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Brick Motion Controller Hardware Reference Manual

System Wiring

13

J5 Limit Inputs (5-8 Axis)

The Brick Motion Controller 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 8-axis configuration.

J5 Limit Inputs

(Female DB-25

Connector)

2

3

4

5

14

15

16

17

1

6

7

18

19

8

9

20

21

10

11

22

23

12

13

24

25

Pin #

Symbol

Function

Description

1

USER5

Input

User Flag 5

2

MLIM5

Input

Negative Limit 5

3

FL_RT5

Input

Flag Return 5

4

USER6

Input

User Flag 6

5

MLIM6

Input

Negative Limit 6

6

FL_RT6

Input

Flag Return 6

7

USER7

Input

User Flag 7

8

MLIM7

Input

Negative Limit 7

9

FL_RT7

Input

Flag Return 7

10

USER8

Input

User Flag 8

11

MLIM8

Input

Negative Limit 8

12

FL_RT8

Input

Flag Return 8

13 GND

Common

14 PLIM5 Input

Positive

Limit

5

15 HOME5 Input

Home

Flag

5

16

BEQU5

Output

Compare Output, EQU 5, signal is TTL (5V) level

17 PLIM6 Input

Positive

Limit

6

18 HOME6 Input

Home

Flag

6

19

BEQU6

Output

Compare Output, EQU 6, signal is TTL (5V) level

20 PLIM7 Input

Positive

Limit

7

21 HOME7 Input

Home

Flag

7

22

BEQU7

Output

Compare Output, EQU 7, signal is TTL (5V) level

23 PLIM8 Input

Positive

Limit

8

24 HOME8 Input

Home

Flag

8

25

BEQU8

Output

Compare Output, EQU 8, signal is TTL (5V) level

If J5 is present and RP89 (limits 5), RP93 (limits 6), RP97 (limits 7) and RP101 (limits 8) are installed to the
unit, the voltage level of the flags can be lowered to 5V. User needs to specify these when ordering the unit.

RP89, RP93, RP97 and RP101 for 5V flags: 1Kohm Sip, 8-pin, four independent Resistors
RP89, RP93, RP97 and RP101 for 12-24Vflags: Empty bank. (Default)

SSee Appendix B for Schematic

Limit and Flag Circuit Wiring

The Brick Motion Controller allows the use of sinking or sourcing position limits and flags to the
controller. 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 (sinking) or from flag to return (sourcing).

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Summary of Contents for 5XX-603869-XUXX

Page 1: ...Brick Motion Controller 3 Programmable Servo Amplifier 4 5xx 603869 xUxx 5 May 2 2007 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 com ...

Page 2: ...s If Delta Tau Data Systems Inc products are directly exposed to hazardous or conductive materials and or environments we cannot guarantee their operation 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 perso...

Page 3: ...for personal injury or equipment damage Read the safety notices in this manual before attempting installation operation or maintenance to avoid serious bodily injury damage to the equipment or operational difficulty WARNING A Warning identifies hazards that could result in personal injury or death It precedes the discussion of interest Caution A Caution identifies hazards that could result in equi...

Page 4: ......

Page 5: ...REVISION HISTORY REV DESCRIPTION DATE CHG APPVD 1 MANUAL CREATION 05 02 07 CP S MILICI ...

Page 6: ......

Page 7: ... Axis 12 J5 Limit Inputs 5 8 Axis 13 AMP1 AMP8 Amplifier connections 1 to 8 15 J6 General Purpose I O 17 Suggested M Variable Addressing for the General Purpose I O J6 18 J7 Extra General Purpose I O Optional 19 Suggested M Variable Addressing for the optional General Purpose I O J7 20 J8 Extra General Purpose I O Optional 21 Suggested M Variable Addressing for the General Purpose I O J8 22 Settin...

Page 8: ...dware Reference Manual ii Table of Contents APPENDIX B 38 Schematics 38 X15 Watchdog 38 J6 and J7 General Purpose I O 38 J4 Limit Inputs for Axis 1 4 40 J5 Limit Inputs for Axis 5 8 41 Dimensional Layout and Connector location 42 ...

