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Delta Tau 5xx-603869-xUxx manual

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  • Page 1

    125 ^1 HARDWARE REFERENCE MANUAL ^2 Brick Motion Controller ^3 Programmable Servo Amplifier ^4 5xx-603869-xUxx ^5 May 2, 2007 Single Source Machine Control Power // Flexibility // Ease of Use 21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com[...]

  • Page 2

    Copyright Information © 2007 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 Da ta Systems, Inc. Information contained in this manual may be updated from time-to-time due to pro duct im provements, etc.[...]

  • Page 3

    After removing the power source from the equipment, wait at least 10 minutes before touching or disconnecting sections of the equipment that norm ally carry electrical charges (e. g., capacitors, contacts, screw connections). To be safe, measure the electri cal contact points with a meter before touching the equipment. The following text formats ar[...]

  • Page 4

    [...]

  • Page 5

    REVISION HISTORY REV. DESCRIPTION DATE CHG APPVD 1 MANUAL CREATION 05/02/07 CP S. MILICI[...]

  • Page 6

    [...]

  • Page 7

    Brick Motion Controller Hardware Refere nce Manual Table of Contents i Table of Contents 125 ................................................................................................................................................................................. I Copyright Inform ation ......................................................[...]

  • Page 8

    Brick Motion Controller Hard wa re Reference Manual ii Table of Contents APPENDIX B ............................................................................................................................................................. 38 Schematics...............................................................................................[...]

  • Page 9

    Brick Motion Controller Hardware Refere nce Manual Introduction 1 INTRODUCTION The Brick Motion Controller is a fully scaleable automation controller utilizing the intelligence and capability of its embe dded Turbo PMAC2. With the ability to store programs locally and built-in PLC execution, it is programmable for virtually any kind of automation a[...]

  • Page 10

    Brick Motion Controller Hard wa re Reference Manual 2 Introduction • Primary encoder for each axis with TTL differen tial/single-ended inputs with A, B quadrature channels and C index channel, 10 MHz cycl e rate, and digital Hall-effect inputs • Five flags per axis using DB-25: HOME, PLIM, MLIM and USER inputs; EQU compare • Optional analog i[...]

  • Page 11

    Brick Motion Controller Hardware Refere nce Manual Specifications 3 SPECIFICATIONS Part Number Numbe r o f Axe s 4: Four Ax es ( Default ) 8: Eight Ax es Brick Controll er Mode l Numbe r De finitio n BC4 - C0 - F00 - 000 – ( 00 0 0 ) C P U Op tio ns - Tur bo PM A C 2 Pro cessor C0 : 80Mhz , 8K x24 I nter nal , 256 Kx24 SRA M, 1MB F lash ( Def aul[...]

  • Page 12

    Brick Motion Controller Hard wa re Reference Manual 4 Specifications Analog I/O Options • Two 16-bit analog inputs • Four 16-bit analog inputs Communication Options • DPRAM option, size 32K x 16-bit wide (required for use with NC software) • ModBus Ethernet Communication Protocol (Software) option • DPRAM and Modbus options combined • R[...]

  • Page 13

    Brick Motion Controller Hardware Refere nce Manual Specifications 5 RECEIVING AND UNPACKING Delta Tau products are thoroughly tested at the factor y and carefully packaged for shipm ent. When the Brick Motion Controller is received, there are seve ral steps that should be performed immediately: 1. Observe the condition of the shipping contai ner an[...]

  • Page 14

    Brick Motion Controller Hard wa re Reference Manual 6 Specifications[...]

  • Page 15

    Brick Motion Controller Hardware Refere nce Manual System Wiring 7 SYSTEM WIRING WARNING: Installation of electrical control equipment is subject to many regulations including national, state, local, and industry guidel ines and rules. General recommendations can be stated but it is important that th e installation be carried out in accordance with[...]

  • Page 16

    Brick Motion Controller Hard wa re Reference Manual 8 System Wiring Connectors X1-X8: Encoder Input (1 to 8) The main encoder input channels for the Brick Motion Controller support onl y differential quadrature feedback. 5V supply to power the encoder is provided. • 4-axis drives with no Option 01 or Option 02 have only X1 to X4, for a total of f[...]

  • Page 17

    Brick Motion Controller Hardware Refere nce Manual System Wiring 9 X9-10: Analog I/O Ch5 (X9) and Ch6 (X10), (Optional) X9/10 (Female DB-9 Connector) Pin # Symbol Function Notes 1 AGND Comm on 2 ADC5/6+ Input 16 -bit Analog Input, c hannel 5/6+ * 3 4 5 6 ADC5/6- Input 16-bit Analo g Input, channel 5/6+ * 7 8 9 For spacing specifications between the[...]

