Delta Tau Geo Brick User Manual Download Page 277

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Geo Brick Drive User Manual

Drive Structure and Troubleshooting

277

Step4:

The download utility will prompt for a .BIN file. MAKE SURE you open the correct file.

Note

The PMAC firmware file for Geo Brick Drives MUST ALWAYS be

TURBO2

.BIN

Step4:

Wait until download is finished, and click done.

Step5:

Close all PMAC applications (i.e. Pewin32Pro2), and recycle power.

Summary of Contents for Geo Brick

Page 1: ...ty Ease of Use 21314 Lassen St Chatsworth CA 91311 Tel 818 998 2095 Fax 818 998 7807 www deltatau com 3 Programmable Servo Amplifier 4 5xx 603800 xUxx 5 March 8 2016 1 USER MANUAL 2 Geo Brick Drive DE...

Page 2: ...and amplifier products contain static sensitive components that can be damaged by incorrect handling When installing or handling Delta Tau Data Systems Inc products avoid contact with highly insulate...

Page 3: ...static electricity and can be damaged by incorrect handling Avoid contact with high insulating materials artificial fabrics plastic film etc Place the product on a conductive surface Discharge any po...

Page 4: ...ER INPUT SECTION ADDED POWER ON OFF SEQUENCE UPDATED LOGIC POWER INPUT SECTION ADDED STO INFORMATION UPDATED X9 X12 SECTION UPDATED MACRO CONNECTIVITY SECTION ADDED SERIAL N0 AND BOARD IDENTIFICATION...

Page 5: ...4...

Page 6: ...Brick Drive 24 8 Axis Geo Brick Drive 25 PINOUTS AND SOFTWARE SETUP 26 J1 Main Bus Power Input 26 Power On Off Sequence 27 Cycling Main Bus Power 27 Recommended Main Bus Power Wiring Protection 29 J2...

Page 7: ...er Count Error Mxx18 67 Encoder Loss Detection Sinusoidal 68 X1 X8 Encoder Feedback Resolver 69 Setting up Resolvers 69 Resolver Excitation Magnitude 70 Resolver Excitation Frequency 70 X1 X8 Encoder...

Page 8: ...nication Port 154 A1 A8 Motor Wiring 155 Motor Cable Noise Elimination 156 Motor Selection 158 5V ENC PWR Alternate Encoder Power 160 Wiring the Alternate 5V Encoder Power 161 Functionality Safety Mea...

Page 9: ...ty Pointers Ixx03 Ixx04 211 Commutation Angle Current Mask Flag Mode Control Ixx72 Ixx84 Ixx24 211 PWM Scale Factor Ixx66 211 Current Feedback Address Ixx82 211 Commutation Position Address Commutatio...

Page 10: ...lags 257 Homing from Master 257 Homing from Slave 257 MACRO Suggested M Variables 258 Absolute Position Reporting over MACRO 260 MACRO Configuration Power Up Sequence 260 DRIVE STRUCTURE AND TROUBLESH...

Page 11: ...ector April 2010 283 EEPROM Write Protect Enable April 2010 283 AMPVER Fail Safe Mechanism Configuration Error May 2010 284 Modifications and Improvements October 2012 285 Control board 285 Power boar...

Page 12: ...d setup time The Geo Brick s embedded 32 axis Turbo PMAC2 motion controller is programmable for virtually any kind of motion control application The built in software PLCs allow for complete machine l...

Page 13: ...cited response to host port P1 P1 1 Counter using variable P1 Disable PLC 1 Disable plc 1 Close Close open buffer Caution All PLC examples are stated in PLC number 1 It is the user s responsibility to...

Page 14: ...tal of 8 encoder inputs PWM amplifier Interface for channel 7 with encoders for axes 5 to 8 4 secondary encoders 0 No options Default 2 Four GPIO Relays On connectors X9 X12 3 Two Analog In two analog...

Page 15: ...ver Feedback Channels and Serial Enc EnDat 2 2 Protocol 4E6 4 Resolver Feedback Channels and Serial Enc BISS B C Protocol 4E7 4 Resolver Feedback Channels and Serial Enc Tamagawa Protocol 4E8 4 Resolv...

Page 16: ...lized However Hall sensors cannot be used with a channel which has been programmed for serial clocking Axes Power Configuration 5 10 Amps or 8 16 Amps 15 30 Amps limited to axes 5 6 Encoder Inputs Up...

Page 17: ...described in later section has to be configured properly to protect against motor equipment damage Description Specifications Over Voltage 283 VAC 400 VDC Under Voltage 87 VAC 123 VDC Over Temperature...

Page 18: ...Power rating Watts 10000W Recommended Shunt Resistor Ohms GAR15 15 Recommended Shunt Power Rating Watts 300W 6 Axis Geo Brick Drive GBL6 xx 5xx xxx xxxxx GBL6 xx 8xx xxx xxxxx Axes 1 4 5 6 1 4 5 6 Out...

Page 19: ...A Output Power Per Axis Modulation depth 60 RMS 1247W 1995W 1247W 1995W 1995W 1247W Output Power Total 9976W 15960W 12968W 12968W Power Dissipation 998W 1596W 1297W 1297W PWM Frequency Operating Range...

Page 20: ...eport any damage immediately to the commercial carrier that delivered the drive Electronic components in this product are design hardened to reduce static sensitivity However use proper procedures whe...

Page 21: ...k Drive can be mounted with a traditional 4 hole panel mount two U shape notches on the bottom and two pear shaped holes on top If multiple Geo Brick Drives are used they can be mounted side by side l...

Page 22: ...ort WD RS232 Analog I O Front View Top View 24VDC Logic Power Shunt Resitor Motor Shield Connection General Purpose I O Limits Flags New Connector October 2012 AC DC Bus Power Input PWM Interface Anal...

Page 23: ...xis Geo Brick Drive GBL4 xx 5xx xxx xxxx And GBL4 xx 8xx xxx xxxx Width Depth Height Weight 114mm 4 50in 178mm 7 00in 391mm 15 40in 4 4Kg 9 6lbs 3 00 76 20 mm 14 31 363 52 mm 15 40 391 16 mm 13 38 339...

Page 24: ...24 6 Axis Geo Brick Drive GBL6 xx 5xx xxx xxxx And GBL6 xx 8xx xxx xxxx Width Depth Height Weight 203mm 8 00in 178mm 7 00in 391mm 15 40in 13 38 339 73 mm 8 00 203 20 mm 7 00 177 83 mm 4 x M4 6 50 165...

Page 25: ...BL8 xx 552 xxx xxxx GBL8 xx 582 xxx xxxx GBL8 xx 852 xxx xxxx GBL8 xx 882 xxx xxxx Width Depth Height Weight 203mm 8 00in 178mm 7 00in 392mm 15 40in 9 0 Kg 19 9lbs 13 38 339 73 mm 8 00 203 20 mm 7 00...

Page 26: ...s power into the Geo Brick Drive J1 Molex 4 pin Male Mating Molex 4 pin Female L3 L2 L1 GND DEL B Pin Symbol Function Three Phase Single Phase DC 1 GND Ground 2 L1 Input AC Line Phase 1 Not Connected...

Page 27: ...ogic power 2 Wait a minimum of 3 seconds 3 Apply main bus power Powering down a Geo Brick Drive must obey the following procedure 1 Disconnect main bus power 2 Wait a minimum of 5 seconds 3 Disconnect...

Page 28: ...s a bleeding resistor to avoid the extended downtime delay Contact Delta Tau for details Newer Models of the Geo Brick Drive The newer models of the Geo Brick Drive are fitted with an internal shunt r...

Page 29: ...directly bonded to the back panel This electrical ground connection allows for each device within the enclosure to have a separate wire brought back to the central earth ground Implement a star point...

Page 30: ...E MAGNETIC CONTACTOR DATA SYSTEMS INC DELTA TAU B L1 L2 L3 GND Shielded And Twisted EMC EMI FILTER Phase Phase Voltage Suppressors Single Phase Main AC Power Wiring Diagram GND Neutral Line PROTECTION...

Page 31: ...mmended FRN R and LPN RK from Cooper Bussmann or similar fuses can be used The following table summarizes fuse gauges for three phase bus input 240VAC at full load Model Fuse amps Model Fuse amps GBL4...

Page 32: ...ic contactor or external machinery in the plant This 3 phase voltage arrester from Phoenix Contact or similar suppressor can be used Bus Power Cables The Geo Brick Drive electronics create a DC bus by...

