Delta Tau Geo MACRO Manuale utente

^1 USER MANUAL & REFERENCE

^2 Geo MACRO Drive

^3 Direct PWM Amplifier over MACRO

^4 500-603701-xUxx

^5 April 27, 2010

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

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 product improvements, etc., and may not conform in

every respect to former issues.

To report errors or inconsistencies, call or email:

Delta Tau Data Systems, Inc. Technical Support

Phone: (818) 717-5656

Fax: (818) 998-7807

Email: [email protected]

Website: http://www.deltatau.com

Operating Conditions

All Delta Tau Data Systems, Inc. motion controller products, accessories, and amplifiers 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 insulated materials. Only qualified personnel

should be allowed to handle this equipment.

In the case of industrial applications, we expect our products to be protected from hazardous or

conductive materials and/or environments that could cause harm to the controller by damaging

components or causing electrical shorts. When our products are used in an industrial environment, install

them into an industrial electrical cabinet or industrial PC to protect them from excessive or corrosive

moisture, abnormal ambient temperatures, and conductive materials. If Delta Tau Data Systems, Inc.

products are directly exposed to hazardous or conductive materials and/or environments, we cannot

guarantee their operation.

Safety Instructions

Qualified personnel must transport, assemble, install, and maintain this equipment. Properly qualified

personnel are persons who are familiar with the transport, assembly, installation, and operation of

equipment. The qualified personnel must know and observe the following standards and regulations:

IEC 364 resp. CENELEC HD 384 or DIN VDE 0100

IEC report 664 or DIN VDE 0110

National regulations for safety and accident prevention or VBG 4

Incorrect handling of products can result in injury and damage to persons and machinery. Strictly adhere

to the installation instructions. Electrical safety is provided through a low-resistance earth connection. It is

vital to ensure that all system components are connected to earth ground.

This product contains components that are sensitive 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 any possible static electricity build-up by touching an

unpainted, metal, grounded surface before touching the equipment.

Keep all covers and cabinet doors shut during operation. Be aware that during operation, the product has

electrically charged components and hot surfaces. Control and power cables can carry a high voltage,

even when the motor is not rotating. Never disconnect or connect the product while the power source is

energized to avoid electric arcing.

After removing the power source from the equipment, wait at least 10 minutes before touching or

disconnecting sections of the equipment that normally carry electrical charges (e.g., capacitors, contacts,

screw connections). To be safe, measure the electrical contact points with a meter before touching the

equipment.

The following text formats are used in this manual to indicate a potential for personal injury or equipment

damage. Read the safety notices in this manual before attempting installation, operation, or maintenance

to avoid serious bodily injury, damage to the equipment, or operational difficulty.

WARNING

A Warning identifies hazards that could result in personal injury or death. It

precedes the discussion of interest.

Caution

A Caution identifies hazards that could result in equipment damage. It precedes

the discussion of interest

Note

A Note identifies information critical to the user’s understanding or use of the

equipment. It follows the discussion of interest.

REVISION HISTORY

REV. DESCRIPTION DATE CHG APPVD

1 UPDATED ENDAT SETUP INFO, P. 82 07/18/06 CP P.SHANTZ

2 UPDATED ERROR CODE EF GATE DRIVE INFO 09/21/06 CP P.SHANTZ

3 CORRECTED GP OUT INPUT FUNCTIONS, P. 39 06/11/08 CP K.ZHAO

4 CORRECTED RESET COMMAND, P. 138 10/30/08 CP S. MILICI

5 CORRECTED M-VARIABLE DEFINITIONS, P. 87

12/08/09 CP S. MILICI

6 CORRECTED ERRORS PPS. 85-87 02/25/10 CP S. MILICI

7 CORRECTED COVER PAGE FORMATTING 03/01/10 CP C. PERRY

8 ADDED SAFETY RELAY PN INFO, P. 108 04/27/10 CP S. MILICI

Geo MACRO Drive User and Reference Manual

Table of Contents i

Table of Contents

Copyright Information................................................................................................................................................i

Operating Conditions .................................................................................................................................................i

