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HARDWARE REFERENCE GUIDE

Power Brick Controller

Single Source Machine Control

……………………………………………..…...……………….

Power // Flexibility // Ease of Use

Tel. (818) 998-2095 Fax. (818) 998-7807 //

www.deltatau.com

DELTA TAU

Data Systems, Inc.

NEW IDEAS IN MOTION

…

PBC

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⏕⏕⏕

⏕⏕0⏕⏕⏕⏕

May 20, 2022

Document # MN-000295

Power Brick Controller

Summary of Contents for PBC Series

Page 1: ...ick Controller Single Source Machine Control Power Flexibility Ease of Use Tel 818 998 2095 Fax 818 998 7807 www deltatau com DELTA TAU Data Systems Inc NEW IDEAS IN MOTION PBC 0 May 20 2022 Document...

Page 2: ...ssory 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 ins...

Page 3: ...ive to 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...

Page 4: ...r Part Number Added Resolver Configuration Added Digital Tracking Filter Setup Added Serial Port RS 232 Description Corrected Motor Setup Sections General Updates and Formatting 05 19 16 DCDP RN RN 5...

Page 5: ......

Page 6: ...ral Dimensions 24 4 Axis PBC Direct PWM 25 4 Axis PBC True DAC Filtered PWM 26 8 Axis PBC Direct Digital PWM 27 8 Axis PBC True DAC Filtered PWM 28 CONNECTIONS AND SOFTWARE SETUP 29 AMP1 AMP8 Output C...

Page 7: ...p 72 X9 X12 Analog Inputs Outputs 79 Setting up the Analog ADC Inputs 80 Setting up the Analog DAC Outputs 84 Setting up the General Purpose Relays 88 Setting up the GP Input 90 X13 Axis 1 4 Limits Fl...

Page 8: ...or Setup Elements 124 Activate the Motors 125 PWM Output Scale Factor 126 Ongoing Phase Position 127 I2T Protection 130 ADC Offsets 132 Current Loop tuning 133 Motor Phasing 135 Open Loop Test 141 Pos...

Page 9: ...tection 188 Digital Quadrature 189 Sinusoidal Resolver HiperFace Encoders 190 Serial Encoders 191 Digital Tracking Filter 192 PTC Motor Thermal Input 194 LED Status 195 Reloading Power PMAC Firmware 1...

Page 10: ...be expanded modularly through MACRO up to 32 servo nodes 24 I O nodes or EtherCat up to 64 additional axes The Power Brick Controller carries up to 48 digital inputs and 24 digital outputs I Os on boa...

Page 11: ...l is enclosed in the following format Caution It is the user s responsibility to manage the application s PLCs properly The code samples are typically enclosed in a PLC buffer with the user defined na...

Page 12: ...Power Brick Controller User Manual Introduction 12 Agency of Approval and Safety Item Description CE Mark EN61326 1 UKCA 2016 No 1091...

Page 13: ...Eth 5 3 Extra Eth Option F Option G Option H 0 No EtherCAT 0 No Gateway F Filtered 1 EtherCAT I O 1 Profibus DP A True 16 bit 2 4 EtherCAT Servo 2 Profibus DP Slave P Direct 3 8 EtherCAT Servo 3 Devi...

Page 14: ...oder Flags Digital I Os MACRO Nodes Servo IOs Analog Outputs Analog Inputs GP Relays 0 4 32 16 1 4 32 16 16 12 4 4 4 2 8 48 24 3 8 48 24 32 24 8 8 8 4 8 48 24 32 24 4 4 True DAC 16 bit 8 8 Option I fo...

Page 15: ...n 4 Hiperface 5 Sinusoidal Sinusoidal 6 Yaskawa 6 Sinusoidal Resolver 7 Tamagawa 7 Resolver Sinusoidal 8 Panasonic A Resolver Resolver 9 Mitutoyo B Resolver ACI Sin B BiSS B C E ACI Sin ACI Sin C Mats...

Page 16: ...fully protected at 12 24 VDC sourcing or sinking user wiring Servo Interface Inputs 4 channels servo interface each including Quadrature encoder differential with index interface UVW digital hall sen...

Page 17: ...erface ACC 84B serial encoder protocols o Matsushita Nikon D o Mitsubishi o EnDat 2 2 with additional information no delay compensation o BiSS B C o Yaskawa II III V with position reset and fault clea...

Page 18: ...h the optional ACC 84B installed a given channel can be configured in software to use either one the Gate3 serial encoder protocols or one of the ACC 84B protocols o If a serial encoder is used on a g...

Page 19: ...ce IEC721 3 3 Minimum Relative Humidity 10 HU Maximum Relative Humidity up to 35 C 95 F 95 HU Maximum Relative Humidity from 35 C up to 50 C 122 F 85 HU Derating for Altitude 0 1000 m 0 3300 ft No de...

Page 20: ...Power Brick Controller User Manual Specifications 20 Protection Specifications Description Specifications PWM Out Of Range Outside the range of 4 20 kHz or on time exceeds 1 4 msec...

Page 21: ...Power Brick Controller User Manual Specifications 21 Electrical Specifications PWM Frequency Operating Range kHz 4 20 Logic Power VDC A 24 5 VDC 5 A...

Page 22: ...er listed on the purchase order Inspect the equipment for external physical damage that may have been sustained during shipment and report any damage immediately to the commercial carrier Electronic c...

Page 23: ...prevent enclosure ambient from exceeding 45 C 113 F The Power Brick Controller can be mounted with a traditional 3 hole panel mount two U shape notches on the bottom and one pear shaped hole on top I...

Page 24: ...Power Brick Controller User Manual Mounting 24 CAD Drawing General Dimensions Dimensions are identical between all part numbers 3x M4 13 44 15 00 7 75 4 00 14 62 2 50...