  • Page 18

    Brick Motion Controller Hard wa re Reference Manual 10 System Wiring X13: USB 2.0 Connector This connector is used in conjunction with US B A-B cable, which can be purchased from any local computer store and is provided when Option 1A is orde red. The A connector is connected to a PC or Hub device; the B connector plugs into the J9-USB port. X14: R[...]

  • Page 19

    Brick Motion Controller Hardware Refere nce Manual System Wiring 11 TB1: Power Connector The TB1 connector at the bottom panel allows the user to supply 24V DC power for the Brick Controller. Watchdog (TB1) (Phoenix 3-pin Terminal Block) 1 2 3 TB- 5: 016-P L 0F05-3 8P Pin # Symbol Function Notes 1 +24VDC Input 2 Chassis GND Input 3 +24V return Inpu[...]

  • Page 20

    Brick Motion Controller Hard wa re Reference Manual 12 System Wiring J4 Limit Inputs (1-4 Axis) The Brick Motion Controller limit and flag circuits give the flexibility to wire in standard 12V to 24V limits and flags or wire in 5V level limits and flags on a channe l basis. The default is set for the standard 12V to 24V inputs, but if the resistor [...]

  • Page 21

    Brick Motion Controller Hardware Refere nce Manual System Wiring 13 J5 Limit Inputs (5-8 Axis) The Brick Motion Controller limit and flag circuits gi ve the flexibility to wire in standard 12V to 24V limits and flags or wire in 5V level limits and flags on a channel basis. The default is set for the standard 12V to 24V inputs, but if the resistor p[...]

  • Page 22

    Brick Motion Controller Hard wa re Reference Manual 14 System Wiring A sample of the positive limit circuit is shown below. The 4.7K resistor packs used will allow 12-24V flag inputs. If 0-5V flags are used, then a 1K Ω resistor pack (RP) can be placed in: Flags 1-4: RP39 (channel 1), RP43 (channel 2) , RP 47 (channel 3), RP51 (channel 4) Flags 5[...]

  • Page 23

    Brick Motion Controller Hardware Refere nce Manual System Wiring 15 AMP1-AMP8: Amplifier connections (1 to 8) AMP1-AMP8 Amplifier connections (1-8) (Female DB-15 Connector) 2 3 4 5 9 10 11 12 6 7 13 14 8 15 1 Pin # Symbol Function Notes 1 DACnA+ Output DAC A output channel n + 2 DACnB+ Output DAC B outp ut channel n + 3 AE_NCn+ Output Amplifier Ena[...]

  • Page 24

    Brick Motion Controller Hard wa re Reference Manual 16 System Wiring Amplifier Fault / Amplifier Enable diagrams[...]

  • Page 25

    Brick Motion Controller Hardware Refere nce Manual System Wiring 17 J6: General Purpose I/O General purpose I/O is available on the Brick Motion Cont roller. All I/O is electrically isolated from the drive. Inputs can be configured for sinking or sourcin g applications. All Inputs are 12-24VDC. All Outputs are 24V nominal operation, 0.5A m aximu m [...]

  • Page 26

    Brick Motion Controller Hard wa re Reference Manual 18 System Wiring Suggested M-Variable Addressing for the General Purpose I/O (J6) Suggested M-var. # Addres s Notes M0-> Y:$78800,0,1 Input 1 Data Line, J6 Pin 1 M1-> Y:$78800,1,1 Input 2 Data Line, J6 Pin 20 M2-> Y:$78800,2,1 Input 3 Data Line, J6 Pin 2 M3-> Y:$78800,3,1 Input 4 Data [...]

  • Page 27

    Brick Motion Controller Hardware Refere nce Manual System Wiring 19 J7: Extra General Purpose I/O (Optional) General purpose I/O is available on the Brick Motion Cont roller. All I/O is electrically isolated from the drive. Inputs can be configured for sinking or sourcin g applications. All Inputs are 12-24VDC. All Outputs are 24V nominal operation[...]

  • Page 28

    Brick Motion Controller Hard wa re Reference Manual 20 System Wiring Suggested M-Variable Addressing for th e optional General Purpose I/O (J7) Suggested M-var. # Addres s Notes M40-> Y:$78803,0,1 Input 17 Data Line, J7 Pin 1 M41-> Y:$78803,1,1 Input 18 Data Line, J7 Pin 20 M42-> Y:$78803,2,1 Input 19 Data Line, J7 Pin 2 M43-> Y:$78803,[...]

