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Delta Tau 3Ax-602646-xUxx manual

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  • Page 1

    ^1 HARDWARE REFERENCE MANUAL ^2 Quad Amp ^3 4-Axis Digital Amplifier ^4 3Ax-602646-xUxx ^5 September 24, 2003 Single Source Machine Control Power // Flexibility // Ease of Use 21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com[...]

  • Page 2

    Copyright Information © 2003 Delta Tau Data Systems, Inc. All rights reserved. This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses are unauthorized without written permission of Delta Tau Data Systems, Inc. Information contained in this manual may be updated from time-to-time due to prod uct improvements, etc., [...]

  • Page 3

    Quad Amp Hardware Reference Manua l Table of Contents i Table of Contents INTRODUCTION ................................................................................................................... .................................... 1 Related Technical Doc umentation ...........................................................................[...]

  • Page 4

    Quad Amp Hardware Reference Manua l Table of Contents i i Jumpers, Potentiometers, Te st Points, and LEDs ................................................................................. .............. 21 Grounding ...................................................................................................................... ...............[...]

  • Page 5

    Quad Amp Hardware Reference Manua l Introduction 1 INTRODUCTION The Delta Tau Data Systems, Inc. 4-axis Digital Amplifier (Quad Amp) is a highly compact digital amplifier and power supply, packaged together to provide four axes of bi-directional (four quadrant) torque control for a variety of AC or DC brushl ess or AC induction motors. All control [...]

  • Page 6

    Quad Amp Hardware Reference Manua l Introduction 2 Quad Amp Basic Specifications Physical Specifications Size ( See Figure 1 ) • Height: 22.0 Inches • Width: 10.5 Inches • Length: 5.125 Inches (without mounting optio n) 9.031 Inches (with mounting option) Weight • 60 lb. (27.3 kg) Temperature Storage: -20 degrees C to +85 degrees C Operatin[...]

  • Page 7

    Quad Amp Hardware Reference Manua l Introduction 3 Main DC bus Voltage 170 VDC ( 120 VAC line i nput) (L1, L2) 300 VDC ( 208 VAC line i nput) (L1, L2, L3) 325 VDC ( 230 VAC line i nput) (L1, L2, L3) For dem o only Internal Shunt Resistor Resistance 15 Ohm Resistor power 1.8 kW External Shunt Resistor (Optional) Resistance 8.5 Ohm Resistor power 2.8[...]

  • Page 8

    Quad Amp Hardware Reference Manua l Introduction 4 USE 1/ 4- I NCH MOUNTIN G HARDWARE ( 4 PL AC ES ) AIR FL OW Figure 1 Quad Amp Specifications Output Specifications for 120/208/230 VAC Amplifier Up to four blocks (options) can be selected in an y power combination. The total power cannot exceed 33 HP. Note: When 30HP is selected only two additiona[...]

  • Page 9

    Quad Amp Hardware Reference Manua l Introduction 5 Opt 5 Opt 6 Opt 7 Opt 8 Opt 9 Opt 10 Opt 11 Opt 12 Opt 13 Opt 14 Continuous HP(100%) 0.75 HP 0.56 kW 1.5 HP 1.1 kW 2 HP 1.5 kW 3 HP 2.2 kW 5 HP 3.7 kW 7.5 HP 5.6 kW 10 HP 7.5 kW 15 HP 11 kW 20 HP 15 kW 30 Hp 22.5 kW Continuous current (RMS) 2 A 4 A 5 A 7 A 15 A 20 A 25 A 35 A 50 A 75 A Continuous 2[...]

  • Page 10

    Quad Amp Hardware Reference Manua l Introduction 6 Protection There are several layers of protection built into the am plifier, including transient voltage filters, transient surge suppressors, fuses, a flyback diode, and a variety of fault detection circuits. These are discussed in the following paragraphs and in the Troubleshooting Chapter. Trans[...]