Page 25: ...User Manual Mounting 25 4 Axis PBC Direct PWM Amp 1 Encoders 1 4 Amp 2 Serial MACRO Amp 3 USB Ethernet EtherCAT Abort WD Amp 4 RTETH Fieldbus Analog I O Alt Enc Po General Purpose I O Flags Limits Ana...

Page 26: ...r Manual Mounting 26 4 Axis PBC True DAC Filtered PWM Amp 1 Encoders 1 4 Amp 2 Serial MACRO Amp 3 USB Ethernet EtherCAT Abort WD Amp 4 RTETH Fieldbus Analog I O Alt Enc General Purpose I O Flags Limit...

Page 27: ...27 8 Axis PBC Direct Digital PWM Amp 1 Encoders 1 4 Amp 2 Serial MACRO Amp 3 USB Ethernet EtherCAT Abort WD Amp 4 Encoders 5 8 Amp 5 RTETH Fieldbus Amp 6 Analog I O Alt Enc General Purpose I O Flags...

Page 28: ...8 Axis PBC True DAC Filtered PWM Amp 1 Encoders 1 4 Amp 2 Serial MACRO Amp 3 USB Ethernet EtherCAT Abort WD Amp 4 Encoders 5 8 Amp 5 RTETH Fieldbus Amp 6 Analog I O Alt Enc P General Purpose I O Flag...

Page 29: ...AMP8 which correspond to Channels 5 8 but all models must be ordered with at least 4 axes corresponding to Channels 1 4 on AMP1 AMP4 True DAC Filtered PWM Option AMP1 AMP8 D sub DA 15F Mating D Sub D...

Page 30: ...DAC Output Single Ended DAC Output Differential DAC Output Sinusoidal DAC Output DAC COM Analog Device DAC DAC Analog Device COM DACA DACA DACB Sine Wave DACB COM Amplifier 8 7 6 5 4 3 2 1 15 14 13 12...

Page 31: ...e The following table summarizes the amplifier enable contact relays logic of operation Channel Command Connection between pins 11 and 4 Connection between pins 11 and 3 Disabled Killed Open Closed En...

Page 32: ...AMP FLT AMP FLT AMP ENA COM AMP FLT COM AMP FLT COM Low True Amplifier Enable Output Sourcing Sinking AMP ENA AE COM AMP ENA AMP FLT AMP FLT AMP FLT AMP FLT AMP ENA COM AMP FLT COM AMP FLT COM COM COM...

Page 33: ...VDC Power From controller 17 RESERVED 18 RESERVED 19 FC1 Feedback 1 of 4 Fault Code Bits Optional 20 FC3 Feedback 1 of 4 Fault Code Bits Optional 21 ADC_CLK Command A D Converter Clock 22 ADC_STB Comm...

Page 34: ...ing 5 amperes per Power Brick Controller If multiple drives are sharing the same 24 Volt power supply it is highly recommended to wire each drive back to the power supply terminals separately This con...

Page 35: ...ta 6 CHW PUL In Out Halls W Pulse Out Serial Clock 7 2 5V Output 2 5 VDC Reference power 8 PTC Input Motor Thermal Input 9 CHA Input Encoder A 10 CHB Input Encoder B 11 CHC Input Index C Amp Enable 12...

Page 36: ...nics to discern the direction of travel which would not be possible with a single signal Channel A Channel B Quadrature encoders can be wired either in a differential or single ended manner Differenti...

Page 37: ...voCapt a 4 PowerBrick 0 Chan 3 ServoCapt a 8 PowerBrick 1 Chan 3 ServoCapt a Activating the corresponding channel is sufficient to display counts in the position window when the motor encoder shaft is...

Page 38: ...osed loop control because the servo loop no longer has any idea what the true physical position of the motor is usually it thinks it is stuck and it can react wildly often causing a runaway condition...

Page 39: ...Out Halls U Direction Out Serial Data AltSin 6 CHW PUL In Out Halls W Step Out Serial Clock AltCos 7 2 5V Output 2 5 VDC Reference power 8 PTC Input Motor Thermal Input 9 SIN Input Sine 10 COS Input C...

Page 40: ...a single 32 bit word without any scaling The Arctangent calculation must be enabled for this channel The encoder type for this motor must be set for a DSPGate3 arctan extension Activating the channel...

Page 41: ...ine PowerBrick 0 Chan 3 AdcEnc 1 Cosine PowerBrick 1 Chan 3 AdcEnc 1 Note The Sine and Cosine data is in the upper 16 bits of these 32 bit structure elements Scaling them properly requires shifting ri...

Page 42: ...nt Error section of this manual Sinusoidal Encoder Loss Detection Warning Loss of the feedback sensor signal is potentially a very dangerous condition in closed loop control because the servo loop no...

Page 43: ...AltSin 6 CHW PUL In Out Halls W Step Out Serial Clock AltCos 7 2 5V Output 2 5 VDC Reference power 8 PTC Input Motor Thermal Input 9 SIN Input Sine 10 COS Input Cosine 11 CHC Input Index C Amp Enable...

Page 44: ...ponent is usually set experimentally to maximize the magnitude of the feedback signal Bits 23 22 specify the magnitude of the excitation output The highest magnitude that does not cause saturation of...

Page 45: ...entally to produce the greatest possible value of the signal s magnitude which is in the lower 16 bits of AtanSumOfSqr Configuring Resolver ECT Once the resolver excitation signal is set up the encode...

Page 46: ...ter It is set up using the following key structure elements Motor pAbsPos PowerBrick 0 Chan 2 AtanSumOfSqr a Motor AbsPosSf Motor PosSf Motor ApsPosFormat 00001010 Upper 16 bits Motor HomeOffset user...

