turbo PMAC to report the electronic identification number from the ID-number module. The identification number is reported as a hexadecimal 16-digit ASCII string, representing a 64bit value. The first two hex digits represent the 8-bit checksum value for the module; these should match the checksum digits engraved on the case of the module.
Geo Brick User Manual 72 DC Brush Motor Drive Setup with Turbo PMAC
Geo Brick User Manual PWM DRIVE COMMAND STRUCTURE The amplifier functions in two modes: Default and Enhanced. Default Mode Default Mode is the mode the amplifier is in when it is first powered on or the power is re-cycled for any reason. Default mode is compatible with the full series of Delta Tau amplifiers and the A/D converters used on these amplifiers. In this mode, the amplifier returns not only the currents for phases A and B but also the fault codes for the axes associated with those currents.
Geo Brick User Manual 74 PWM Drive Command Structure
Geo Brick User Manual TROUBLESHOOTING The Geo Brick utilizes a scrolling single-digit 7-segment display. When control power is applied to the drive, the 7-segment display will have a blinking “.” (period) indicating that the software and hardware are running normally. This blinking period is running all of the time except if the PMAC CPU has faulted, then it stays on. When any of the drive’s output sections are enabled, the display will include a “0”.
Geo Brick User Manual D1: Geo Brick Drive Status Display Codes The 7-segment display on the current model, 16 numeric codes plus two decimal points, provides the following codes: D1 14 3 6 11 2 7 8 10 13 1 VCC VCC DPR G F E D C B A 5082-7730 Display Fault code ADC bits Description 11:4 Fault code Axis faults : n stands for axis number (n=1-8) 01 Axis n Peak Current Fault – indicates the peak current was excessive nF1 long enough to trip the peak current fault, but there was not enough current to cause
Geo Brick User Manual Status LEDs LED Function Color Description EN5 Enable Axis #5 Green EN6 Enable Axis #6 Green EN7 Enable Axis #7 Green EN8 Enable Axis #8 Green +5V WD BUS Logic Power WatchDog DC Bus Voltage Green Red Red Green when fifth axis enabled (analog output). (Only when the analog I/O is ordered.) (Unlit does not necessarily mean fault.) Green when sixth axis enabled (analog output). (Only when the analog I/O is ordered.) (Unlit does not necessarily mean fault.
Geo Brick User Manual Once the watchdog timer has tripped, power to the Turbo PMAC must be cycled off and on, or the INIT/ hardware reset line must be taken low, then high, to restore normal functioning. Diagnosing Cause of Watchdog Timer Trip Because the watchdog timer is designed to trip on a variety of hardware and software failures, and the trip makes it impossible to query the card, it can be difficult to determine the cause of the trip.
Geo Brick User Manual Troubleshooting 79
Geo Brick Hardware Reference Manual APPENDIX A Mating Connector and Cable Kits Cable sets can be purchased directly from Delta Tau to make the wiring of the system easier. Available cable kits (CABKITxx) are listed below. However, for those who wish to manufacture their own cable sets, the table below provides Connector Kits to use with each drive. Connector Kits (CONKITxx) include the MOLEX connectors and pins for the AC input, 24VDC power supply and the motor outputs.
Geo Brick User Manual – Preliminary Documentation CONKIT5A Connector D/T part number D/T part number individuals 24VDC 200-043645-200 Motor (x4) 200-000F04-HSG AC Input 200-H00F04-049 Shunt Resistor 200-000F02-HSG Molex part number Housing: #014-043645-200 43645-0200 Pins: #014-043030-008 43030-0007/-0008/-0009 Housing: #014-000F04-HSG 44441-2004 Pins: #014-043375-001 43375-0001 Housing: 014-H00F04-049 42816-0412 Pins: 014-042815-031 42815-0031 Housing: 014-000F02-HSG 44441-2002 P
Geo Brick Hardware Reference Manual PWM Cable Ordering Information Cable CABPWM-1 CABPWM-2 CABPWM-3 CABPWM-4 CABPWM-5 CABPWM-6 82 Length 600mm 900mm 1.5m 1.8m (24") (36") (60") (72") 2.1m (84") 3.
Geo Brick User Manual – Preliminary Documentation Cable Drawings 5A/10A and 8A/16A Motor Cable Appendix A 83
Geo Brick Hardware Reference Manual B DELTA TAU DATA SYSTEMS, 15A/30A Motor Cable 84 Appendix A
Appendix A 3 F EE T DE S CRI P TI ON T AB ULA TIO N TO CAB LE . LAB E L T O B E P ERM A NENT LY A TTA CHE D I NDELI B LE INK PRI NTE D O N LA BE L. NUM BE R A ND REV IS I ON US I NG B LA CK 3. CAB LE T O BE I NDENT IF IE D W ITH P ART NO .0-M 1982. Z PF W2 A ND ME ET CS A S TA NDARD 22. 2 LA BE LE D UNDE R W IRI NG HA RNE SS P ROG RAM WI TH UL RE COGNI ZE D CO MP ONE NTS A ND 2. CAB LE /HA RNE SS A S SE M BLI E S TO B E MA DE CA BLE AND IS 2 4 FE E T LONG.