Page 33: ...minal block as opposed to the older Molex type which allows for easier connection without the need of special crimping tools The newer models were introduced in October of 2012 They can be recognized...

Page 34: ...ternal use Pin Symbol Function Description Notes 1 24VDC RET Common Logic power return Control power return 2 24VDC Input Logic power input 5 Newer Models J2 Phoenix TB 4 pin Female Mating Phoenix TB...

Page 35: ...w power to the motors The STO is triggered and power is disconnected from the motors if the 24V is disconnected from STO IN pin 1 In this mode the Drive will display an AF2 fault on the 7 sgment displ...

Page 36: ...es all configurations are strongly advised to install an external shunt resistor 4 And 8 Axis Geo Brick J3 Molex 2 pin Female Mating Molex 2 pin Male Regen Regen Regen Regen CAP GBL4 GBL6 GBL8 Pin Sym...

Page 37: ...C 450 F This thermostat is accessible through the two black leads It is important that these two leads be wired in a safety circuit to halt operation should the resistor temperature exceed the specifi...

Page 38: ...unction Description 1 USER1 Input User Flag 1 2 MLIM1 Input Negative Limit 1 3 FL_RT1 Input Flag Return 1 4 USER2 Input User Flag 2 5 MLIM2 Input Negative Limit 2 6 FL_RT2 Input Flag Return 2 7 USER3...

Page 39: ...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...

Page 40: ...NC POS LIMIT 3 7 NC NEG LIMIT 3 7 HOME 3 7 USER 4 8 NC POS LIMIT 4 8 NC NEG LIMIT 4 8 HOME 4 8 EQU 1 5 EQU 2 6 EQU 3 7 EQU 4 8 COM 5VDC 24VDC FLAG RETURN 1 5 FLAG RETURN 2 6 FLAG RETURN 3 7 FLAG RETUR...

Page 41: ...Home flag 4 input status M421 X 078018 17 Positive Limit 4 flag input status M422 X 078018 18 Negative Limit 4 flag input status Limits and Flags Axis 5 8 Suggested M Variables M515 X 078100 19 User 5...

Page 42: ...Input Outputs Common 12 GP01 Output Sourcing Output 1 13 GP02 Output Sourcing Output 2 14 GP03 Output Sourcing Output 3 15 GP04 Output Sourcing Output 4 16 GP05 Output Sourcing Output 5 17 GP06 Outpu...

Page 43: ...OM Input Outputs Common 12 GPO9 Output Sourcing Output 9 13 GPO10 Output Sourcing Output 10 14 GPO11 Output Sourcing Output 11 15 GPO12 Output Sourcing Output 12 16 GPO13 Output Sourcing Output 13 17...

Page 44: ...der models of the Geo Brick Drive use the PS2501L 1NEC photocoupler They are rated to a maximum current of 500 mA and are overload protected The outputs in the newer models of the Geo Brick Drive cont...

Page 45: ...COM 12VDC 24VDC 14 15 16 17 18 19 32 33 34 35 36 37 INPUT 5 21 INPUT 11 27 OUTPUT 2 10 OUTPUT 3 11 OUTPUT 4 12 OUTPUT 5 13 OUTPUT 6 14 OUTPUT 7 15 OUTPUT 8 16 IN COM 09 16 25 32 IN COM 01 08 17 24 OU...

Page 46: ...1 Output 6 J6 Pin 17 Pin 35 M39 Y 078802 6 1 Output 7 J6 Pin 18 Pin 36 M40 Y 078802 7 1 Output 8 J6 Pin 19 Pin 37 General Purpose I Os Additional J7 Suggested M Variables Inputs M17 Y 78803 0 1 Input...

Page 47: ...Brick Drive User Manual Pinouts and Software Setup 47 J8 PWM Amplifier Interface J8 is used to connect to third party PWM amplifiers This is a limited option contact technical support for setup detai...

Page 48: ...Output 10 HWA Input Handwheel Quadrature A 11 HWB Input Handwheel Quadrature B 12 HWC Input Handwheel Quadrature C 13 5V Output For troubleshooting no practical use 14 AIN2 Input Analog Input 2 15 AIN...

Page 49: ...000340 ADC3 is referenced to 078800 000340 78B40 I5064 000340 ADC4 is referenced to 078800 000340 78B40 I5065 000340 ADC5 is referenced to 078800 000340 78B40 I5066 000340 ADC6 is referenced to 07880...

Page 50: ...C4 M6995 Y 003408 12 12 S ADC5 M6996 Y 00340A 12 12 S ADC6 M6997 Y 00340C 12 12 S ADC7 M6998 Y 00340E 12 12 S ADC8 M6991 Y 003400 12 12 U ADC1 M6992 Y 003402 12 12 U ADC2 M6993 Y 003404 12 12 U ADC3 M...

Page 51: ...p between the PWM clock frequency of the clock receiving gate and the clock generating gate should always be respected in such a way that Where n is an integer Examples With Servo IC 0 sourcing the cl...

Page 52: ...PWM 1 PFM Analog Output M variable M7050 Y 78412 8 16 S These I O nodes have to be setup once on power up power up PLC Example Open PLC 1 clear I6612 100 8388608 I10 While I6612 0 Endw M7051 0 PWM mo...

Page 53: ...E FREQUENCY DEVICE AMPLIFIER PULSE DIR COM Using the Delta Tau Calculator or referring to the Turbo Software Reference Manual the desired maximum PFM Frequency and pulse width can be chosen DT Calcula...

Page 54: ...hannel2 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 Testing...

Page 55: ...el 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Quadrature Encoder CHA CHA 5V PWR GND CHB CHB CHC CHC External 5V Power Supply 5V COM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18...

Page 56: ...tepper amp enable 12 GND Common Common ground 13 CHV DIR In Out Halls V Direction Output for Stepper 14 CHT PUL In Out Halls T Pulse Output for Stepper 15 Unused Note Use an encoder cable with high qu...

Page 57: ...15 1 A A B B C C 5VDC GND Encoder shield solder to shell U V W T Differential Quadrature Encoder with hall sensors optional 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 A B C 5VDC GND Encoder shield solder to...

Page 58: ...ange 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 ch...

Page 59: ...8807 6 1 1 Encoder present no Fault 4 Y 78807 3 1 8 Y 78807 7 1 Caution Appropriate action user written plc needs to be implemented when an encoder loss is encountered To avoid a runaway an immediate...

Page 60: ...tor 1 Encoder Loss Status Bit Mtr1EncLoss Y 078807 0 1 define Mtr2EncLoss M280 Motor 2 Encoder Loss Status Bit Mtr2EncLoss Y 078807 1 1 define Mtr3EncLoss M380 Motor 3 Encoder Loss Status Bit Mtr3EncL...

Page 61: ...ed Note The default mode does not provide a PFM amplifier enable output signal This should be requested upon ordering the Geo Brick Drive to avoid changing jumper settings internal to the drive and ri...

Page 62: ...Max Phase Clock default I7101 0 Servo IC 1 Phase Clock Divider default I7102 3 Servo IC 1 Servo Clock Divider default I7103 2290 Servo IC 1 PFM Clock divider I7104 13 Servo IC 1 PFM Pulse Width Contro...

Page 63: ...ain I533 4 100 0 Motors 5 8 Integral Gain I534 4 100 0 Motors 5 8 Integral Mode I535 4 100 0 Motors 5 8 Acceleration FeedForward Gain Testing the PFM Output using example settings Command Output Mxx07...

Page 64: ...In Out W Hall 7 2 5 Volts Output Reference Power 2 5 volts 8 Unused 9 Sin Input Sine 10 Cos Input Cosine 11 CHC Input Index 12 GND Common Common Ground 13 CHV In Out V Hall 14 CHT In Out T Hall 15 Un...

Page 65: ...igh res interpolator PMAC2 Style 2 Enter Source Address see table below 3 Enter A D Converter Address see table below 4 A D Bias always zero Channel Source Address A D converter Address Channel Source...

Page 66: ...Bias Term and Entry result Channel 7 I8018 FF8110 High resolution interpolator I8019 078B0C A D converter address I8020 000000 Bias Term and Entry result Channel 8 I8021 FF8118 High resolution interp...

Page 67: ...is then set and latched to 1 until reset or cleared The three most common root causes of this error Real encoder hardware problem Trying to move the encoder motor faster than it s specification Using...

Page 68: ...be a very small number resulting in a small magnitude of the sum of squares in at least part of the cycle If both signals cease to be driven externally the sum of squares will be small over the entir...