Page 47: ...lity of trapping encoder count loss errors for resolvers This is described in detail in the Encoder Count Error section of this manual Resolver Encoder Loss Detection Warning Loss of the feedback sens...

Page 48: ...ut Encoder Power 5 VDC max 250 mA per channel 5 DATA In Out DAT DAT PS MRR SDI blu blk SLO SD 6 CLOCK Output CLK MA 7 2 5V Output 2 5 VDC Reference 8 PTC Input Motor Thermal Input 9 10 11 ENA Output S...

Page 49: ...er inputs software configuration enabling serial encoder line SerialEncEna Quadrature encoder inputs serial encoder enable line must be 0 Alternate Sinusoidal encoder inputs with sinusoidal encoder op...

Page 50: ...2 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Bits 31 20 specify the serial interface transmission frequency...

Page 51: ...8 PowerBrick 1 Chan 3 SerialEncCmd Bit Binary Hex Bits 31 16 specify the command code This field is protocol specific Bits 15 14 specify the parity This field is protocol specific Bit 13 specifies th...

Page 52: ...ulti Turn Position PowerBrick i Chan j SerialEncDataB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Parity Error Bit Length Resolution Mode Trig Ena G to B M Di...

Page 53: ...r Brick Controller EnDat additional information is supported via the optional ACC 84B serial interface A 37 bit EnDat 2 2 encoder for continuous position reporting 000111 07 Report Position 101010 2A...

Page 54: ...cables To perform the delay identification and compensation cycle on this encoder set PowerBrick i Chan j SerialEncCmd 80071025 then wait for bit 31 to clear This same encoder can be reset with a comm...

Page 55: ...l Encoder Command word The upper 8 bits contain the address of the encoder in the interface The Hiperface protocol permits up to 8 separate encoders to be daisy chained on a single multi drop interfac...

Page 56: ...the following Serial Data Registers PowerBrick i Chan j SerialEncDataA Possible Single Multi Turn Position PowerBrick i Chan j SerialEncDataB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 1...

Page 57: ...Yaskawa no longer produces Sigma I absolute encoders However newer generations of Yaskawa Sigma servo drives synthesize the Yaskawa Sigma I protocol for return to the controller even when using newer...

Page 58: ...turns count bits 15 8 represent bits of the ten s digit bits 23 16 represent bits of the hundred s digit bits 31 24 represent bits of the thousand s digit In the Data B register Bits 7 0 represent bit...

Page 59: ...2 1 0 Multi Turn Position Single Turn Position PowerBrick i Chan j SerialEncDataB Alarm Code Temperature Multi Turn Position Timeout Err CRC Err Coding Err M Divisor N Divisor Reserved Clock Edge Trig...

Page 60: ...Brick i Chan j SerialEncDataB Alarm Code Temperature Multi Turn Position Yaskawa Sigma II II V Encoders Alarm Code Serial Encoder Data B Register Bit Alarm Code 20 21 Power on error self detected 22 2...

Page 61: ...isters PowerBrick i Chan j SerialEncDataA Single Turn Position PowerBrick i Chan j SerialEncDataB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Status Field Ala...

Page 62: ...position value in the encoder is reset to 0 This should be done in one shot mode making the element equal to 004A3000 007A3000 00DA3000 or 00F23000 respectively When the reset operation is done the co...

Page 63: ...der ID Code Single Turn Position PowerBrick i Chan j SerialEncDataB Status Field Alarm code when commanded Multi Turn Position Or Encoder ID Code Bits 24 31 SerialEncDataA of the encoder ID code are f...

Page 64: ...value is reported in bits 8 15 of SerialEncDataB If the command code is set to 85 absolute position is reported similarly to 01 M Divisor N Divisor Reserved Clock Edge Trigger Delay Protocol 31 30 29...

Page 65: ...20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Status Field Alarm code Encoder ID Bit Alarm Code 16 Initialization error 17 Mismatch of optical and capacitive sensors 18 Optical sensor error 19...

Page 66: ...SerialEncDataB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Alarm Code Multi Turn Position Bit Alarm code 24 Interpolator error 25 Absolute track error 26 Busy...

Page 67: ...er with 17 bits of single turn or an equivalent 1 m linear scale position data located in the lower 17 bits of Serial Encoder Data A register PowerBrick i Chan j SerialEncDataA 31 30 29 28 27 26 25 24...

Page 68: ...ndle the rollover gracefully Also the scale factor should reflect the new location of the LSB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Activating the corre...

Page 69: ...ion data in serial data register A is sufficient for producing the proper ongoing position Activating the corresponding motor channel and setting up the position and velocity pointers is sufficient to...

Page 70: ...using index1 3 bits to place the MSB at bit 31 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Multi Turn Position Data Single Turn Position Data Activating the c...

Page 71: ...in serial data register A Some people may elect to use only the single turn data for ongoing position processing This would require shifting to the left 8 bits index1 8 and setting EncTable i ScaleFa...

Page 72: ...Z from the online terminal or a HOMEZ n where n is the motor number from a PLC can be issued to retrieve the absolute position Following are examples for setting up the absolute position read with var...

Page 73: ...ated in serial data A and B registers consecutively PowerBrick i Chan j SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 PowerBrick i Chan j SerialE...

Page 74: ...Power Brick Controller User Manual Connections and Software Setup 74 Motor 1 HomeOffset 0...

Page 75: ...l data A register and continuously extending to bit 3 of serial data register B PowerBrick i Chan j SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...

Page 76: ...9 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Multi Turn Position Data The single turn data must be shifted 8 bits left first to make it contiguous with the multi turn...

Page 77: ...4 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Multi Turn Position Data The single turn data must be shifted 8 bits left first This shift is done using the upper 5 bits of the aa byte...

Page 78: ...for performing this operation The automatic settings can now be set up to read the absolute position at the first corresponding user defined register Motor AbsPosFormat Once the example code in the sa...