  • Page 11

    Quad Amp Hardware Reference Manua l Introduction 7 Configurable Options Each Quad Amplifier is shipped with an Identifi cation Tag (see Figure 1). The identification tag is attached to the top panel of the Quad Amplifier. It indicates the rating of each axis, the AC operating voltage, and the control input voltage. Since every Qu ad Am plifier is a[...]

  • Page 12

    Quad Amp Hardware Reference Manua l Introduction 8 Accessories Item Description Note 3A1-602582-100 Circuit Break er 50 Amps 450 V AC 3 Phase With extern al trip 3A2-602582-100 Circuit Break er 70 Amps 250 V AC 3 Phase N A 200-602739-02 4 PWM I nput Cables 36” long cable with DB36 pin mini connectors at each end Two require d per Acc-8F. Connects[...]

  • Page 13

    Quad Amp Hardware Reference Manua l Getting Started 9 GETTING STARTED Receiving and Handling Inspection up on Receipt Upon the receipt of equipment, inspect all mercha ndise for any indication of damage that may have incurred during shipping and handli ng. If any items are dam aged, do not accept them until the freight carrier makes an appropriate [...]

  • Page 14

    Quad Amp Hardware Reference Manua l Getting Started 1 0 Heat Dissipation The external mounting options (Opt3, Opt3A and Opt 3B) allow the Quad Amplifier to be installed inside a cabinet, with the Quad Amplifier h eat sink mounted external to the cabinet or in an air plenum . In the case of Opt 3B, provide good air circulation, in a plen um, with a [...]

  • Page 15

    Quad Amp Hardware Reference Manua l Theory of Operatio n 11 THEORY OF OPERATION Operation The Quad Amplifier is a universal 4-axis 3-phase di rect PWM drive which utilizes the latest in smart power technology from the world’s leading vendors a nd the cutting edge algorith ms of the new PMAC2 controller family. The Quad Amplifier is capable of dri[...]

  • Page 16

    Quad Amp Hardware Reference Manua l Theory of Operation 12 Current Sense Board The Current Sense Board has eight Hall Effect (LEM ) modules for current sense and eight on-board A/D converters that transform four channels of motor current to di gital form. Each channel provides information on two phases (A phase and B phase). The third phase is math[...]

  • Page 17

    Quad Amp Hardware Reference Manua l Theory of Operatio n 13 Heat Dissipation The capability of the Quad Amplifier and the IGBT m odules is based upon the heat they can dissipate; the more quickly heat can be removed from the IGBT m odule, the more current it can handle. Heat is created whenever an IGBT is turned on or off. These transitions are cal[...]

  • Page 18

    Quad Amp Hardware Reference Manua l Theory of Operation 1 4[...]

  • Page 19

    Quad Amp Hardware Reference Manua l Installation 15 INSTALLATION Wiring the Quad Amplifier System Quad Amplifier Channel Connections The Quad Amplifier channels must be connected in a particular order for proper operation. It is essential that the timing of all signals associated with the Quad Amplifier logic board shares the ADC converter clocks f[...]

  • Page 20

    Quad Amp Hardware Reference Manua l Installation 1 6 Non-Standard Quad Amplifier Setup This example shows the Quad Amplifier setup with PMAC axes 1, 2, 7, and 8 are connected to first Quad Amplifier #1 and PMAC Axes 3, 4, 5 and 6 are conne cted to first Quad Amplifier #2. Since first Quad Amplifier channels 1-2 and 3-4 share ADC clock signa ls, the[...]

  • Page 21

    Quad Amp Hardware Reference Manua l Installation 17 CONNECT TO A C C- 8 F MOT OR GROUNDS 1 23 4 WWWW VVVV UUUU MOTOR CABLES AXIS 1 AXIS 2 AX IS 3 AXIS 4 MOT OR OVERTEMP CONNE CTOR AXIS 1 AXIS 3 AXIS 4 AXIS 2 CONTRO L AC VOL T AGE EXTERNAL GROUN D FA U LT T R I P E- STOP/ READY BUS+ SHUNT BUS- CHASSIS GROUN D L3 L2 L1 OPTIO NAL EXTE RNAL SHUNT C1 C2[...]