Page 9: ...le Brick Motion Controller The Brick Motion Controller s functionality doesn t stop there but also includes features such as extensible I O via ModBus TCP master or ModBus TCP slave for third party HMI hardware Our PC based HMI package connected through USB 2 0 or Ethernet makes the Brick Motion Controller a powerful single source solution Brick Motion Controller Features The Brick Motion Controll...

Page 10: ...d C index channel 10 MHz cycle rate and digital Hall effect inputs Five flags per axis using DB 25 HOME PLIM MLIM and USER inputs EQU compare Optional analog inputs and outputs 5VDC Optional two PWM outputs Optional Dual Port RAM Required for NC Optional Modbus Protocol Optional Sinusoidal encoder feedback Optional Resolver feedback Optional EnDat Hiperface interfaces ...

Page 11: ...l Encoder Feedback Channels 4B 4 Resolver Feedback Channels 4C 4 Serial Encoder Feedback Channels 4D 4 Sinusoidal Encoder and Serial Encoder Feedback Channels 8A 8 Sinusoidal Encoder Feedback Channels 8B 8 Resolver Feedback Channels 8C 8 Serial Encoder Feedback Channels 8D 8 Sinusoidal Encoder and Serial Encoder Feedback Channels Serial Encoder Protocols BC X XX XXX XXX XXXX 0 No Serial Encoder Pr...

Page 12: ...annels No Special Feedback Channels 4 Sinusoidal Encoder Feedback Channels 4 Resolver Feedback Channels 4 Serial Encoder Feedback Channels 4 Sinusoidal Encoder and Serial Encoder Feedback Channels 8 Sinusoidal Encoder Feedback Channels 8 Resolver Feedback Channels 8 Serial Encoder Feedback Channels 8 Sinusoidal Encoder and Serial Encoder Feedback Channels Serial Encoder Protocols No Serial Encoder...

Page 13: ...tronic components in this product are design hardened to reduce static sensitivity However use proper procedures when handling the equipment 6 If the Brick Motion Controller is to be stored for several weeks before use be sure that it is stored in a location that conforms to published storage humidity and temperature specifications stated in this manual Use of Equipment The Brick Motion Controller...

Page 14: ...Brick Motion Controller Hardware Reference Manual 6 Specifications ...

Page 15: ...ltiple screw locations The Brick Motion Controller is brought to the earth ground via the fourth pin on the J1 connector located at the bottom of the unit through a heavy gauge multi strand conductor to the central earth ground location Earth Grounding Paths High frequency noises from the PWM controlled power stage will find a path back to the drive It is best that the path for the high frequency ...

Page 16: ... Connector 2 3 4 5 9 10 11 12 6 7 13 14 8 15 1 Pin Symbol Function Notes 1 CHAn Input Axis n Encoder A 2 CHBn Input Axis n Encoder B 3 CHCn Input Axis n Encoder Index 4 ENCPWRn Output Encoder Power 5V 5 CHUn DIRn In Out Axis n U Commutation If set for Steppers axis n Direction output 6 CHWn PULn In Out Axis n W Commutation If set for Steppers axis n Pulse output 7 2 5V Output 2 5V Reference power ...

Page 17: ...DC5 6 Input 16 bit Analog Input channel 5 6 7 8 9 For spacing specifications between the DB connectors see Appendix A of this manual X11 12 Analog I O Ch7 X11 and Ch8 X12 Optional X11 12 Female DB 9 Connector Pin Symbol Function Notes 1 AGND Common 2 ADC7 8 Input 12 bit Analog Input channel 7 8 3 4 5 6 ADC7 8 Input 12 bit Analog Input channel 7 8 7 8 9 For spacing specifications between the DB con...

Page 18: ...rm media dependent interface MDI crossover MDIX so that the transmitter on one end of the data link is connected to the receiver on the other end of the data link a crossover patch cable is typically used If an RJ45 hub is used then a regular straight cable must be implemented Maximum length for Ethernet cable should not exceed 100m 330ft X15 Watchdog The X15 connector allows the user to send an o...