Page 79: ...Pin Symbol Function Description 1 AGND Ground Common Analog Ground 2 DAC1 Output Analog Output 1 3 AE_NO_1 Relay Normally Open GP Relay Brake 1 4 ADC2 Input Analog Input 2 5 AE_COM_2 Common GP Relay...

Page 80: ...ick i Chan j AdcAmp 2 The structure elements do not allow bit masking of the upper 16 bits hence scaling shifting is required to obtain the raw ADC data Using the explicit address registers makes it e...

Page 81: ...is the ADC channel number 1 or 2 of the corresponding xx connector X9 X10 X11 or X12 Sys WpKey AAAAAAAA Disable Write Protection PowerBrick 0 AdcAmpHeaderBits 0 PowerBrick 1 AdcAmpHeaderBits 0 PowerBr...

Page 82: ...OBAL ADC2X10ZeroOffset 0 038 Zero Volt Offset ADC2 X10 volt USER ADJUSTABLE GLOBAL ADC1X11ZeroOffset 0 038 Zero Volt Offset ADC1 X11 volt USER ADJUSTABLE GLOBAL ADC2X11ZeroOffset 0 038 Zero Volt Offse...

Page 83: ...rsion Table ECT into which the motor s position and velocity elements are assigned to Example EncTable 9 Type 1 EncTable 41 pEnc PowerBrick 0 Chan 0 AdcAmp 2 a EncTable 41 pEnc1 Sys pushm EncTable 41...

Page 84: ...graded for servo use True DAC outputs are typically used in servo applications The analog output command data resides in the upper 16 bits of the 32 bit structure element PowerBrick i Chan j PWM 3 The...

Page 85: ...Output Data PowerBrick 1 Chan 3 PackOutData 0 DAC2 X12 Unpack Output Data PowerBrick 0 Chan 0 OutputMode PowerBrick 0 Chan 0 OutputMode 7 D phase PWM PowerBrick 0 Chan 1 OutputMode PowerBrick 0 Chan...

Page 86: ...AC and DAC in differential mode Scaled DAC Output In Volts The outputs can be scaled and converted into user voltage units The following example PLC scales the data as needed to allow the user to comm...

Page 87: ...ER ADJUSTABLE GLOBAL DAC1X9CtPerVolt 1338 DAC1 X9 Scale Factor Counts Volt USER ADJUSTABLE GLOBAL DAC2X9CtPerVolt 1338 DAC2 X9 Scale Factor Counts Volt USER ADJUSTABLE GLOBAL DAC1X10CtPerVolt 1338 DAC...

Page 88: ...erBrick 1 Chan 3 OutFlagC If PowerBrick i Chan j OutFlagC 0 the circuit between the common pin and the Relay pin is open If PowerBrick i Chan j OutFlagC 1 the circuit between the common pin and the Re...

Page 89: ...Chan 0 OutFlagC PTR GPRelay2X9 PowerBrick 0 Chan 1 OutFlagC PTR GPRelay1X10 PowerBrick 0 Chan 2 OutFlagC PTR GPRelay2X10 PowerBrick 0 Chan 3 OutFlagC GP Relay 1 X9 GP Relay 2 X9 GP Relay 1 X10 GP Rela...

Page 90: ...2 respectively If the relay is wired in sourcing mode this input cannot be used The structure element bit reflecting the status of this input is PowerBrick i Chan j T It is a low true input meaning i...

Page 91: ...Symbol Function 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...

Page 92: ...mbol 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...

Page 93: ...rable 5 24 VDC Power supply USER 1 5 NC POS LIMIT 1 5 NC NEG LIMIT 1 5 HOME 1 5 FLAG RETURN 1 5 EQU 1 5 USER 2 6 NC POS LIMIT 2 6 NC NEG LIMIT 2 6 HOME 2 6 FLAG RETURN 2 6 EQU 2 6 USER 3 7 NC POS LIMI...

Page 94: ...lag PowerBrick 0 Chan 0 HomeFlag Channel 1 Home Flag PTR Ch1EQU PowerBrick 0 Chan 0 Equ Channel 1 EQU PTR Ch2PlusLimit PowerBrick 0 Chan 1 PlusLimit Channel 2 Positive Limit PTR Ch2MinusLimit PowerBri...

Page 95: ...werBrick 1 Chan 1 UserFlag Channel 6 User Flag PTR Ch6HomeFlag PowerBrick 1 Chan 1 HomeFlag Channel 6 Home Flag PTR Ch6EQU PowerBrick 1 Chan 1 Equ Channel 6 EQU PTR Ch7PlusLimit PowerBrick 1 Chan 2 Pl...

Page 96: ...OM_EMT Input Common Emitter 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...

Page 97: ...M_EMT Input Common Emitter 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...

Page 98: ...M_EMT Input Common Emitter 12 GPO17 Output Sourcing Output 17 13 GPO18 Output Sourcing Output 18 14 GPO19 Output Sourcing Output 19 15 GPO20 Output Sourcing Output 20 16 GPO21 Output Sourcing Output 2...

Page 99: ...ower supply at one end and to the Power Brick at the other Note The inputs can be wired either sourcing or sinking in sets of eight each set possesses its own common Outputs The outputs use the PS2701...

Page 100: ...10 OUTPUT 3 11 OUTPUT 4 12 OUTPUT 5 13 OUTPUT 6 14 OUTPUT 7 15 OUTPUT 8 16 12 24 VDC INPUT 1 17 INPUT 2 18 INPUT 3 19 INPUT 4 20 INPUT 5 21 INPUT 6 22 INPUT 7 23 INPUT 8 24 INPUT 9 25 INPUT 10 26 INP...