Page 69: ...solver feedback devices Setting up Resolvers The Resolver data sampling is done at phase rate and processed in the encoder conversion table The commutation occurring at phase rate position is retrieve...

Page 70: ...13 12 6 6 0 14 13 7 6 9 15 14 8 7 7 Resolver Excitation Frequency The Resolvers excitation frequency is divided from the Phase clock and is setup to be the same as but not greater than the Resolvers e...

Page 71: ...omatic encoder conversion table utility that can be used to implement both the Resolver entry and Tracking Filter Under Configure Encoder Conversion Table Channel 1 Resolver Setup Example Resolver Ent...

Page 72: ...kwise I8009 478B10 Excitation address I8010 000000 SIN COS Bias word I8011 D8350B Tracking filter from conversion location 350B I8012 400 Maximum change in counts cycle I8013 80000 Proportional gain I...

Page 73: ...ional gain I8054 0 Reserved setup word I8055 1 Integral gain Channel 8 I8056 F78B0E Resolver Counter Clockwise I8057 478B10 Excitation address I8058 000000 SIN COS Bias word I8059 D8353B Tracking filt...

Page 74: ...I6802 0 I7000 5895 Servo IC0 I7001 0 I7002 0 I10 838613 Servo Time Interrupt define ResExcMag M8000 Excitation Magnitude define ResExcFreq M8001 Excitation Frequency ResExcMag Y 78B11 0 4 Excitation...

Page 75: ...power 5 RS485 Input Data Packet 6 Unused 7 Unused 8 Unused 9 SIN Sine signal input 10 COS Cosine signal input 11 Unused 12 GND Common Common ground 13 Unused 14 RS485 Input Data Packet 15 Unused This...

Page 76: ...High res interpolator PMAC2 Style 2 Enter Source Address see table below 3 Enter A D Converter Address see table below 4 A D Bias typically 0 Channel Source Address A D converter Address Channel Sour...

Page 77: ...result at 3515 Channel 8 I8021 FF8118 High resolution interpolator entry 78118 I8022 078B0E A D converter address 78B0E I8023 000000 Bias Term and Entry result at 3518 Now the position and velocity po...

Page 78: ...ng 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 Reg...

Page 79: ...ith the encoder To compensate for external system delays this trigger has a programmable 4 bit delay setting in 20 sec increments 23 16 15 12 11 10 9 8 7 6 5 4 3 2 1 0 M_Divisor N_Divisor Trigger Cloc...

Page 80: ...er Position 50 Read Encoder Status 53 Reset Encoder 15 14 0 Reserved Reserved and always reads zero 13 R W 0 Trigger Mode Trigger Mode to initiate communication 0 continuous trigger 1 one shot trigger...

Page 81: ...19 16 07 0 23 0 TimeOut Error CheckSum Error Parity Error Error Bit Position Data 31 24 Position Data 23 0 HiperFace Serial Data A HiperFace Serial Data B Channel 1 Y 78B20 Y 78B21 Channel 2 Y 78B24...

Page 82: ...0 0 8 1 2 0 0 4 clock Edge Note The only user configurable HiperFace Global Control field is the baud rate M and N divisors The channel control registers are programmed to read position 42 Bit Descrip...

Page 83: ...ster Ch1HFCtrl X 78B20 0 24 U Channel 1 HiperFace control register Address Ch2HFCtrl X 78B24 0 24 U Channel 2 HiperFace control register Address Ch3HFCtrl X 78B28 0 24 U Channel 3 HiperFace control re...

Page 84: ...constructs the absolute position for channels 1 through 8 It is pre configured for the user to input their encoder information and specify which channels are being used Using The Absolute Position Re...

Page 85: ...temporary holding register 2 define ChNoHex M6010 Channel Number in Hex define ChAbsCalc M6011 Abs calc flag 1 true do read 0 false do not do read define LowerSTBits P7017 Lower Single Turn Bits RegA...

Page 86: ...TTemp1 Temp1 EndIf Else Single Turn Res 24 SINGLE TURN DATA LowerSTBits 24 UpperSTBits STRes 24 STTemp1 exp UpperSTBits ln 2 STTemp2 STTemp1 1 Two2STDec 16777216 STTemp1 Two2STHex Two2STDec 1 STData S...

Page 87: ...is then set and latched to 1 until reset or cleared The three most common root causes of this error Real encoder hardware problem Trying to move the encoder motor faster than it s specification Using...

Page 88: ...be a very small number resulting in a small magnitude of the sum of squares in at least part of the cycle If both signals cease to be driven externally the sum of squares will be small over the entire...

Page 89: ...sed 9 Unused 10 Unused 11 Unused 12 GND Common Common Ground 13 Clock Output Serial Encoder Clock 14 Data Input Data Packet 15 Unused Note Some SSI devices require 24V power which has to be brought in...

Page 90: ...ternal system delays this trigger has a programmable 4 bit delay setting in 20 sec increments 23 16 15 12 11 10 9 8 7 6 5 4 3 2 1 0 M_Divisor N_Divisor Trigger Clock Trigger Edge Trigger Delay Protoco...

Page 91: ...5 14 R W 0x00 Parity Type Parity Type of the received data 00 None 10 Even 01 Odd 11 Reserved 13 R W 0 Trigger Mode Trigger Mode to initiate communication 0 continuous trigger 1 one shot trigger All t...

Page 92: ...l Encoder Data A 23 22 08 07 0 23 0 Parity Err Position Data 31 24 Position Data 23 0 SSI Encoder Data A SSI Encoder Data B Channel 1 Y 78B20 Y 78B21 Channel 2 Y 78B24 Y 78B25 Channel 3 Y 78B28 Y 78B2...

Page 93: ...0 1 1 0 0 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1 0 6 3 0 0 0 2 clock Edge Field Value Notes Global Control Word M divisor 99 Hex 0x63 630002 N divisor 0 Hex 0x0 Trigger clock 0 Trigger on Phase recommen...

Page 94: ...not create conflicts with these parameters M5990 5991 Self referenced M Variables M5990 5991 0 Reset at download GLOBAL CONTROL REGISTERS define SSIGlobalCtrl1_4 M5990 Channels 1 4 SSI global control...

Page 95: ...used 9 Unused 10 Unused 11 Unused 12 GND Common Common Ground 13 Clock Output Serial Encoder Clock 14 Data Input Data Packet 15 Unused Note Some EnDat devices require 24V power which has to be brought...

Page 96: ...on with the encoder To compensate for external system delays this trigger has a programmable 4 bit delay setting in 20 sec increments 23 16 15 12 11 10 9 8 7 6 5 4 3 2 1 0 M_Divisor N_Divisor Trigger...

Page 97: ...Receive Reset EnDat2 2 only 07 000111 Encoder to Send Position EnDat 2 1 2 2 2A 101010 Encoder to Receive Reset EnDat 2 1 2 2 15 14 R 00 Reserved Reserved and always reads zero 13 R W 0 Trigger Mode T...

Page 98: ...onse from the encoder EnDat Data C and D registers are reserved and always read zero EnDat Data B EnDat Data A 23 22 21 20 16 15 0 23 0 TimeOut Err CRC Err Err flag Position Data 39 24 Position Data 2...

Page 99: ...ge Field Value Notes Global Control Word M divisor 0 Hex 0x00 000003 N divisor 0 Hex 0x0 Trigger clock 0 Trigger on Phase recommended Trigger Edge 0 Rising edge recommended Trigger Delay 0 No delay ty...

Page 100: ...ISTERS define EnDatGlobalCtrl1_4 M5990 Channels 1 4 EnDat global control register EnDatGlobalCtrl1_4 X 78B2F 0 24 U Channels 1 4 EnDat global control register address CHANNEL CONTROL REGISTERS define...

Page 101: ...9 Unused 10 Unused 11 Unused 12 GND Common Common Ground 13 Clock Output Serial Encoder Clock MO 14 Data Input Output Data Packet SLO 15 Unused Note Some BiSS devices require 24V power which has to b...

Page 102: ...oder To compensate for external system delays this trigger has a programmable 4 bit delay setting in 20 sec increments 23 16 15 12 11 10 9 8 7 6 5 4 3 2 1 0 M_Divisor N_Divisor Trigger Clock Trigger E...

Page 103: ...polynomial The mask bits M 7 0 represent the coefficients 8 1 respectively in the polynomial M7x8 M6x7 M5x6 M4x5 M3x4 M2x3 M1x2 M0x1 1 The coefficient for x0 is always 1 and therefore not included in...

Page 104: ...ter 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...