  • Page 22

    Quad Amp Hardware Reference Manua l Installation 18 Pin# Symbol Function Description Notes 1 Fc_A1 Input 2 Fc_C1 Input 3 Clk0+ Input A/D Conve rt Clock 4 Conv ert0+ Input A/D Convert Strobe 5 Atddaa1+ Output Chan A ADC Serial Data 6 Atddab1+ Output Chan B ADC Serial Data 7 Aena1+ Input Amp Enable Positive Enable 8 Fault1+ Out put Amp Fault Negative[...]

  • Page 23

    Quad Amp Hardware Reference Manua l Installation 19 Figure 7 Quad Amp Main Circuit Wiring Diagram Main AC Input Power Connect desired main input power to input terminal s marked L1, L2, and L3 (see Figure 7). The power ground can be connected at the terminal marked CHAS GND or at the grounding screw, marked E, located on the end panel of the Quad A[...]

  • Page 24

    Quad Amp Hardware Reference Manua l Installation 2 0 For 460 VAC Operation Jump pin 4 to pin 5. Power is applied to pins 1 and 8 via AC input connector C3. For 480 VAC Operation Jump pin 4 to pin 5 and pin 8 to pin 9. Power is a pplied to pins 1 and 10 via AC input co nnector C3. Figure 8 120V/208V/230V Quad Amplifi er Transformer T201 Schem atic D[...]

  • Page 25

    Quad Amp Hardware Reference Manua l Installation 21 Bus Power Enable/Emergency Stop CAUTION: Any wiring should be attempted only after th e drive has been isol ated from the main AC supply and 10 to 12 minutes has elapsed to allow the internal bus capacitors to discharge. The normally open (NO) Main AC Contactor auxiliary contacts must be wired and[...]

  • Page 26

    Quad Amp Hardware Reference Manua l Installation 22 12 3 3 2 1 Figure 10 Logic I/O Board Jumper and L ED Locations Name Position Description Default E1-E4 IN Shield To Local Ground Open OUT E7 IN Do Not Use Ope n OUT E8 IN Enable Shunt Tran sistor In Module Open OUT E9 IN Enable Shunt Tran sistor In Module Open OUT E10 IN Do Not Use Open OUT E28 IN[...]

  • Page 27

    Quad Amp Hardware Reference Manua l Installation 23 Figure 11 Current Sense Board Jumper and LED Locations Name Position Description Default E1A-E4A IN Enable Serial Fault Data, Phase A Open OUT E1B-E4B IN Enable Serial Fault Data, Phase B Open OUT E5 IN Clock Polari ty 2 and 3 J umpered OUT E6 IN Convert Polarity 2 and 3 Jumpered OUT LED Symbol De[...]

  • Page 28

    Quad Amp Hardware Reference Manua l Installation 2 4 Figure 62 Soft Start Board Jumper, Potent iometer, Test Point, and LED Locations Name Position Description Default E1 1- 2 jumper Inte rnal Power Suppl y Connection 2-3 open JP6 Jumper E-Stop Configurat ion JP7 Jumper E-Stop Configurat ion Symbol` Description Tp Factory Set Notes R4 & TP5 Hig[...]

  • Page 29

    Quad Amp Hardware Reference Manua l Installation 25 Grounding General It is important to follow some precautions to avoi d ground loops or unwanted electrical noise disturbances. • All signal cables must be shielded. • Two or more power wires in the same sleeve must be twisted and shielded. • A shield that does not carry current can be connec[...]

  • Page 30

    Quad Amp Hardware Reference Manua l Installation 2 6 Note: The Quad Amplifier has a built-in protecti on against accidentally setting I900 (PWM frequency) too high, and exceeding the P WM input f requency rating of the power blocks. I9n6 For machine interface channel n, I9n6 must be set to 0 to select PWM output format. If i9n6 is set to 1 or 3 whi[...]