Page 101: ...Brick 0 GpioData 0 22 1 Output 7 X15 Pin 18 Pin 36 PTR Output8 PowerBrick 0 GpioData 0 23 1 Output 8 X15 Pin 19 Pin 37 X16 Digital I O Pointers X16 INPUTS PTR Input17 PowerBrick 1 GpioData 0 0 1 Input...

Page 102: ...X25 Pin 24 PTR Input43 u io C00004 10 1 Input 43 X25 Pin 6 PTR Input44 u io C00004 11 1 Input 44 X25 Pin 25 PTR Input45 u io C00004 12 1 Input 45 X25 Pin 7 PTR Input46 u io C00004 13 1 Input 46 X25 Pi...

Page 103: ...n Symbol Function 1 IN MACRO Ring Receiver 2 OUT MACRO Ring Transmitter Notes The fiber optic version of MACRO uses 62 5 125 multi mode glass fiber optic cable terminated in an SC style connector The...

Page 104: ...stop under the IEC 61800 5 2 machine safety standard suitable for applications such as aborting motion for opening machine door or replacing tool s If an Abort input button is used it must be a norma...

Page 105: ...tors in the coordinate system are brought to a closed loop controlled stop Abort 1 All motors in the coordinate system are immediately disabled killed without delay for brake engagement Disable 2 All...

Page 106: ...lly Closed 24 VDC Power Supply COM 24 VDC 5 3 COM 24 VDC Logic device safe shutdown 24 VDC Power Supply COM 24 VDC 5 4 COM 24 VDC Logic device safe shutdown The watchdog relay s are triggered when A h...

Page 107: ...exceed 500 mA Wiring the Encoder Supply Pin Symbol Description Note 1 5V External 5 VDC Input when using external supply 2 5 VDC Output Tie to pin 1 to use internal power supply 3 GND 0 VDC Input whe...

Page 108: ...tain feedback devices can be set up to read absolute position or perform phasing on power up either automatic firmware functions or user written PLCs If the encoder power is not available these functi...

Page 109: ...or this connector s pinout and functionality X21 Real Time Ethernet RTETH1 Refer to the ACC 72EX Manual for this connector s pinout and functionality X22 FB Diagnostic Refer to the ACC 72EX Manual for...

Page 110: ...tly communicate to the Power PMAC board through this single hardware port ETH 0 1 8 Pin RJ45 Receptacle Pin Symbol Function Description 1 P0MDI0 BIDIR LINE 0 POS 2 P0MDI0 BIDIR LINE 0 NEG 3 P0MDI1 BID...

Page 111: ...o prevent ground loop problems Each port can control its own EtherCAT ring allowing Power PMAC to be the master to two separate rings simultaneously Note Two EtherCAT rings can be controlled by one Po...

Page 112: ...orientation With this port the Power PMAC CPU acts as the host computer and various peripheral devices can be connected through this port This connector should be used for Host PC to Power PMAC commun...

Page 113: ...e through this USB port Power PMAC will then act just like a USB flash drive This is useful for recovering Power PMAC projects which were stored in flash memory in the event that the Power PMAC is som...

Page 114: ...ION DESCRIPTION NOTES 1 N C NO CONNECT 2 DTR BIDIRECT DATA TERM RDY TIED TO DSR 3 TXD INPUT RECEIVE DATA HOST TRANSMIT DATA 4 CTS INPUT CLEAR TO SEND HOST READY BIT 5 RXD OUTPUT SEND DATA HOST RECIEVE...

Page 115: ...p 115 SD Card Connection The Power Brick Controller provides a socket for SD card insertion This permits the use of standard camera card flash memory for many uses It is even possible to boot the CPU...

Page 116: ...c 24 VDC power encoder motor and main DC bus power for your amplifier s must be wired properly per the instructions in the connections section prior to setting up any motor channel STEP 1 Global Reset...

Page 117: ...k Controller User Manual Manual Motor Setup 117 Global Reset Starting from factory default settings issuing a global reset followed by a Save and a is highly recommended This ensures a good clean star...

Page 118: ...or increasing the servo clock could come from several factors such as high speed precision applications synchronizing to external events high speed position capture compare and kinematics calculation...

Page 119: ...werBrick i Chan j ServoClockDiv 1 The PWM frequency is determined from the phase clock using the following equation PowerBrick i Chan j PwmFreqMult 1 fPWM 2 fPhase Note A Save followed by a or power c...

Page 120: ...werBrick 0 Chan 0 PackOutData 0 Channel 1 Unpack Output Data PowerBrick 0 Chan 1 PackOutData 0 Channel 2 Unpack Output Data PowerBrick 0 Chan 2 PackOutData 0 Channel 3 Unpack Output Data PowerBrick 0...

Page 121: ...is a good point of the setup to consider scaling the motor to user engineering units using Motor PosSf and Motor Pos2Sf Scaling to user engineering units is advantageous because it allows jogging the...

Page 122: ...uld cause the motor the move or jump if it has not been set up The abort input must be wired in 24 VDC or disabled in software Sys pAbortAll 0 prior to attempting to enable the motor If the 24 VDC abo...

Page 123: ...move or jump if it has not been set up The abort input must be wired in 24 VDC or disabled in software Sys pAbortAll 0 prior to attempting to enable the motor If the 24 VDC abort input is not wired in...

Page 124: ...ensors FFF00000 e g For 14 bit current sensors FFFC0000 Motor 1 AdcMask FFF00000 Motor 2 AdcMask FFF00000 Motor 3 AdcMask FFF00000 Motor 4 AdcMask FFF00000 Motor 5 AdcMask FFF00000 Motor 6 AdcMask FFF...

Page 125: ...Manual Manual Motor Setup 125 Activate the Motors Activate Motors Motor 1 ServoCtrl 1 Motor 2 ServoCtrl 1 Motor 3 ServoCtrl 1 Motor 4 ServoCtrl 1 Motor 5 ServoCtrl 1 Motor 6 ServoCtrl 1 Motor 7 Servo...