Page 105: ...0 0 0 0 0 0 0 0 1 0 1 1 6 3 0 0 0 B clock Edge Field Value Notes Global Control Word M divisor 99 Hex 0x63 63000B N divisor 0 Hex 0x0 Trigger clock 0 Trigger on Phase recommended Trigger Edge 0 Risin...

Page 106: ...onfigurations do not create conflicts with these parameters M5990 5991 Self referenced M Variables M5990 5991 0 Reset at download GLOBAL CONTROL REGISTERS define SSIGlobalCtrl1_4 M5990 Channels 1 4 Bi...

Page 107: ...dix section The following flowchart summarizes the recommended method to use regardless of the Multiturn MT data specification It is only dependent on the Singleturn ST resolution for rotary encoders...

Page 108: ...Type for commutated motors e g brushless With technique 1 if the Singleturn Multiturn data bits fulfill 24 bits and are contiguous then serial data register A can be used as the commutation source Oth...

Page 109: ...utation Offset it is ST 18 for rotary or RES 18 for linear SF is the encoder resolution scale factor calculated previously Position And Velocity Scale Factors Position Error Limit With technique 2 and...

Page 110: ...Entry for the changes to take effect Source Address Serial Data Register A Channel 1 Y 78B20 Channel 5 Y 78B30 Channel 2 Y 78B24 Channel 6 Y 78B34 Channel 3 Y 78B28 Channel 7 Y 78B38 Channel 4 Y 78B2C...

Page 111: ...1 X Register 0 Y Register Bits16 21 Number of Bits to read Resolution 25 bits or 011001 Ixx95 Binary Hex 9 9 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Bits 0 15 reserved always 0 In this mode PMAC read...

Page 112: ...ally on Power up Otherwise a 1 command is necessary to read and report the absolute position Note With absolute serial encoders no multi turn data the power on position format is set up for unsigned o...

Page 113: ...nnel 1 Y 78B20 Channel 5 Y 78B30 Channel 2 Y 78B24 Channel 6 Y 78B34 Channel 3 Y 78B28 Channel 7 Y 78B38 Channel 4 Y 78B2C Channel 8 Y 78B3C This is a 2 line ECT entry its equivalent script code I8000...

Page 114: ...osition window 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 line...

Page 115: ...h no filtering Width in Bits 18 Offset Location of LSB Singleturn protocol bits 18 e g 25 18 7 No shifting Source Address serial data register A same as position ECT for this motor Remember to click o...

Page 116: ...sters Serial Register A Ch1 Y 78B20 Serial Register B Ch1 Y 78B21 37 bits 0 23 47 With the setting of Ixx80 0 the actual position is not reported automatically on power up It will be reported after sc...

Page 117: ...ed M Variable Open PLC 1 clear I5111 100 8388608 I10 while I5111 0 endw 100 msec delay CMD 1K Make sure motor s killed I5111 100 8388608 I10 while I5111 0 endw 100 msec delay CMD 1 Read un scaled abso...

Page 118: ...8B34 Channel 3 Y 78B28 Channel 7 Y 78B38 Channel 4 Y 78B2C Channel 8 Y 78B3C This is a 2 line ECT entry its equivalent script code I8000 278B20 Unfiltered parallel pos of location Y 78B20 I8001 014000...

Page 119: ...ts in the position window 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 linea...

Page 120: ...h no filtering Width in Bits 18 Offset Location of LSB Singleturn protocol bits 18 e g 20 18 2 No shifting Source Address Serial data register A same as position ECT for this motor Remember to click o...

Page 121: ...8B21 32 bits 0 23 47 With the 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 Example 2 Channel...

Page 122: ...ion 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 Some serial encoders use an...

Page 123: ...1 2 3 4 EncPwr Output Encoder Power 5 Volts 5 SDI Input Serial Data In 6 7 8 9 10 11 12 GND Common Common Ground 13 14 SDO Output Serial Data Out 15 If you prefer to keep the original Molex connector...

Page 124: ...e 5 SDO Blue 6 SDI Blue Black Blue White Note All Yaskawa Sigma II Sigma III protocols whether incremental or absolute and regardless of the resolution are supported This option allows the Brick to co...

Page 125: ...generated from a M 1 divider clocked at 100 MHz 15 12 R W 0x0 N_Divisor Final clock frequency for SER_Clock The final clock is generated from a N 2 divider clocked by the intermediate clock 11 10 R 00...

Page 126: ...ntinuous trigger 1 one shot trigger All triggers occur at the defined Phase Servo clock edge and delay setting See Global Control register for these settings 12 R W 0 Trigger Enable Enable trigger for...

Page 127: ...zation PLC Open PLC 1 clear CMD WX 78B20 1400 CMD WX 78B24 1400 CMD WX 78B28 1400 CMD WX 78B2C 1400 CMD WX 78B30 1400 CMD WX 78B34 1400 CMD WX 78B38 1400 CMD WX 78B3C 1400 Disable plc 1 Close Yaskawa...

Page 128: ...no filtering 2 from the corresponding Yaskawa data register channel The second line represents the width of the data to be read and bit location of the LSB of the data in the source word Channel 1 Yas...

Page 129: ...processed data I203 3504 Motor 2 Position feedback address ECT processed data I204 3504 Motor 2 Velocity feedback address ECT processed data I303 3506 Motor 3 Position feedback address ECT processed...

Page 130: ...urn Data 0 3 4 bits define MTD4_15 M7002 Multi Turn Data 4 15 12 bits define MTD0_15 M7003 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 Mtr...

Page 131: ...Y 78B34 Channel 3 Y 78B28 Channel 7 Y 78B38 Channel 4 Y 78B2C Channel 8 Y 78B3C The on going servo and commutation position data is setup using a 2 line Entry in the Encoder Conversion Table The first...

Page 132: ...Y 78B3C I8015 021004 Width and Bias total of 33 bits LSB starting at bit 4 Position Ixx03 and Velocity Ixx04 Pointers I103 3502 Motor 1 Position feedback address ECT processed data I104 3502 Motor 1...

Page 133: ...rd define STD0_16 M7002 Single Turn Data 0 16 17 bits define MTD0_15 M7003 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...

Page 134: ...8B34 Channel 3 Y 78B28 Channel 7 Y 78B38 Channel 4 Y 78B2C Channel 8 Y 78B3C The on going servo and commutation position data is setup using a 2 line Entry in the Encoder Conversion Table The first li...

Page 135: ...Y 78B3C I8015 024004 Width and Bias total of 36 bits LSB starting at bit 4 Position Ixx03 and Velocity Ixx04 Pointers I103 3502 Motor 1 Position feedback address ECT processed data I104 3502 Motor 1...

Page 136: ...ster1 2nd word define STD0_19 M1002 Single Turn Data 0 19 20 bits define MTD0_15 M1003 Multi Turn Data 0 15 16 bits FirstWord Y 78B20 0 24 SecondWord Y 78B21 0 4 STD0_19 MTD0_15 define Mtr1ActPos M162...

Page 137: ...8B24 Channel 6 Y 78B34 Channel 3 Y 78B28 Channel 7 Y 78B38 Channel 4 Y 78B2C Channel 8 Y 78B3C The on going servo and commutation position data is setup using a 2 line Entry in the Encoder Conversion...

Page 138: ...Y 78B3C I8015 00D006 Width and Bias total of 13 bits LSB starting at bit 6 Position Ixx03 and Velocity Ixx04 Pointers I103 3502 Motor 1 Position feedback address ECT processed data I104 3502 Motor 1...

Page 139: ...B24 Channel 6 Y 78B34 Channel 3 Y 78B28 Channel 7 Y 78B38 Channel 4 Y 78B2C Channel 8 Y 78B3C The on going servo and commutation position data is setup using a 2 line Entry in the Encoder Conversion T...

Page 140: ...Y 78B3C I8015 011006 Width and Bias total of 17 bits LSB starting at bit 6 Position Ixx03 and Velocity Ixx04 Pointers I103 3502 Motor 1 Position feedback address ECT processed data I104 3502 Motor 1...

Page 141: ...78B2A 8 8 Channel 7 Y 78B3A 8 8 Channel 4 Y 78B2E 8 8 Channel 8 Y 78B3E 8 8 Bit Error Name Type Alarm Type Clear Action Notes 8 Fixed at 1 9 Encoder Error Alarm Session Flag Power cycle Encoder Error...

Page 142: ...control capture on flag high I7012 2 Channel 1 capture flag select minus or negative end limit Homing to the index pulse normally performed after referencing to a hardware flag is an internal function...