Page 19: ...ower for the Brick Controller Watchdog TB1 Phoenix 3 pin Terminal Block 1 2 3 TB 5 016 PL0F05 38P Pin Symbol Function Notes 1 24VDC Input 2 Chassis GND Input 3 24V return Input S1 Re Initialization on Reset Control Hold switch in during power cycle for PMAC re initialization S2 Firmware Reload Enable Hold switch in during power cycle for PMAC firmware reload ...

Page 20: ... 9 FL_RT3 Input Flag Return 3 10 USER4 Input User Flag 4 11 MLIM4 Input Negative Limit 4 12 FL_RT4 Input Flag Return 13 GND Common 14 PLIM1 Input Positive Limit 1 15 HOME1 Input Home Flag 1 16 BEQU1 Output Compare Output EQU 1 signal is TTL 5V level 17 PLIM2 Input Positive Limit 2 18 HOME2 Input Home Flag 2 19 BEQU2 Output Compare Output EQU 2 signal is TTL 5V level 20 PLIM3 Input Positive Limit 3...

Page 21: ...put Positive Limit 5 15 HOME5 Input Home Flag 5 16 BEQU5 Output Compare Output EQU 5 signal is TTL 5V level 17 PLIM6 Input Positive Limit 6 18 HOME6 Input Home Flag 6 19 BEQU6 Output Compare Output EQU 6 signal is TTL 5V level 20 PLIM7 Input Positive Limit 7 21 HOME7 Input Home Flag 7 22 BEQU7 Output Compare Output EQU 7 signal is TTL 5V level 23 PLIM8 Input Positive Limit 8 24 HOME8 Input Home Fl...

Page 22: ...g Sinking Separate Supply 2 3 4 5 14 15 16 17 1 6 7 18 19 8 9 20 21 10 11 22 23 12 13 24 25 24V Supply 0V 24V USER 1 Neg Limit 1 Pos Limit 1 Home 1 EQU 1 USER 2 Neg Limit 2 Pos Limit 2 Home 2 EQU 2 USER 3 Neg Limit 3 Pos Limit 3 Home 3 EQU 3 USER 4 Neg Limit 4 Pos Limit 4 Home 4 EQU 4 GND GBL_Sourcing Flags FLG_RTN1 FLG_RTN2 FLG_RTN3 FLG_RTN4 2 3 4 5 14 15 16 17 1 6 7 18 19 8 9 20 21 10 11 22 23 1...

Page 23: ...pen channel n 4 AE_NOn Output Amplifier Enable Relay Normally Closed channel n 5 AFAULTn Input Amplifier Fault channel n 6 N C No connection 7 N C No connection 8 AGND Common Analog Ground 9 DACnA Output DAC A output channel n 10 DACnB Output DAC B output channel n 11 AE_COMn Common Amplifier Enable Relay Common channel n 12 AFAULTn Input Amplifier Fault channel n 13 N C No connection 14 AGND Comm...

Page 24: ...Brick Motion Controller Hardware Reference Manual 16 System Wiring Amplifier Fault Amplifier Enable diagrams ...

Page 25: ...rcing Output 4 16 GP05 Output Sourcing Output 5 17 GP06 Output Sourcing Output 6 18 GP07 Output Sourcing Output 7 19 GP08 Output Sourcing Output 8 20 GPIN02 Input Input 2 21 GPIN04 Input Input 4 22 GPIN06 Input Input 6 23 GPIN08 Input Input 8 24 GPIN10 Input Input 10 25 GPIN12 Input Input 12 26 GPIN14 Input Input 14 27 GPIN16 Input Input 16 28 IN_COM_09 16 Input Input 09 to 16 Common 29 COM_COL In...

Page 26: ...Data Line J6 Pin 6 M11 Y 78801 3 1 Input 12 Data Line J6 Pin 25 M12 Y 78801 4 1 Input 13 Data Line J6 Pin 7 M13 Y 78801 5 1 Input 14 Data Line J6 Pin 26 M14 Y 78801 6 1 Input 15 Data Line J6 Pin 8 M15 Y 78801 7 1 Input 16 Data Line J6 Pin 27 M32 Y 078802 0 1 Output 1 Data Line 12 30 M33 Y 078802 1 1 Output 2 Data Line 13 31 M34 Y 078802 2 1 Output 3 Data Line 14 32 M35 Y 078802 3 1 Output 4 Data L...