  • Page 29

    Brick Motion Controller Hardware Refere nce Manual System Wiring 21 J8: Extra General Purpose I/O (Optional) General purpose I/O is available on the Brick Motion Cont roller. All I/O is electrically isolated from the drive. Inputs can be configured for sinking or sourcin g applications. All Inputs are 12-24VDC. All Outputs are 24V nominal operation[...]

  • Page 30

    Brick Motion Controller Hard wa re Reference Manual 22 System Wiring Suggested M-Variable Addressing for the General Purpose I/O (J8) Suggested M-var. # Addres s Notes M64-> Y:$78A00,0,1 Input 33 Data Line, J6 Pin 1 M65-> Y:$78A00,1,1 Input 34 Data Line, J6 Pin 20 M66-> Y:$78A00,2,1 Input 35 Data Line, J6 Pin 2 M67-> Y:$78A00,3,1 Input [...]

  • Page 31

    Brick Motion Controller Hardware Refere nce Manual System Wiring 23 Sample J6/J7, I/O Wiring Diagrams 36 33 1 20 2 3 4 5 9 10 28 27 26 25 24 21 22 23 11 8 7 6 29 30 32 16 15 14 13 12 17 18 19 31 34 35 37 GPI N 0 1 GPI N 1 5 GPI N 1 4 GPI N 1 3 GPI N 1 2 GPI N 1 1 GPI N 1 0 GPI N 0 9 GPI N 0 8 GPI N 0 6 GPI N 0 5 GPI N 0 4 GPI N 0 7 GPI N 0 3 GPI N [...]

  • Page 32

    Brick Motion Controller Hard wa re Reference Manual 24 System Wiring Setting up Quadrature Encoders Digital quadrature encoders are the most common pos ition sensors used with Geo Drives. Interface circuitry for these encoders comes standard on bo ard-level Turbo PMAC controllers, UMAC axis- interface boards, Geo drives, and QMAC control boxes. Sig[...]

  • Page 33

    Brick Motion Controller Hardware Refere nce Manual System Wiring 25 Encoder Loss Setup The Brick Motion Controller has encoder-loss detect ion circuitry for each encoder input. Designed for use with encoders with differential line-driver outputs , the circuitry monitors each input pair w ith an exclusive-or (XOR) gate. If the encoder is wo rking pr[...]

  • Page 34

    Brick Motion Controller Hard wa re Reference Manual 26 System Wiring For more details about Encoder Loss look into the Turbo USERs Manual chapter: Making Your Application Safe . Setting up the Analog Inputs (optional) The Brick Motion Controller can be ordered with two or four 16-bi t hi-resolution analog to digital converters. The Brick Motion Con[...]

  • Page 35

    Brick Motion Controller Hardware Refere nce Manual System Wiring 27 etc.), then writing values to the M-variable. Th e analog outputs are intended to drive high-im pedance inputs with no significant current draw. The 220 Ω output resistors will keep the current draw lower than 50 mA in all cases and prevent damage to the output circuitry, but any[...]

  • Page 36

    Brick Motion Controller Hard wa re Reference Manual 28 System Wiring hardware clock signals are SCLK (encoder sample clock), PFM_CLK (pulse frequency modulator clock), DAC_CLK (digital-to-analog converter clock), and ADC_CLK (analog-to-digital converter clock). Parameters to Set Up Pe r-Channel Hardware Signals I70n6 is the output mode; “n” is [...]

  • Page 37

    Brick Motion Controller Hardware Refere nce Manual System Wiring 29 Setting up for Pulse and Direction Output The following section shows how to quickly setup the key variables for a stepper motor (PFM) system. The step and direction outputs are RS422 compatible and are capab le of being connected in either differential mode or single ended config [...]

  • Page 38

    Brick Motion Controller Hard wa re Reference Manual 30 System Wiring I7m04: PFM Pulse Width Control The pulse width is specified in PFM clock cycles and h as a range of 1 to 255 cycles. The default value is 15. Since the default value of PFM clock is actually set to 9.8304 MHz, the default output pulse width will be 15/9,830400 = 1.5258 µ S. Note [...]

  • Page 39

    Brick Motion Controller Hardware Refere nce Manual System Wiring 31 Ixx30: Motor xx Proportional Gain To create a closed loop position response with a natu ral frequency of approximate ly 25 Hz and a damping ratio of 1, use the following calculation: ) MHz ( PFMCLK * 08 Ixx 000 , 660 30 Ixx = Example: PFMCLK is set to default of 9.83 MHz, and Ixx08[...]