Page 143: ...12 bit filtered PWM analog output channel 5 6 8 BRCOM Common Brake 5 6 Relay Common 9 BR NO Output Brake 5 6 Relay Normally Open X11 X12 Analog Inputs Outputs X11 X12 D Sub DE 9F Mating D Sub DE 9M 2...

Page 144: ...5 9 8 7 6 1 ADC ADC AGND 10VDC Input Signal 2 3 4 5 9 8 7 6 1 ADC AGND 10VDC Input Signal Note For single ended connections tie the negative ADC pin to ground Note The analog inputs use the ADS8321 Co...

Page 145: ...lWord M7201 define ADC7Temp M7202 define ADC7Read M705 ADC7FullWord Y 78115 0 24 U ADC 7 24 bit word ADC7Temp Self Addressed M var Temporary calc ADC7Read Self Addressed M var ADC 7 reading define ADC...

Page 146: ...clock source master I19 is equal to 7007 by default indicating that Servo IC 0 is the master gate However the analog outputs on X9 through X12 are generated out of Servo IC1 The relationship between...

Page 147: ...ink Analog Outputs Suggested M Variables De activate Motors 5 8 to write directly to the analog outputs I500 4 100 0 De activate channels 5 8 I569 4 100 816 Set Output Limit User Input Analog Outputs...

Page 148: ...e and the related registers suggested M variables are meaningless Caution This option utilizes the Omron G6S 2F relay which is rated to up to 220VAC However it is advised to use an external relay for...

Page 149: ...device Brake BRAKE RET DC Power Supply 12 24VDC COM BRAKE RET 2 3 4 5 9 8 7 6 1 Logic device Brake BRAKE DC Power Supply COM 12 24V Note The brake relays on X9 X10 X11 and X12 are tied to the amplifi...

Page 150: ...e If the brake relay option is in use otherwise whichever scheme desirable If pin 8 is wired to common ground then use the sourcing scheme If pin 8 is wired to 24V then use the sinking scheme Sourcing...

Page 151: ...e same level e g laptop on battery then the use of an industrial USB hub is highly advised X14 RJ45 Ethernet Connection This connector is used to establish Ethernet communication between the PC and th...

Page 152: ...VDC Abort Input Switch optional The hardware Abort input functionality differs slightly from the software global Abort CTRL A command The main differences are highlighted in the following table Motor...

Page 153: ...the hardware Abort Input functionality Wiring the Watchdog Output Watchdog Output Normally Open Watchdog Output Normally Closed 1 2 3 4 5 24 VDC Power Supply COM 24VDC Logic device safe shutdown COM...

Page 154: ...al port is set by variable I54 At power up reset The Geo Brick Drive sets the active baud based on the setting of I54 and the CPU speed I52 Note that the baud rate frequency is divided down from the C...

Page 155: ...Connector p n 014 000F04 HSG for internal use Delta Tau Pins p n 014 043375 001 for internal use High 15 30A power Axes A5 A6 Molex 4 pin Female Mating Molex 4 pin Male U V W GND Tie cable shield to s...

Page 156: ...ally in noise sensitive applications such as using high resolution sinusoidal encoders or high rate of communication which could suffer from Electro Magnetic Interference EMI Proper grounding shieldin...

Page 157: ...l motor leads several times through a ferrite core ring DigiKey Micro Metals T400 26D Fair Rite 2643540002 or equivalent ferrite cores are recommended This adds high frequency impedance to the outgoin...

Page 158: ...pecially in applications using belt or rubber based couplings The ratio of load to motor inertia is typically around 3 1 Mechanical gearing is often used to reduce reflected inertial load going back t...

Page 159: ...tance H RP Phase Resistance TM Required Continuous Torque N M KT Motor Torque Constant RMS N M A Mderate De rate parameter typically 0 8 For a Linear Motor 6 V M 3 K D V R K F K F L D V V V V DC derat...

Page 160: ...ons x X X X The add in board any non zero digit in the highlighted part number field for MACRO and special feedback requires an additional 0 5A 5V power This alters the total power available for encod...

Page 161: ...er supply with an external one By default pins 1 2 are tied together to use the internal power supply To wire an external power supply remove the jumper tying pins 1 2 and connect the external 5V to p...

Page 162: ...he loop on a motor without encoder feedback can be dangerous Caution Make sure that the encoders are powered up before executing any motor motion commands Losing encoder power can lead to dangerous ru...

Page 163: ...ng the basic steps to follow for successfully setting up a motor with the Geo Brick Drive Encoder Motor wiring Factory Default Reset Save recommended Encoder Software Setup Verify Feedback Rotate Moto...

Page 164: ...work fine for the majority of applications they are set as follows Phase Clock 9 000 KHz PWM Clock 4 500 KHz Servo Clock 2 258 KHz The need to change clock rates depends on specific requirements and m...

Page 165: ...for these clock settings can be found using the clock calculator in the Pewin32Pro2 under PMAC Resources PMAC2 Frequency Calculators PMAC2 Frequencies The equivalent script code for these settings I6...

Page 166: ...e clock settings have been configured correctly I15 0 Trigonometric calculation in degrees define MaxPhaseFreq P8000 Max Phase Clock KHz define PWMClk P8001 PWM Clock KHz define PhaseClk P8002 Phase C...

Page 167: ...14 230 VAC User Input define Mtr1Voltage 156 Motor 1 Rated Voltage VDC 110 VAC Motor User Input define Mtr2Voltage 156 Motor 2 Rated Voltage VDC 110 VAC Motor User Input define Mtr3Voltage 156 Motor 3...

Page 168: ...source address I583 78B30 Motor 5 Commutation source address I683 78B34 Motor 6 Commutation source address I783 78B38 Motor 7 Commutation source address I883 78B3C Motor 8 Commutation source address I...

Page 169: ...going Commutation Position Address I883 353B Motor 8 On going Commutation Position Address I101 8 100 1 Motors 1 8 Commutation Enabled from X register Yaskawa With Yaskawa feedback devices it is reco...

Page 170: ...ntinuous and 30 amps instantaneous will be used as current limits And Time allowed at peak is 2 seconds An 8 axis 5 10 Amp Geo Brick Drive driving eight 3 9 amp motors I15 0 Trig Operations in Degrees...

Page 171: ...18 262144 SSI EnDat BiSS Technique 3 SF 2ST Yaskawa Sigma II SF 2ST 32 SF 32 2ST Where ST is the rotary encoder Singleturn resolution in bits For a linear motor the number of commutation cycles Ixx70...

Page 172: ...Ixx70 4 4 1 Ixx71 33554432 4 8388608 ADC Offsets Ixx29 Ixx79 The ADC offsets importance may vary from one system to another depending on the motor s type and application requirements They can be left...

Page 173: ...ACTuningPro2 automatic or interactive utility can be used to fine tune the Current Loop An acceptable Current Loop step response would look like Note Current Loop Natural Frequencies in the range of 2...

Page 174: ...BiSS Absolute Power On Phasing Yaskawa absolute encoders WARNING An unreliable phasing search method can lead to a runaway condition Test the phasing search method carefully to make sure it works pro...

Page 175: ...register suggested M variable Mxx71 0 7 Issue a nK to kill the motor 8 Restore Ixx29 and Ixx79 to their original values 9 Clear the phasing search error bit Suggested M Variable Mxx48 0 10 The motor...

Page 176: ...1 0 Endw Delay CMD 1o0 Issue nO0 I5111 100 8388608 I10 while I5111 0 Endw Delay while I129 1500 Force motor to Phase A I129 I129 10 I179 0 by pushing current incrementally I5111 100 8388608 I10 while...

Page 177: ...justable Ixx80 4 2 guess method no absolute position read no power on phasing Stepper Phasing Method The stepper is a finer phasing method than the 2 guess It is generally used for motors with signifi...

Page 178: ...ion The Geo Brick Drive supports the conventional 120 spacing hall sensors type each nominally with 50 duty cycle and nominally 1 3 cycle apart The Geo Brick Drive has no automatic hardware or softwar...

Page 179: ...ely 5 Gathering and plotting data for a short positive travel of the motor should look like Motor 1 Hall Sensors Vs Phase Position Time sec Hall Sensors UVW Mxx28 Phase Position Mxx71 degrees State 1...

Page 180: ...e table below define HallsTrans3_1 M7025 Reversed direction 3 to 1 define Mtr1HEZ P7025 Hall effect zero define Mtr1HEZTemp P7026 Intermediate calculation HallsTrans3_1 HallsTrans3_1 C00000 Bit 22 1 f...