Page 27: ...urcing Output 12 16 GPO13 Output Sourcing Output 13 17 GPO14 Output Sourcing Output 14 18 GPO15 Output Sourcing Output 15 19 GPO16 Output Sourcing Output 16 20 GPIN18 Input Input 18 21 GPIN20 Input Input 20 22 GPIN22 Input Input 22 23 GPIN24 Input Input 24 24 GPIN26 Input Input 26 25 GPIN28 Input Input 28 26 GPIN30 Input Input 30 27 GPIN32 Input Input 32 28 IN_COM_25 32 Input Input 25 to 32 Common...

Page 28: ... Input 27 Data Line J7 Pin 6 M51 Y 78804 3 1 Input 28 Data Line J7 Pin 25 M52 Y 78804 4 1 Input 29 Data Line J7 Pin 7 M53 Y 78804 5 1 Input 30 Data Line J7 Pin 26 M54 Y 78804 6 1 Input 31 Data Line J7 Pin 8 M55 Y 78804 7 1 Input 32 Data Line J7 Pin 27 M56 Y 078805 0 1 Output 9 Data Line 12 30 M57 Y 078805 1 1 Output 10 Data Line 13 31 M58 Y 078805 2 1 Output 11 Data Line 14 32 M59 Y 078805 3 1 Out...

Page 29: ...Sourcing Output 20 16 GP21 Output Sourcing Output 21 17 GP22 Output Sourcing Output 22 18 GP23 Output Sourcing Output 23 19 GP24 Output Sourcing Output 24 20 GPIN34 Input Input 34 21 GPIN36 Input Input 36 22 GPIN38 Input Input 38 23 GPIN40 Input Input 40 24 GPIN42 Input Input 42 25 GPIN44 Input Input 44 26 GPIN46 Input Input 46 27 GPIN48 Input Input 48 28 IN_COM_41 48 Input Input 41 to 48 Common 2...

Page 30: ...t 43 Data Line J6 Pin 6 M75 Y 78A01 3 1 Input 44 Data Line J6 Pin 25 M76 Y 78A01 4 1 Input 45 Data Line J6 Pin 7 M77 Y 78A01 5 1 Input 46 Data Line J6 Pin 26 M78 Y 78A01 6 1 Input 47 Data Line J6 Pin 8 M79 Y 78A01 7 1 Input 48 Data Line J6 Pin 27 M80 Y 078A02 0 1 Output 17 Data Line 12 30 M81 Y 078A02 1 1 Output 18 Data Line 13 31 M82 Y 078A02 2 1 Output 19 Data Line 14 32 M83 Y 078A02 3 1 Output ...

Page 31: ...nking 01 16 Inputs Sinking 01 08 Outputs COM_EMT GPO1 GPO2 GPO4 GPO5 GPO6 GPO7 GPO8 GPO3 Output 01 Output 02 Output 03 Output 04 Output 07 Output 06 Output 05 Output 08 2 3 4 5 9 10 11 8 7 6 16 15 14 13 12 17 18 19 36 33 1 20 28 27 26 25 24 21 22 23 29 30 32 31 34 35 37 GPIN01 GPIN15 GPIN14 GPIN13 GPIN12 GPIN11 GPIN10 GPIN09 GPIN08 GPIN06 GPIN05 GPIN04 GPIN07 GPIN03 GPIN02 GPIN16 IN_COM_01 08 IN_C...

Page 32: ...s of each differential pair and 12V between a signal and the GND voltage reference Differential encoder signals can enhance noise immunity by providing common mode noise rejection Modern design standards virtually mandate their use for industrial systems especially in the presence of PWM power amplifiers which generate a great deal of electromagnetic interference Hardware Setup The Geo Drive accep...