Page 126: ...age 170 Motor 4 DC rated voltage VDC User Input GLOBAL Mtr5DCVoltage 170 Motor 5 DC rated voltage VDC User Input GLOBAL Mtr6DCVoltage 170 Motor 6 DC rated voltage VDC User Input GLOBAL Mtr7DCVoltage 1...

Page 127: ...h e g 60 96 mm RESmm is the linear encoder resolution a k a pitch in the same unit as the ECL e g 1 m 0 001 mm ResPolePairs is the resolver number of pole pairs Quadrature Encoder Motor pPhaseEnc Powe...

Page 128: ...tor PhasePosSf 2048 NoOfPolePairs 212 2ST Linear Motor PhasePosSf 2048 RESmm 212 ECLmm Example A serial encoder with 36 bits of single turn ST position data located in serial data A and B registers co...

Page 129: ...20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Multi Turn Position Data Single Turn Position Data PowerBrick Chan SerialEncDataB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10...

Page 130: ...rect settings cause Power PMAC to detect high current values and it may take some time even after the settings have been corrected for the integrated values to decay to permit the amplifier to be enab...

Page 131: ...ser Input Motor 1 MaxDac Ch1RmsPeakCur 40132 44 Ch1MaxAdc Motor 1 I2TSet Ch1RmsContCur 40132 44 Ch1MaxAdc Motor 1 I2tTrip POW Motor 1 MaxDac 2 POW Motor 1 I2TSet 2 Ch1TimeAtPeak If the motor current l...

Page 132: ...If this is already performed on the amplifier side then it is not needed here Otherwise the current null or offsets finding period is set in terms of phase cycles Typical setting of 1000 cycles at 10...

Page 133: ...and rough phasing are typically in the range of Motor x I2TSet 2 Magnitude Motor x I2TSet This allows enough current to overcome static non linear components for a good response without the risk of o...

Page 134: ...for most applications With higher performance motors e g linear the current loop s natural frequency can be pushed higher However tightening the current loop with a lower performance system could hav...

Page 135: ...Controller supports a variety of phase referencing techniques Unless the motor phase offset is known mechanically from the motor encoder halls assembly manufacturer uncommon and may be inconsistent se...

Page 136: ...motor The following table is a summary of the suggested phasing method to use with respect to each type of feedback device Type of Feedback Device Initial Phasing Getting Started Final Implementation...

Page 137: ...being a valid search Typically set to 1 5th of a commutation cycle 2048 5 Motor PowerOnMode specifies whether a search move is applied on power up This is not advised with the automatic stepper phasi...

Page 138: ...The motor should lock into a position and exhibit some stiffness when trying to move it by hand 4 Increase Motor IbBias as necessary until the motor is locked tightly Exceeding the value of Motor I2TS...

Page 139: ...ve starting estimate Motor I2TSet 2 MtrxPhaseAPos is the actual position of the motor when locked on to phase A MtrxPhaseBPos is the actual position of the motor when locked on to phase B MtrxPhasingD...

Page 140: ...IaBias Mtr1PhasingMag Motor 1 IaBias 1 Motor 1 IbBias 0 CALL Timer 0 001 CALL Timer 2 WHILE ABS Motor 1 FltrVel 5 Mtr1PhaseAPos ABS Motor 1 ActPos Motor 1 HomePos CALL Timer 0 250 WHILE Motor 1 IbBias...

Page 141: ...tuning utility in the IDE software The test amplitude depends on the load gearing of the motor Conservative values between 1 10 are good starting estimates The test time is typically under 500 msec n...

Page 142: ...he response plot as a velocity saw tooth A successful open loop test response looks like Open loop Test Troubleshooting Tips The open loop test can fail in two ways Motor cogs to a phase locks up Plot...

Page 143: ...ype is always set to PWM The simple auto tune is self explanatory move the slide left for a slower natural frequency and right for a higher natural frequency Checking the enable feedforward box will a...

Page 144: ...ing all the gains used in the servo algorithm various pre configured command profiles and filter tools The two most common move profiles used in tuning are Step and Parabolic Interactive Tuning An acc...

Page 145: ...se would look like Desirable characteristics to note following error green curve above centered about 0 with minimal amplitude Note With higher resolution encoders the Motor x Servo MaxPosErr may need...

Page 146: ...ibed in the examples below configured and saved issuing a n or Motor PhaseFindingStep 1 will initiate the absolute phasing computation A successful operation sets the Motor PhaseFound bit of the motor...

Page 147: ...120 60 0 60 Setting up digital Hall Effect sensors absolute phasing requires The motor to be phased initially using the stepper manual technique Moving the motor either by hand or with jog commands Mo...

Page 148: ...or PhasePos and the corresponding PowerBrick Chan UVW should produce the following 2048 12 If the transition is 1 3 Motor AbsPhasePosSF 2048 12 If the transition is 3 1 Motor AbsPhasePosOffset is equa...

Page 149: ...project as well as in the PMAC PTR Ch1Halls PowerBrick 0 Chan 0 UVW OPEN PLC HallsPLC Motor 1 AbsPhasePosSF 0 Motor 1 AbsPhasePosOffset 0 Check Direction WHILE Motor 1 AbsPhasePosSF 0 IF Ch1Halls 1 W...

Page 150: ...d position loop tuning then come back for hall phasing correction Note Hall phasing correction requires homing the motor The following are the necessary steps to implement the hall phasing correction...

Page 151: ...a rotary motor ShiftBits is typically the starting bit in Serial Data Register A ECLmm is the linear motor electrical cycle length or magnetic pitch e g 60 96 mm RESmm is the linear encoder resolutio...