Page 181: ...330 It is stored saved in a user defined variable I7012 3 Motor 1 Capture Control Index high and Flag high I7013 0 Motor 1 Capture Control flag select Home Flag define Mtr1DesVelZero M133 Motor 1 Desi...

Page 182: ...Phase90Deg 4 define Phase150Deg 6 define Phase210Deg 2 define Phase270Deg 3 define Phase330Deg 1 3 define Phase30Deg 3 define Phase90Deg 1 define Phase150Deg 5 define Phase210Deg 4 define Phase270Deg...

Page 183: ...ncBits0_3 Y 78B34 0 4 Ch7YasIncBits0_3 Y 78B38 0 4 Ch8YasIncBits0_3 Y 78B3C 0 4 define Ch1YasIncHalls M128 define Ch2YasIncHalls M228 define Ch3YasIncHalls M328 define Ch4YasIncHalls M428 define Ch5Ya...

Page 184: ...phase position counts Ixx70 Mtr1PhaseSrchErr Y 0000C0 8 1 1 Phasing error fault bit Zone 1 Definitions User Input define Phase30Deg 1 define Phase90Deg 5 define Phase150Deg 4 define Phase210Deg 6 defi...

Page 185: ...to lock tightly onto a phase 4 Wait for the motor to settle 5 Record the absolute position from the position window or issue a nP to return the motor position in the terminal window 6 Issue a nK to k...

Page 186: ...haseTest 0 User Input Mtr4PhaseTest 0 Mtr8PhaseTest 0 User Input define ChPhaseSel P7066 Select channels to perform power on phasing in Hexadecimal ChPhaseSel 0 Channels selected for power on phasing...

Page 187: ...seOffset PhaseOffset I Ixx71 I5111 100 8388608 I10 while I5111 0 endw Compute present phase position PresPhasePos M ActPos I Ixx08 32 PresPhasePos PresPhasePos P MtrSF PresPhasePos PresPhasePos I Ixx7...

Page 188: ...et found experimentally Read from Serial data register A Read from Position ECT result Read from Commutation ECT result Ixx81 Serial data register A Ixx83 Pos ECT result Comm ECT result Ixx91 Unsigned...

Page 189: ...locked onto a phase 7 Record the following value this is the motor s phase offset Technique 1 Technique 2 3 For Ixx01 3 For Ixx01 1 Query the motor s corresponding serial data register A e g RY 78B20...

Page 190: ...If Ixx01 3 Ixx91 is set up for unsigned Y register Singleturn bits For example A 30 bit 18 bit Singleturn 12 bit Multiturn rotary encoder would yield Ixx91 120000 If Ixx01 1 Ixx91 is set up for unsig...

Page 191: ...are set to zero prior to issuing n then restored and motor killed after the phase position has been set e g Open PLC 1 Clear Make sure that the absolute position is read and reported prior to this sc...

Page 192: ...M880 Mtr1STD0_23 Y 278B20 0 24 Mtr2STD0_23 Y 278B24 0 24 Mtr3STD0_23 Y 278B28 0 24 Mtr4STD0_23 Y 278B2C 0 24 Mtr5STD0_23 Y 278B20 0 24 Mtr6STD0_23 Y 278B34 0 24 Mtr7STD0_23 Y 278B38 0 24 Mtr8STD0_23...

Page 193: ...0 8 define Mtr1CommSize I171 define Mtr1CommCycles I170 define Mtr1CommRatio P170 Motor 1 commutation cycle size Ixx71 Ixx70 counts Mtr1CommRatio Mtr1CommSize Mtr1CommCycles Open plc 1 clear Mtr1Phase...

Page 194: ...ative command should create a velocity and position counting in the negative direction The open loop test can be done manually from the terminal window e g 1O5 while gathering position velocity data o...

Page 195: ...ncoder With Resolvers Change the direction from clock wise to counter clock wise in the first encoder conversion table entry see resolver feedback setup section With Absolute Serial Encoders EnDat SSI...

Page 196: ...tuning WARNING Remember to perform an Open Loop Test after phasing and before trying to close the loop on the motor to make sure that the encoder decode I7mn0 is correct A positive open loop command s...

Page 197: ...aw e g using the current calculation PLC and finding the setting which minimizes the current draw of the motor without causing it to lose phase typically triggering a fatal following error or over cur...

Page 198: ...e 8 16A powered with 208VAC three phase is driving a 230VAC spindle on channel 4 define Mtr4Speed 1760 Motor Rated Speed w o field weakening rpm User Input define LineFrequency 60 Line frequency for r...

Page 199: ...usVoltage Mtr4Voltage I477 Mtr4EstMagCur Ch4MaxOutput SQRT 2 Ch4MaxADC Initial Guess Motor Slip Gain Ixx78 Ixx78 controls the relationship between the torque command and the slip frequency of the magn...

Page 200: ...ving a 12 45 Amp motor 12 amps continuous and 30 amps instantaneous will be used as current limits And Time allowed at peak is 2 seconds A 4 axis 8 16 Amp Geo Brick Drive is driving a 7 20 Amp AC Indu...

Page 201: ...default of zero especially if a motor setup is to be reproduced on multiple machines by copying the configuration file of the first time integration However they should ultimately be set to minimize m...

Page 202: ...e PMACTuningPro2 Software Manual Open Loop Test Issue a conservative open loop command from a terminal window i e 4o10 and monitor the velocity in the position window The motor should rotate in the po...

Page 203: ...t encoder decode generally show erratic data in the Open Loop test as opposed to a nice inverted saw tooth shape curve with DC Brushless motors In either cases I7mn0 for motor 4 i e I7040 needs to be...

Page 204: ...teractive utility can be used for tuning 2000 counts 1 2 rev Step Move for 1000 milliseconds 1 sec 16000 counts 4 revs Parabolic Move for 2000 milliseconds 2sec Note Due to the slow response nature of...

Page 205: ...magnitude of the quadrature current perpendicular to this component In open loop mode and given a fixed magnetization current Ixx77 the induction motor will accelerate at the slip gain rate Ixx78 and...

Page 206: ...value allowing the motor to reach its base speed Kill the motor Slip Gain With AC induction motor the slip gain Ixx78 controls the relationship between the torque command and the slip frequency of ma...

Page 207: ...Slip Gain Optimization Experimental Data Note High slip gain values can cause the motor to hunt and lose smoothness Correcting I2T Settings The motor continuous current limit has to be corrected for t...

Page 208: ...208 VAC bus Optimized Ixx77 208 VAC bus Lower Ixx77 Max Speed s Before Field weakening Field weakening can be set up experimentally with the goal of finding the lowest minimum value of Ixx77 which al...

Page 209: ...ing the current calculation PLC and finding the setting that minimizes the current draw of the motor without causing it go get out of phase typically triggering a fatal following error or over current...

Page 210: ...ation and servo loop feedback Encoder Conversion Table Setup The first entry in the encoder conversion table ECT for each Induction Motor must read the servo loop output like an absolute encoder This...

Page 211: ...over travel limits PWM Scale Factor Ixx66 If Motor Rated Voltage Bus Voltage I466 1 10 I7000 Motor 4 PWM Scale Factor Set to 10 above PWM Count If Bus Voltage Motor Rated Voltage A Geo Brick Drive con...

Page 212: ...d Electrical Cycles per Revolution 60 256 Servo Clock 1000 define Mtr4Speed 1760 Motor 4 Base Speed Spec RPM User Input define ElecCyclePerRev 2 No of pole pairs of Elec Cycles User Input define Servo...

Page 213: ...current limits And Time allowed at peak is 2 seconds A 4 axis 8 16 Amp Geo Brick Drive is driving a 7 20 Amp AC Induction Motor on channel 4 The continuous current limit is 7 The instantaneous current...

Page 214: ...stant Tp 1 PhaseClk 1000 Note that PhaseClk is defined in Clock Calc We LineFrequency 2 PI Mtr4Wm Mtr4Speed 2 PI Mtr4Poles 60 2 I478 We Mtr4Wm Tp I477 32768 Motor 4 Slip Gain Constant Calculating Slip...

Page 215: ...Loop An acceptable Current Loop step response would look like Note Current Loop Natural Frequencies in the range of 200 500 Hz are good enough for most applications Tuning the current loop too tightly...

Page 216: ...gle Mtr4StepAngle 360 ElecCyclePerRev 4 define Mtr4CtsPerRev P7011 Motor 4 Counts Per Revolution Mtr4CtsPerRev 360 512 Mtr4StepAngle Example A 4 pole AC Induction motor has 2 electrical cycles per rev...