Page 33: ...is no automatic action taken on detection of encoder loss Users who want to take action on detecting encoder loss should write a PLC program to look for a change in the encoder loss bit and take the appropriate action Generally the only appropriate response is to kill open loop zero output disabled the motor with lost encoder feedback other motors may be killed or aborted as well This next example...

Page 34: ...e 10V signal output The duty cycle of the PWM signal is what generates the magnitude the voltage output The frequency of the PWM signal determines the magnitude and frequency of ripple on that 10V signal As you lower the PWM frequency and subsequently increase your output resolution you increase the magnitude of the ripple as well as slow down the frequency of the ripple as well Depending on the s...

Page 35: ...inimum frequency I7000 should be set to is 1088 calculated as 27 06856KHz I7001 determines how the actual phase clock is generated from the MaxPhase clock using the equation PhaseFreq kHz MaxPhaseFreq kHz I7001 1 I7001 is an integer value with a range of 0 to 15 permitting a division range of 1 to 16 Typically the phase clock frequency is in the range of 8 kHz to 12 kHz About 9 KHz is standard set...

Page 36: ...he choice For information on this variable consult the Turbo Software Reference Manual Ixx69 is the motor output command limit The analog outputs on PMAC1 style boards and some PMAC2 accessories are 16 bit or 18 bit DACs which map a numerical range of 32 768 to 32 767 into a voltage range of 10V to 10V relative to analog ground AGND For our purposes of a filtered PWM output this value still repres...

Page 37: ...fier enable outputs Pin 8 was not connected to anything Software Setup After having the hardware ready for steppers the user needs to set the software for Pulse and direction output as well There are several I variables that must be set up properly for proper operation of the Pulse and direction output in a Brick Motion Controller system It is recommended for the user to also look into the Turbo S...

Page 38: ...al pulse and direction Caution If I7mn0 and I7mn8 are not matched properly motor runaway will occur I7mn6 Servo IC m Channel n Output Mode Select I7mn6 determines whether the A and B outputs are DAC or PWM and whether the C output is PFM pulse and direction or PWM Typically it is set to 0 either for 3 phase PWM or to 3 for DACs and PFM Set the output mode for the Brick Motion Controller for Pulse ...

Page 39: ...32 would change inversely For instance if Ixx30 were twice the above calculation then Ixx32 would be half its calculation Ixx33 Motor xx Integral Gain Typically This I variable should be set to 0 The digital electronic loop does not present offsets or disturbances that need correction in the PMAC Ixx33 may be set to force zero steady state errors should they be present with electronic encoder feed...

Page 40: ...stem make sure I7mn6 is set for PWM and PFM output mode I7116 2 CH5A and CH5B outputs will be PWM and CH5C output will be PFM I7126 2 CH6A and CH6B outputs will be PWM and CH6C output will be PFM I7136 2 CH7A and CH7B outputs will be PWM and CH7C output will be PFM I7146 2 CH8A and CH8B outputs will be PWM and CH8C output will be PFM I7110 8 Simulated feedback for channel 5 I7120 8 Simulated feedb...

Page 41: ...screte outputs off and proportional outputs DAC PWM PFM to zero level In Turbo PMAC2 systems there is a hard contact relay with both normally open and normally closed contacts In a system these outputs should be used to drop power to the amplifiers and other key circuitry if the card fails Once the watchdog timer has tripped power to the Turbo PMAC must be cycled off and on or the INIT hardware re...

Page 42: ...c power and repeat to see if they are causing the problem Check for adequate 24V power supply levels check at the Brick Motion Controller connector side not at the supply Inspect for hardware damage 4 If the watchdog insists after all the above you should contact DeltaTau Inc to get an RMA number and ship the drive for repairs ...

Page 43: ...r feedback 2 3 4 5 9 10 11 12 6 7 13 14 8 15 1 2 3 4 5 9 10 11 12 6 7 13 14 8 15 1 1 541 015 3 115 05 X9 12 DB 9 Connectors for Analog I O 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 1 213 015 2 45 05 Screw Lock Size for all DB connectors 18 7 4 40 FEMALE SCREWLOCK QTY 2 per connector Steel Zinc Plated 126 DIA 235 DIA LOCKWASHER QTY 2 per connector Clear Chromate ...