  • Page 31

    Quad Amp Hardware Reference Manua l Installation 27 During this tuning process, P2Setup also determin es the commutation parameters and commands the PMAC appropriately. Power Block Option Continuous Hp Continuous Current (A) Peak Current 2 Sec (A) Max ADC Value 208/230 VAC 5 0.75 2 5 6.25 6 1.5 4 11 13.75 7 2 5 15 18.75 8 3 7 21 26.25 9 5 15 36 45 [...]

  • Page 32

    Quad Amp Hardware Reference Manua l Installation 28[...]

  • Page 33

    Quad Amp Hardware Reference Manua l Troubleshoot i ng 29 TROUBLESHOOTING Logic Fault Detection and Fault Codes The Quad Amplifier is capable of detecting and repo rting a variety of fault conditions. These conditions are broken into two types: axis-specific and global. Axis-Specific Faults This type of fault is related to one axis only a nd typical[...]

  • Page 34

    Quad Amp Hardware Reference Manua l Troubleshoot ing 3 0 Note: Jumpers E1A, E1B, E2A, E2B, E3A, E3B, E4A, E4B must be installed on the current sense board so that the 4-bit faul t code can be accessed at PMAC2 Gate Array Registers. Once such a condition occurs, the PLC notifies the u ser with an on-screen message and then disables itself. Note that[...]

  • Page 35

    Quad Amp Hardware Reference Manua l Troubleshoot i ng 31 In the case of multiple axis-specific faults on one ax is, the higher-numbered fault shall be indicated. In the case of axis-specific faults on multiple axes, the axis with the higher-numbered fault shall be displayed along with the decimal point indicting its a xis number. In the case of axi[...]

  • Page 36

    Quad Amp Hardware Reference Manua l Troubleshoot ing 32 Motor moves after a command is issued but under volt age fault comes on sh ortly after. Also, the Soft Start resistor heats up (and possibly b urns). Verify if the bus voltage sags when the motor is c ommanded t o move. The Main IGBT probably do es not turn on. Check if the wiring between E1 a[...]

  • Page 37

    Quad Amp Hardware Reference Manua l Illustrated Repair Parts List 33 ILLUSTRATED REPAIR PARTS LIST Purpose This chapter contains the Repair Parts List (RPL) for the 4-Axis Digital Amplifier (Quad Amplifier ). The RPL identifies the customer replaceable units (CRUs) of Quad Amplifier with an illustration and a Group Assembly Parts List (GAPL). Scope[...]

  • Page 38

    Quad Amp Hardware Reference Manua l Illustrated Repair Parts List 3 4 Figure 12 Delta Tau Data Systems 4 Axis Digital Amplifier[...]

  • Page 39

    Quad Amp Hardware Reference Manua l Illustrated Repair Parts List 35 Figure And Index Number Part Number Description 1 2 3 4 5 6 7 Qty Per Assy Manu- facturer Part Number 7-1 500-602645-103 QUAD Digital Amplifier (Top Assy) Delta Tau -10 300-602761-103 PCBA, Lo gic I/O 1 Delta Tau -20 400-6028 00-103 Soft Start Assy 1 Delta Tau -30 300-60267 7-102 [...]

  • Page 40

    Quad Amp Hardware Reference Manua l Illustrated Repair Parts List 3 6 Figure And Index Number Part Number Description 1 2 3 4 5 6 7 Qty Per Assy Manu- facturer Part Number -270 014-030 M03- HSM 3 Pos. Pl ug (P2) 1 Amp 1- 480700-0 -280 014-00 MF04- 0HM 4 Pos. Pl ug P3) 1 Amp 1-480702-0 -290 300-603 001-100 Mov Assy 230V AC 600V (for standard po wer [...]