  • Page 40

    Brick Motion Controller Hard wa re Reference Manual 32 System Wiring Example: User wants channels 5 to 8 to be used with st epper motors. First the user needs to wire the Stepper drive, and so as to enable the Stepper output pin 8 needs to be shorted to pin 4 (+5V) for X5 to X8. Assume for this example that all the stepper mo tors that will be used[...]

  • Page 41

    Brick Motion Controller Hardware Refere nce Manual Troubleshoot ing 33 Watchdog Timer Brick Motion Controller has an on-board watchdog time r. This subsystem provides a fail-safe shutdown to guard against software and hardware malfunction. To keep it from tripping the hardware circuit for the watchdog timer requires that two basic conditions be met[...]

  • Page 42

    Brick Motion Controller Hard wa re Reference Manual 34 Troublesho oting • Disconnect any accessories and cables other than th e logic power and repeat to see if they are causing the problem • Check for adequate 24V power suppl y levels (check at the Brick Motion Cont roller connector side, not at the supply) • Inspect for hardware damage 4. I[...]

  • Page 43

    Brick Motion Controller User Manual – Preliminar y Documentation Appendix A 35 APPENDIX A DB- Connector Spacing Specifications X1-8: DB-15 Connectors for encoder feedback 2 3 4 5 9 10 11 12 6 7 13 14 8 15 1 2 3 4 5 9 10 11 12 6 7 13 14 8 15 1 1.541±.015 3.115±. 05 X9-12: DB-9 Connecto rs for Analog I/O 2 3 4 5 6 7 8 9 1 2 3 4 5 6 7 8 9 1 1.213+[...]

  • Page 44

    Brick Motion Controller Hard wa re Reference Manual 36 Appendi x A Type of Cable for Encoder Wiring Low capacitance shielded twisted pair cable is ideal for wiring differentia l encoders. The better the shield wires, the better the noise immunity to the external equipment wiring. Wiring practice for shielded cables is not an exact science. Differen[...]

  • Page 45

    Brick Motion Controller User Manual – Preliminar y Documentation Appendix A 37 Note: If noise is a problem in the application, careful attention must be given to the method of grounding that i s used in the system. Amplifier and motor grounding can play a significant role in how noise is generated in a machine. Noise may be reduced in a motor-bas[...]

  • Page 46

    Brick Motion Controller Hard wa re Reference Manual 38 Appendi x C APPENDIX B Schematics X15: Watchdog GND WDO WDO (JWDO) COM U29 NC7SZ08M5 (SOT23-5) 1 2 4 5 3 DGND_PLANE DGND_PLANE D18 MMBD301LT1 (SOT23) 1 3 N.O. TB2 TERMBLK 3 (.150 PITCH) 1 2 3 WDO K5 FBR12ND05 4 3 5 9 10 8 1 12 BWDO N.C. WDO WDO J6 and J7: General Purpose I/O Inputs GPIN04 C243 [...]

  • Page 47

    Brick Motion Controller User Manual – Preliminar y Documentation Appendix C 39 Outputs GPO3+ R85 2.2K R84 2.2K D73 MBRS140T3 2 1 D86 MBRS140T3 2 1 D72 MBRS140T3 2 1 Opto Gnd Plane D85 MBRS140T3 2 1 GPO4-- GPO2+ D77 MBRS140T3 2 1 Q12 NZT560A (SOT-223) 1 3 2 F8 RUE090 Raychem 30R090 Littelfuse D87 MBRS140T3 2 1 F2 RUE090 Raychem 30R090 Littelfuse G[...]

  • Page 48

    Brick Motion Controller Hard wa re Reference Manual 40 Appendi x C J4: Limit Inputs for Axis 1-4 PLIM2 J10 DB25S 1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13 PLIM3 BEQU3 HOME2 RP42 4.7KSIP8I 1 2 3 4 5 6 7 8 USER3 BEQU4 FL_RT3 FL_RT2 MLIM1 USER3 MLIM3 C162 .1 C174 .1 U42 PS2705-4 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 AC1[...]

  • Page 49

    Brick Motion Controller User Manual – Preliminar y Documentation Appendix C 41 J5: Limit Inputs for Axis 5-8 FL_RT5 RP102 1KSIP8I 1 2 3 4 5 6 7 8 HOME7 USER7 MLIM6 C214 .1 J20 DB25S 1 14 2 15 3 16 4 17 5 18 6 19 7 20 8 21 9 22 10 23 11 24 12 25 13 MLIM5 HOME6 U60 PS2705-4 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 AC1 AC1 AC2 AC2 AC3 AC3 AC4 A[...]

  • Page 50

    Brick Motion Controller Hard wa re Reference Manual 42 Appendi x C Dimensional Lay out a nd Connector location[...]