Page 152: ...ording the 17 bits of position data PhaseForcePos PowerBrick Chan SerialEncDataA 00001FFF Example A serial encoder with 20 bits of single turn position data located in serial data A register and start...

Page 153: ...PhaseForceTest value can be found by performing a manual force phasing locking the motor onto phase B and recording 32 bits of position data serial data register A PhaseForcePos PowerBrick Chan Serial...

Page 154: ...Turn Position Data Single Turn Position Data PowerBrick Chan SerialEncDataB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Motor pAbsPhasePos PowerBrick Chan Ser...

Page 155: ...PolePairs is the number of pole pairs of a rotary motor ResPolePairs is the resolver number of pole pairs Motor AbsPhasePosOffset PhaseForceTest Motor AbsPhasePosSf Where PhaseforceTest is the value r...

Page 156: ...ove or jump if it has not been set up The abort input must be wired in 24 VDC or disabled in software Sys pAbortAll 0 prior to attempting to enable the motor If the 24 VDC abort input is not wired in...

Page 157: ...ck 1 Chan 3 Status a Amplifier Fault Level This varies with amplifier Motor 1 AmpFaultLevel 1 Motor 2 AmpFaultLevel 1 Motor 3 AmpFaultLevel 1 Motor 4 AmpFaultLevel 1 Motor 5 AmpFaultLevel 1 Motor 6 Am...

Page 158: ...E software has the ability to configure this automatically in its final step of configuring a non commutated motor One can also perform the calibration manually with the following procedure Issue a no...

Page 159: ...be used In torque control mode the result of the position velocity servo loop is output to the amplifier typically through a D A converter circuit with an output range of 10V corresponding to the full...

Page 160: ...ity in the IDE software The test amplitude depends on the load gearing of the motor Conservative values between 1 10 are good starting estimates The test time is typically under 500 msec nominally 100...

Page 161: ...g in the negative direction This is typically observed in the response plot as a velocity saw tooth A successful open loop test response looks like Open loop test troubleshooting tips The open loop te...

Page 162: ...ype is always set to PWM The simple auto tune is self explanatory move the slide left for a slower natural frequency and right for a higher natural frequency Checking the enable feedforward box will a...

Page 163: ...ing all the gains used in the servo algorithm various pre configured command profiles and filter tools The two most common move profiles used in tuning are Step and Parabolic Interactive Tuning An acc...

Page 164: ...se would look like Desirable characteristics to note following error green curve above centered about 0 with minimal amplitude Note With higher resolution encoders the Motor x Servo MaxPosErr may need...

Page 165: ...has not been set up The abort input must be wired in 24 VDC or disabled in software Sys pAbortAll 0 prior to attempting to enable the motor If the 24 VDC abort input is not wired in or is not disable...

Page 166: ...as follows PWM Frequency Resolution Ripple The higher the PWM frequency the lower is the resolution with a low ripple signal output The lower the PWM frequency the higher is the resolution with a high...

Page 167: ...l This varies with amplifier Motor 1 AmpFaultLevel 1 Motor 2 AmpFaultLevel 1 Motor 3 AmpFaultLevel 1 Motor 4 AmpFaultLevel 1 Motor 5 AmpFaultLevel 1 Motor 6 AmpFaultLevel 1 Motor 7 AmpFaultLevel 1 Mot...

Page 168: ...be used In torque control mode the result of the position velocity servo loop is output to the amplifier typically through a D A converter circuit with an output range of 10V corresponding to the full...

Page 169: ...The IDE software has the ability to configure this automatically in its final step of configuring a non commutated motor One can also perform the calibration manually with the following procedure Iss...

Page 170: ...ity in the IDE software The test amplitude depends on the load gearing of the motor Conservative values between 1 10 are good starting estimates The test time is typically under 500 msec nominally 100...

Page 171: ...his is typically observed in the response plot as a velocity saw tooth A successful open loop test response looks like Open loop test troubleshooting tips The open loop test can fail in two ways Motor...

Page 172: ...ype is always set to PWM The simple auto tune is self explanatory move the slide left for a slower natural frequency and right for a higher natural frequency Checking the enable feedforward box will a...

Page 173: ...ing all the gains used in the servo algorithm various pre configured command profiles and filter tools The two most common move profiles used in tuning are Step and Parabolic Interactive Tuning An acc...

Page 174: ...se would look like Desirable characteristics to note following error green curve above centered about 0 with minimal amplitude Note With higher resolution encoders the Motor x Servo MaxPosErr may need...

Page 175: ...s AMP1 AMP8 Pins 5 6 13 and 14 of the encoder feedback connectors X1 X8 share three different functions only one of these functions per channel can be used configured in software at one time Pulse and...

Page 176: ...f speed for signal quality due to quantization noise and jitter 2 Compute the minimum possible pulse width for the chosen max frequency 3 Choose a pulse width greater than or equal to the computed min...

Page 177: ...ng an External Stepper Amplifier Motor Closing the loop or jogging a motor driven by an external amplifier requires the following settings Example for Channel 1 Motor 1 The MaxDac computed empirically...

Page 178: ...e for voltage biases in the encoder and or receiving circuitry Excessive biases due to scale read head misalignment noise or mechanical assembly may result in rough motion visible velocity harmonics a...

Page 179: ...erBrick 0 Chan 2 AdcEnc 1 GLOBAL Enc3SineOffset 0 Enc3CosineOffset 0 PTR Enc4Sine PowerBrick 0 Chan 3 AdcEnc 0 PTR Enc4Cosine PowerBrick 0 Chan 3 AdcEnc 1 GLOBAL Enc4SineOffset 0 Enc4CosineOffset 0 PT...

Page 180: ...Enc2Sine MaxEnc2Cosine Enc2Cosine MinEnc2Cosine Enc2Cosine IF Enc2Sine MaxEnc2Sine MaxEnc2Sine Enc2Sine IF Enc2Sine MinEnc2Sine MinEnc2Sine Enc2Sine IF Enc2Cosine MaxEnc2Cosine MaxEnc2Cosine Enc2Cosi...