Geo Brick Hardware Reference Manual 3-Phase power cable 86 Appendix A
Geo Brick User Manual – Preliminary Documentation Regenerative Resistor: GAR48/78 Model Description GAR48 300W, 48 OHM regenerative resistor with Thermostat protection. Includes 18-inch wire cable. Single or dual axis. 300W, 78 OHM regenerative resistor with Thermostat protection. Includes 18-inch wire cable. Single or dual axis.
Geo Brick Hardware Reference Manual DB- Connector Spacing Specifications X1-8: DB-15 Connectors for encoder feedback 3.115±.05 1.541±.015 8 7 15 6 14 5 13 4 12 3 11 2 10 1 8 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 5 6 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 88 .235 DIA .
Geo Brick User Manual – Preliminary Documentation Type of Cable for Encoder Wiring Low capacitance shielded twisted pair cable is ideal for wiring differential encoders. The better the shield wires, the better the noise immunity to the external equipment wiring. Wiring practice for shielded cables is not an exact science. Different applications will present different sources of noise, and experimentation may be required to achieve the desired results.
Geo Brick Hardware Reference Manual Cables for single-ended encoders should be shielded for the best noise immunity. Single-ended encoder types cannot take advantage of the differential noise immunity that comes with twisted pair cables. Note: If noise is a problem in the application, careful attention must be given to the method of grounding that is used in the system. Amplifier and motor grounding can play a significant role in how noise is generated in a machine.
Geo Brick User Manual – Preliminary Documentation APPENDIX B Schematics X15: Watchdog DGND_PLANE BWDO 3 4 5 3 2 4 D18 MMBD301LT1 (SOT23) 9 1 12 TB2 1 2 3 5 K5 NC7SZ08M5 (SOT23-5) 1 1 WDO 3 WDO U29 (JWDO) COM N.C. N.O. TERMBLK 3 (.150 PITCH) 10 8 FBR12ND05 DGND_PLANE GND J6 and J7: General Purpose I/O Inputs MMBZ33VALT1 .1uf C243 .1uf U70 ACI1A ACI1B ACI2A ACI2B ACI3A ACI3B ACI4A ACI4B C1 E1 C2 E2 C3 E3 C4 E4 7 5 3 1 2 D57 1 2 D56 1 D55 D58 2 4 6 8 RP160 2.
Geo Brick Hardware Reference Manual Outputs D71 Opto Gnd Plane 2 2.2K D74 D75 D76 2 2 2 2 2 D73 D77 D78 1 1 1 1 1 1 1 1 GPO1+ RUE090 Raychem 30R090 Littelfuse GPO1-- 3 R80 Q5 NZT560A (SOT-223) D72 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 MBRS140T3 F1 1 2 2 2 COM_COL 5 6 7 8 ANO2 CAT2 C2 E2 ANO3 CAT3 C3 E3 ANO4 CAT4 C4 E4 16 15 14 13 1 R81 2.2K GPO2-F3 12 11 10 9 1 R82 2.
Geo Brick User Manual – Preliminary Documentation J4: Limit Inputs for Axis 1-4 16 15 14 13 12 11 10 9 U39 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 PS2705-4 16 15 14 13 12 11 10 9 U40 C1 E1 AC1 AC1 C2 E2 AC2 AC2 C3 E3 AC3 AC3 C4 E4 AC4 AC4 C160 C162 .1 .1 C161 C163 .1 .1 1 2 5 6 7 8 PS2705-4 16 15 14 13 12 11 10 9 U41 C1 E1 AC1 AC1 C2 E2 AC2 AC2 C3 E3 AC3 AC3 C4 E4 AC4 AC4 C164 C166 .1 .1 C165 C167 .1 .
Geo Brick Hardware Reference Manual J5: Limit Inputs for Axis 5-8 16 15 14 13 12 11 10 9 U59 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 PS2705-4 16 15 14 13 12 11 10 9 U60 C1 E1 AC1 AC1 C2 E2 AC2 AC2 C3 E3 AC3 AC3 C4 E4 AC4 AC4 C200 C202 .1 .1 C201 C203 .1 .1 1 2 5 6 7 8 PS2705-4 16 15 14 13 12 11 10 9 U61 C1 E1 AC1 AC1 C2 E2 AC2 AC2 C3 E3 AC3 AC3 C4 E4 AC4 AC4 C204 C206 .1 .1 C205 C207 .1 .
Geo Brick User Manual – Preliminary Documentation APPENDIX C Board Jumpers E10 – E12: Power-Up/Reset Load Source E Point & Physical Layout Description E10: To load active memory from flash IC on power-up/reset/remove jumper E10; Jump E11 pin 1 to 2 Jump E12 pin 1 to 2. E11: Other combinations are for factory use only; the board will not operate in any other configuration. Default No E10 jumper installed E11 and E12, jump pin 1 to 2.
Geo Brick Hardware Reference Manual E25-28: Select Encoder Index input or AENA output (channels 1-4) E Point and Physical Layout Description Default E25: No Jumper for TTL Level input for Ch1 Index signal (C) Jumper 1-2 to output AENA1 at Ch1 encoder connector No jumper installed E26: No Jumper for TTL Level input for Ch2 Index signal (C) Jumper 1-2 to output AENA2 at Ch2 encoder connector No jumper installed E27: No Jumper for TTL Level input for Ch3 Index signal (C) Jumper 1-2 to output AENA3 a