Page 217: ...error fault bit M748 Y 3C0 8 1 Motor 7 Phasing error fault bit M848 Y 440 8 1 Motor 8 Phasing error fault bit M129 Y BC 0 24 U Motor 1 Direct Current Loop Integrator Output M229 Y 13C 0 24 U Motor 2 D...

Page 218: ...M Scale Factor I366 1 10 I7000 Mtr3Voltage DCBusInput Motor 3 PWM Scale Factor I466 1 10 I7000 Mtr4Voltage DCBusInput Motor 4 PWM Scale Factor I566 1 10 I7000 Mtr5Voltage DCBusInput Motor 5 PWM Scale...

Page 219: ...continuous and 30 amps instantaneous will be used as current limits And Time allowed at peak is 2 seconds An 8 axis 5 10 Amp Geo Brick Drive driving 3 9 amp motors I15 0 Trigonometric calculation in...

Page 220: ...ively read in Suggested M variables Mxx05 Mxx06 Current Loop Gains Open Loop Enc Decode Ixx61 Ixx62 Ixx76 I7mn0 Tuning fine the current loop with DC brush motors is neither critical nor required Set I...

Page 221: ...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 Acceptable Step and Parabolic posi...

Page 222: ...gnetic noise and capacitive coupling Wiring Simplicity Single plug connection between controllers amplifiers and I O modules minimizing wiring complexity in large systems High Speed data transfer rate...

Page 223: ...ing Whenever the Geo Brick Drive is a slave the MACRO configuration is called MACRO auxiliary This is a designation which was implemented in the firmware for the Brick family of controllers If the Geo...

Page 224: ...O node consists of 4 registers 1 x 24 bit and 3 x16 bit registers upper MACRO IC 0 Servo Node Registers Node 0 1 4 5 8 9 12 13 24 bit Y 78420 Y 78424 Y 78428 Y 7842C Y 78430 Y 78434 Y 78438 Y 7843C 1...

Page 225: ...Description MX anynode slave variable MX0 P1 Read and report slave variable P1 MX anynode slave variable constant MX0 P1 1 Write a 1 to slave variable P1 Program Buffer Commands Syntax Example Descrip...

Page 226: ...the position loop and sends torque commands to the Slave The Slave closes the current loop and handles the commutation of the motor PWM Mode Useful when centralized commutation and tuning current PID...

Page 227: ...In normal operation of MACRO master slave I2T settings Ixx57 and Ixx58 should be configured on the master side and set to zero on the slave side 5 Clock settings considerations The MACRO ring is sync...

Page 228: ...Minimum Sync Packet Count 9 Flag Control Ixx24 disable over travel limits on slave side enable on master side I124 8 100 20001 Disable over travel limits channels 1 8 10 MACRO slave command address Ix...

Page 229: ...EndW I144 178423 Turn Auxiliary Control on I5111 250 8388608 I10 While I5111 0 EndW P8000 0 EndIf Close Issuing MX0 P8000 1 from the master will then initiate the phasing routine Note about Slave Moto...

Page 230: ...Macro IC0 Ring Configuration Status typical master IC setting I6841 0FF333 Macro IC0 Node Activate Ctrl Servo nodes 0 1 4 5 8 9 12 13 User Input I78 32 Macro Type 1 Master Slave Communications Timeout...

Page 231: ...0E 7th 11 or 15 3516 4th 8 or 12 3510 8th 12 or 16 3518 However if the Encoder Conversion Table has been modified then the MACRO motors nodes entries need to be configured properly This can be done us...

Page 232: ...12 4th 8 or 12 3445 Servo Node 5 8th 12 or 16 344D Servo Node 13 11 The motor command output address Ixx02 is initiated by default in the firmware MACRO motor Motor Ixx02 Register MACRO motor Motor I...

Page 233: ...40 specifies whether this is a master or a slave I6841 specifies which MACRO nodes are enabled Note that it is not advised to enable nodes which will not be used Ixx44 specifies the MACRO command addr...

Page 234: ...002 Macro IC0 Servo Clock Frequency Control Note It is not necessary for the master to have the MACRO IC sourcing the clock But if it is desired I19 can be simply set to 6807 followed by a save and a...

Page 235: ...her entries are used in the Encoder Conversion Table then the position Ixx03 and Velocity Ixx04 pointers of the MACRO motors are valid by default set by firmware and need not be changed MACRO motor Mo...

Page 236: ...Node 0 5th 9 or 13 78430 Servo Node 8 2nd 6 or 10 78424 Servo Node 1 6th 10 or 14 78434 Servo Node 9 3rd 7 or 11 78428 Servo Node 4 7th 11 or 15 78438 Servo Node 12 4th 8 or 12 7842C Servo Node 5 8th...

Page 237: ...de 13 12 The Flag Control Ixx24 is typically set to 40001 60001 to disable hardware over travel limits 13 The commutation position address Ixx83 is initiated by default in the firmware MACRO motor Mot...

Page 238: ...lk MaxPhaseFreq I6801 1 ServoClk PhaseClk I6802 1 define Mtr9ContCurrent 3 Continuous Current Limit Amps User Input define Mtr9PeakCurrent 9 Instantaneous Current Limit Amps User Input define MaxADC 1...

Page 239: ...cally with quadrature or sinusoidal encoders an indication of reversed encoder direction with respect to the output command The encoder decode parameter can then be changed from 7 to 3 or vice versa P...

Page 240: ...ng table summarizes the basic clock Geo Brick Drive recommended and MACRO communication settings for the ring in the diagram above MS commands are allowed once the clocks are synchronized and nodes ar...

Page 241: ...ontrol I6802 I7002 Macro IC0 Servo Clock Frequency Control Note It is not necessary for the master to have the MACRO IC sourcing the clock But if it is desired I19 can be simply set to 6807 followed b...

Page 242: ...MACRO Drive if more than one is in the ring starting from the OUT Transmit fiber or RJ45 out of the Geo Brick Drive 10 When in ASCII mode download from the editor or issue the following commands in t...

Page 243: ...CRO motors are valid by default set by firmware and need not be changed MACRO motor Motor Ixx03 Ixx04 MACRO motor Motor Ixx03 Ixx04 1st 5 or 9 350A 5th 9 or 13 3512 2nd 6 or 10 350C 6th 10 or 14 3514...

Page 244: ...Node 0 5th 9 or 13 78430 Servo Node 8 2nd 6 or 10 78424 Servo Node 1 6th 10 or 14 78434 Servo Node 9 3rd 7 or 11 78428 Servo Node 4 7th 11 or 15 78438 Servo Node 12 4th 8 or 12 7842C Servo Node 5 8th...

Page 245: ...or 15 344C Servo Node 12 4th 8 or 12 3445 Servo Node 5 8th 12 or 16 344D Servo Node 13 The Flag Control Ixx24 is typically set to 40001 60001 to disable hardware over travel limits The commutation po...

Page 246: ...PWMClk P7001 PWM Clock KHz define PhaseClk P7002 Phase Clock KHz define ServoClk P7003 Servo Clock KHz MaxPhaseFreq 117964 8 2 I6800 3 PWMClk 117964 8 4 I6800 6 PhaseClk MaxPhaseFreq I6801 1 ServoClk...

Page 247: ...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...

Page 248: ...des These I O nodes are then extracted in a PLC code on the master side and placed into open memory registers This technique is suitable for digital inputs and outputs Using servo nodes This method is...

Page 249: ...yte Y 78801 0 8 2nd byte Y 78805 0 8 J7 3rd Byte Y 78803 0 8 J7 4th Byte Y 78804 0 8 For the digital inputs and outputs we will use the I O node data transfer method MACRO I O node 2 will be used to c...

Page 250: ...lave side the machine s inputs state is copied into first 2 x 16 bit registers of MACRO I O node 2 At the master side these MACRO I O node registers are copied using a PLC code into pre defined open m...

Page 251: ...define LatchIn3 M7012 define LatchIn4 M7013 MACRO I O Node Registers define N2Twenty4 M7016 24 bit register node 2 define N2First16 M7017 1st 16 bit register node 2 define N2Second16 M7018 2nd 16 bit...

Page 252: ...7004 Digital Outputs Latch define LatchIn1 M7005 Digital Inputs Latch 1 define LatchIn2 M7006 Digital Inputs Latch 2 MACRO I O Node Registers define N2Twenty4 M7008 Node 2 24 bit register define N2Fir...