Page 181: ...5Sine MaxEnc5Cosine Enc5Cosine MinEnc5Cosine Enc5Cosine IF Enc5Sine MaxEnc5Sine MaxEnc5Sine Enc5Sine IF Enc5Sine MinEnc5Sine MinEnc5Sine Enc5Sine IF Enc5Cosine MaxEnc5Cosine MaxEnc5Cosine Enc5Cosine I...

Page 182: ...ENCODER 7 BIAS CORRECTIONS IF SineCycles 0 MaxEnc7Sine Enc7Sine MinEnc7Sine Enc7Sine MaxEnc7Cosine Enc7Cosine MinEnc7Cosine Enc7Cosine IF Enc7Sine MaxEnc7Sine MaxEnc7Sine Enc7Sine IF Enc7Sine MinEnc7...

Page 183: ...nc4CosineOffset 65536 Channel 4 Cosine Offset PowerBrick 1 Chan 0 AdcOffset 0 Enc5SineOffset 65536 Channel 5 Sine Offset PowerBrick 1 Chan 0 AdcOffset 1 Enc5CosineOffset 65536 Channel 5 Cosine Offset...

Page 184: ...using resolver or halls absolute power on phasing Motor AbsPhasePosSf present value Motor AbsPhasePosOffset 2048 present value If using resolver absolute power on position Motor AbsPosSf present valu...

Page 185: ...User Manual Special Functions Troubleshooting 185 Note For non commutated motors with 10V output it is best to simply swap the DAC and DAC leads going into the amplifier Then changing the encoder deco...

Page 186: ...imer subprogram and specifying a time argument in seconds causes the desired delay in a script PLC example Note The Timer subprogram can be called from motion programs or other subprograms as well How...

Page 187: ...ultimately that the motor is losing counts which could result in a fatal following error erroneous commutation or position drift over time Common root causes of the encoder count error Encoder problem...

Page 188: ...al position of the motor is usually it thinks it is stuck and it can react wildly often causing a runaway condition The Power Brick Controller has circuitry dedicated to monitoring the presence of a p...

Page 189: ...tatus 0 in normal mode 1 and latched upon detecting an encoder loss Automatic Kill Action for Quadrature Encoders Arming the automatic kill action with quadrature encoders In this mode the status of t...

Page 190: ...e status bit PowerBrick Chan SosError is automatically set to 1 Automatic Kill Action for Sinusoidal Resolver HiperFace Encoders Arming the automatic kill action with Sinusoidal Resolver or HiperFace...

Page 191: ...e data set was valid or not This is particularly recommended for the SSI protocol where the data patterns cannot be used to detect a timeout error For the SSI protocol the parity error flag is bit 31...

Page 192: ...er rate The following PLC depicts the digital tracking filter equations and produces the three indexes necessary to apply the filter in the corresponding Encoder Conversion Table GLOBAL TrackFltrCutOf...

Page 193: ...equency and 1 damping ratio will produce These index values copied into EncTable index1 EncTable index2 and EncTable index4 respectively will apply the desired filtering Note If these indexes are non...

Page 194: ...In normal mode operation the circuit is open and PTC pin 8 is pulled up to 5 VDC internally this corresponds to a setting of 1 in software If the motor is overheated the circuit is closed and PTC pin...

Page 195: ...on WD Watchdog Green Normal Mode Operation Red Fault Watchdog MACRO Link MACRO Green MACRO connected Operational Red MACRO not connected Ring broken RDY WD Ready Watchdog Green PMAC Ready Boot Complet...

Page 196: ...ll the latest firmware through the IDE click on Delta Tau Configure Download Firmware Under the PowerPMAC Firmware tab click the Download Firmware button On clicking the button the IDE will ask whethe...

Page 197: ...lename should be powerpmac deb Wait for the IDE to finish downloading the firmware file and then for Power PMAC to reboot If it does not reconnect successfully after rebooting click Communication Setu...

Page 198: ...stick SD Card to a PC using any OS which can work with FAT32 partition Create a folder named PowerPmacFirmwareInstall on the USB memory stick SD Card root folder Place the installation package powerp...

Page 199: ...the IDE click Tools Options Near the bottom of the screen in the left pane click PowerPMAC Network Settings and then the following window should appear On this window enter the NewIPAddress desired Y...

Page 200: ...etwork settings follow these steps 1 Modify the interfaces file created by Power PMAC under PowerPmacIP folder by connecting the USB memory stick SD Card on PC opening the file using any text editor w...

Page 201: ...tings Method 2 to be used when not communicating Connect a USB memory stick or SD Card to a PC using any OS which can work with FAT32 partition Create a folder named PowerPmacFactoryReset on the USB m...

Page 202: ...ce the Real Time Interrupt time i e set Sys RtIntPeriod higher reduce the servo phase clock rates or optimize your programming If the Watchdog problem is intermittent you may have a loading spike due...

Page 203: ...Power Brick Controller User Manual Appendix A Digital Inputs Schematic 203 APPENDIX A DIGITAL INPUTS SCHEMATIC...

Page 204: ...Power Brick Controller User Manual Appendix B Digital Outputs Schematic 204 APPENDIX B DIGITAL OUTPUTS SCHEMATIC...

Page 205: ...Power Brick Controller User Manual Appendix C Analog I Os Schematics 205 APPENDIX C ANALOG I OS SCHEMATICS...

Page 206: ...Power Brick Controller User Manual Appendix C Analog I Os Schematics 206...

Page 207: ...Power Brick Controller User Manual Appendix D Limits Flags Schematic 207 APPENDIX D LIMITS FLAGS SCHEMATIC...

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