Page 44: ...ie the shield wires together if there are not enough terminals available Keep the exposed wire lengths as close as possible to the terminals on the interpolator Note It has been observed that there is an inconsistency in the shielding styles that are used by different encoder manufacturers Be sure to check pre wired encoders to ensure that the shield wires are not connected at the encoder s side S...

Page 45: ...he 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 Noise may be reduced in a motor based system by the use of inductors placed between the motor and the amplifier ...

Page 46: ...3VALT1 1 2 3 D51 MMBZ5V6ALT1 1 2 3 RP152 1 2KSIP8I 2 1 3 4 5 6 7 8 D34 MMBZ33VALT1 1 2 3 D32 MMBZ33VALT1 1 2 3 GPIN05 IN_COM_01 08 D58 MMBZ5V6ALT1 1 2 3 RP153 1 2KSIP8I 2 1 3 4 5 6 7 8 D33 MMBZ33VALT1 1 2 3 D38 MMBZ33VALT1 1 2 3 D53 MMBZ5V6ALT1 1 2 3 RP159 1 2KSIP8I 2 1 3 4 5 6 7 8 GPIN08 U72 PS2705 4 1 2 15 16 4 5 7 8 9 10 12 13 3 6 14 11 ACI1A ACI1B E1 C1 ACI2B ACI3A ACI4A ACI4B E4 C4 C3 E2 ACI2...

Page 47: ... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ANO1 CAT1 ANO2 CAT2 ANO3 CAT3 ANO4 CAT4 E4 C4 E3 C3 E2 C2 E1 C1 GPO3 GPO5 R80 2 2K GPO2 GPO5 D74 MBRS140T3 2 1 R81 2 2K R87 2 2K F5 RUE090 Raychem 30R090 Littelfuse Q8 NZT560A SOT 223 1 3 2 GPO2 D88 MBRS140T3 2 1 R83 2 2K GPO1 Opto Gnd Plane GPO3 GPO7 D78 MBRS140T3 2 1 Q10 NZT560A SOT 223 1 3 2 GPO2 F7 RUE090 Raychem 30R090 Littelfuse GPO8 GPO8 GPO6 GPO1 F4 ...

Page 48: ...D RP38 4 7KSIP8I 1 2 3 4 5 6 7 8 HOME2 BEQU4 RP39 x1KSIP8I IN SOCKET 1 2 3 4 5 6 7 8 C169 1 FL_RT1 PLIM1 FL_RT3 RP45 4 7KSIP8I 1 2 3 4 5 6 7 8 HOME3 RP50 4 7KSIP8I 1 2 3 4 5 6 7 8 HOME4 USER4 RP41 4 7KSIP8I 1 2 3 4 5 6 7 8 MLIM3 GND RP51 x1KSIP8I IN SOCKET 1 2 3 4 5 6 7 8 FL_RT2 BEQU2 C164 1 HOME1 BEQU1 C167 1 RP37 4 7KSIP8I 1 2 3 4 5 6 7 8 MLIM4 U40 PS2705 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16...

Page 49: ...12 13 14 15 16 AC1 AC1 AC2 AC2 AC3 AC3 AC4 AC4 E4 C4 E3 C3 E2 C2 E1 C1 C209 1 RP96 4 7KSIP8I 1 2 3 4 5 6 7 8 RP100 4 7KSIP8I 1 2 3 4 5 6 7 8 USER8 HOME7 RP97 x1KSIP8I IN SOCKET 1 2 3 4 5 6 7 8 USER5 HOME7 C201 1 PLIM7 MLIM8 BEQU6 PLIM5 MLIM6 USER8 HOME6 RP88 4 7KSIP8I 1 2 3 4 5 6 7 8 RP89 x1KSIP8I IN SOCKET 1 2 3 4 5 6 7 8 GND HOME8 FL_RT5 C207 1 USER6 USER5 RP95 4 7KSIP8I 1 2 3 4 5 6 7 8 HOME5 HO...

Page 50: ...Brick Motion Controller Hardware Reference Manual 42 Appendix C Dimensional Layout and Connector location ...

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