Page 253: ...ut 12 Input13 X 10FF 20 1 Input 13 Input14 X 10FF 21 1 Input 14 Input15 X 10FF 22 1 Input 15 Input16 X 10FF 23 1 Input 16 J7 Outputs define Output9 M7109 define Output10 M7110 define Output11 M7111 de...

Page 254: ...2 M702 Y 078112 8 16 S Analog DAC 3 M802 Y 07811A 8 16 S Analog DAC 4 Note Some Geo Brick Drives may not be fully populated with all the analog inputs and outputs The non existent ones can be simply d...

Page 255: ...writes Master Settings I6841 I6841 3300 Enable servo nodes 8 9 12 13 M1302 Y 78430 8 16 S Analog DAC 1 M1402 Y 78434 8 16 S Analog DAC 2 M1502 Y 78438 8 16 S Analog DAC 3 M1602 Y 7843C 8 16 S Analog...

Page 256: ...2 12 U ADC5 Unipolar M6996 Y 00340A 12 12 U ADC6 Unipolar M6997 Y 00340C 12 12 U ADC7 Unipolar M6998 Y 00340E 12 12 U ADC8 Unipolar We will use the MACRO auxiliary MX read commands to transfer the J9...

Page 257: ...otor 1 on the Slave Station or Servo IC 0 channel 1 MX0 I7012 2 Servo IC 0 Channel 1Capture Control flag high MX0 I7013 3 Servo IC 0 Channel 1Capture Flag Select Control user flag In a two 8 axis Bric...

Page 258: ...Node 4 user flag Macro IC 0 Node 5 Flag Registers M450 X 003445 0 24 Macro IC 0 Node 5 flag status register M451 Y 003445 0 24 Macro IC 0 Node 5 flag command register M453 X 003445 20 4 Macro IC 0 Nod...

Page 259: ...o IC 0 Node 12 user flag Macro IC 0 Node 13 Flag Registers M850 X 00344D 0 24 Macro IC 0 Node 13 flag status register M851 Y 00344D 0 24 Macro IC 0 Node 13 flag command register M853 X 00344D 20 4 Mac...

Page 260: ...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 communicati...

Page 261: ...terminal block logic and STO connector The optional add in board comprises primarily of Non standard quadrature feedback processing circuitry i e sinusoidal serial Additional analog inputs analog outp...

Page 262: ...ly inserting the serial number and pressing the enter key This page will display Description and part number of the top assembly Geo Brick Drive Part numbers and revision numbers of the sub assembly b...

Page 263: ...ts to the Controls Section The ADC Strobe Word in this mode has to be set saved to 3FFFFF Caution The ADC Strobe Word I7m06 has been masked in PMAC firmware version 1 944 and above to avoid bad user s...

Page 264: ...F 300FFF 301FFF The IGBT Temperature Bus Voltage Axis and Global faults data can be retrieved from ADC phases A and B of each axis The information consists of 8 bits of data located in bits 4 through...

Page 265: ...k Current Fault Indicates that a current output greater than the amplifier peak current specification but less than the short circuit nF3 threshold has been detected and sustained for about 10 millise...

Page 266: ...AF4 0E Shunt RMS Fault Indicates that the shunt resistor turn on time has exceeded the permissible time of 2 seconds Make sure that the main bus power is within spec AFb 07 Main Bus Over Voltage Faul...

Page 267: ...Mtr1ADCB Y 78006 4 8 Channel 1 ADC Phase B ACBusVoltage Self referenced M variable to store Bus Voltage reading IGBTAxis1Temp Self referenced M variable to store IGBT Temperature reading LastIC0Strob...

Page 268: ...Global Variable 1 define GlobalVar2 P7058 General Purpose Global Variable 2 define Axis1CurrentOutput P7059 User variable to store Axis 1 current Mtr1ActQuadCurrent X 0000B9 8 16 S 1 Actual quadratur...

Page 269: ...3 Enabled or Brake Relay 3 output is true Off Unlit RLY X12 Axis 4 Status Brake Relay 4 Status On Green Green when Axis 4 Enabled or Brake Relay 4 output is true Off Unlit 5V 5V Logic Power On Green G...

Page 270: ...ighted in red in the terminal window This error occurs if any of the following is true The addressed motor is not phased In this mode the phasing search error bit is highlighted in the Motor Status wi...

Page 271: ...uch computation Kinematics requiring faster CPU option Wrong clock settings In this mode the user has downloaded or written bad values to clock setting parameters Hardware 5V failure internal In this...

Page 272: ...in the TYPE command TURBO2 X4 This command causes Turbo PMAC to return a string reporting the configuration of the board s Although this is a general Turbo PMAC online command it will report a unique...

Page 273: ...The response is a 6 digit hex value The information reported in the amplifier version number is mostly for internal use and technical support troubleshooting Example Ampmod Function Report Geo Brick D...

Page 274: ...AMPCLRF Caution The AMPCLRF command will enable then kill all the motors to clear faults If AMPCLRF is issued with no existing errors all previously enabled motors will be killed which can be hazardou...

Page 275: ...ommunication write protection for Changing IP address Gateway IP or MASK Enabling ModBus Reloading communication boot and firmware These functions are accessible through the Configure Ethernet 100 Bas...

Page 276: ...de 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 unde...

Page 277: ...download utility will prompt for a BIN file MAKE SURE you open the correct file Note The PMAC firmware file for Geo Brick Drives MUST ALWAYS be TURBO2A BIN Step4 Wait until download is finished and c...

Page 278: ...ge the desired address field Step2 Hold the BOOT SW switch down Step3 Press on the corresponding Store button Store IP for changing IP address Gateway IP for changing Gateway IP Gateway Mask for chang...

Page 279: ...ound 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 Installing this feature successfully requi...

Page 280: ...the BOOT SW switch down Step2 Click on Store Boot Step3 The utility will prompt for the boot file MAKE SURE you open the correct IIC file ending with BootFx2 iic and wait for firmware load successful...

Page 281: ...switch held down will permanently erase any user configured parameters Reset SW instructions Power down the unit then power back up while holding the Reset SW switch down Release the Reset SW once the...

Page 282: ...ackground PLCs I5111 500 8388608 I10 500 ms delay using C S1 countdown timer WHILE I5111 0 END WHILE CMD AMPVER I5111 20 8388608 I10 20 ms delay using C S1 countdown timer WHILE I5111 0 This provides...

Page 283: ...upply must be used to drive the encoders A new connector 5V ENC PWR is introduced to support this scheme Note See 5V ENC PWR section for pin out and wiring scheme EEPROM Write Protect Enable April 201...

Page 284: ...ck power block and the amplifier status is not reported properly making the application unsafe Motors are not allowed to be enabled in this mode Recycling power on the Geo Brick Drive may clear the er...

Page 285: ...er distribution Minimizes noise disturbance Resolves intermittent MACRO data blips e g motor position spikes More robust digital outputs protection Self protected MOSFETS over voltage over current I2T...

Page 286: ...Geo Brick Drive User Manual Appendix A 286 APPENDIX A Schematic Samples Watchdog X15 Inputs J6 J7...

Page 287: ...Geo Brick Drive User Manual Appendix A 287 Outputs J6 J7 603793 109 and earlier Outputs J6 J7 603793 10A and later...

Page 288: ...Geo Brick Drive User Manual Appendix A 288 Limits Flags J4...

Page 289: ...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 D...

Page 290: ...X10 Jump Pins 2 to 3 for AENA6 on X10 See Part Number E8 3 2 1 Jump pins 1 to 2 for GPIO3 on X11 Jump Pins 2 to 3 for AENA3 on X11 See Part Number E9 3 2 1 Jump pins 1 to 2 for GPIO4 on X12 Jump Pins...

Page 291: ...Jumper for TTL Level input for Ch3 Index signal C Jumper 1 2 to output AENA3 at Ch3 encoder connector No Jumper E28 2 1 No Jumper for TTL Level input for Ch4 Index signal C Jumper 1 2 to output AENA4...

Page 292: ...r units Where ST is the rotary encoder Singleturn resolution in bits RES is the linear encoder resolution in user units e g mm ServoClk is the PMAC servo update rate in KHz Ixx08 is Motor xx s positio...

Page 293: ...perform proper motor phasing Example Take a 37 bit absolute serial rotary encoder 25 bit single turn 12 bit multi turn and its equivalent linear scale e g 10 nm resolution and compare for two differen...

Page 294: ...bit Shift 14 645 81 916 Technique 2 no Shift 468 667 2621 334 Note Notice the lower programmable closed loop velocity settings with techniques 1 and 3 5 bit shift associated with the default position...

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