Safety Instructions......................................................................................................................................................i

INTRODUCTION .......................................................................................................................................................1

User Interface ............................................................................................................................................................1

Geo MACRO Drives .............................................................................................................................................1

Geo PMAC Drives ................................................................................................................................................2

Geo Direct-PWM Drives.......................................................................................................................................2

MACRO Defined ......................................................................................................................................................2

Feedback Devices......................................................................................................................................................3

Compatible Motors....................................................................................................................................................3

Maximum Speed....................................................................................................................................................3

Torque...................................................................................................................................................................3

Motor Poles ..........................................................................................................................................................4

Motor Inductance..................................................................................................................................................4

Motor Resistance ..................................................................................................................................................4

Motor Back EMF ..................................................................................................................................................4

Motor Torque Constant.........................................................................................................................................5

Motor Inertia ........................................................................................................................................................5

Motor Cabling.......................................................................................................................................................5

SPECIFICATIONS .....................................................................................................................................................7

Part Number ..............................................................................................................................................................7

Geo MACRO Feedback Options...............................................................................................................................8

Package Types...........................................................................................................................................................8

Electrical Specifications............................................................................................................................................9

230VAC Input Drives...........................................................................................................................................9

480VAC Input Drives..........................................................................................................................................11

Environmental Specifications..................................................................................................................................13

Recommended Fusing and Wire Gauge ..................................................................................................................13

RECEIVING AND UNPACKING...........................................................................................................................15

Use of Equipment....................................................................................................................................................15

MOUNTING ..............................................................................................................................................................17

Low Profile..............................................................................................................................................................18

Single Width............................................................................................................................................................19

Double Width ..........................................................................................................................................................20

CONNECTIONS .......................................................................................................................................................21

System (Power) Wiring...........................................................................................................................................21

Wiring AC Input, J1 ............................................................................................................................................23

Wiring Earth-Ground .........................................................................................................................................23

Wiring 24 V Logic Control, J4............................................................................................................................24

Wiring the Motors ...................................................................................................................................................24

J2: Motor 1 Output Connector Pinout...............................................................................................................24

J3: Motor 2 Output Connector Pinout...............................................................................................................24

Wiring the Motor Thermostats ................................................................................................................................25

Wiring the Regen (Shunt) Resistor, J5 ....................................................................................................................25

J5: External Shunt Connector Pinout ................................................................................................................26

Shunt Regulation.................................................................................................................................................27

Minimum Resistance Value.................................................................................................................................27

Maximum Resistance Value ................................................................................................................................27

Energy Transfer Equations .................................................................................................................................27

Bonding...................................................................................................................................................................29

Filtering...................................................................................................................................................................30

Geo MACRO Drive User Manual

ii Table of Contents

CE Filtering ........................................................................................................................................................30

Input Power Filtering .........................................................................................................................................31

Motor Line Filtering ...........................................................................................................................................31

I/O Filtering........................................................................................................................................................31

Connecting Main Feedback Sensors (X1 & X2) .....................................................................................................32

Digital Quadrature Encoders .............................................................................................................................32

Digital Hall Commutation Sensors.....................................................................................................................33

SSI Encoders.......................................................................................................................................................33

Sinusoidal Encoders ...........................................................................................................................................34

Hiperface® Interface ..........................................................................................................................................35

EnDat Interface...................................................................................................................................................36

Resolvers.............................................................................................................................................................37

Connecting Secondary Quad. Encoders (X8 & X9)................................................................................................38

Connecting General Purpose I/O & Flags (X3).......................................................................................................39

Sample wiring the I/O .........................................................................................................................................39

Sample Wiring the Flags.....................................................................................................................................40

Connecting MACRO Ring ......................................................................................................................................41

Fiber Optic MACRO connections (X5)...............................................................................................................41

RJ-45 Copper MACRO connections (X10 &X11)...............................................................................................41

Connecting optional Analog Inputs (X6 & X7) ......................................................................................................42

SOFTWARE SETUP FOR GEO MACRO DRIVES .............................................................................................43

Introduction .............................................................................................................................................................43

Establishing MACRO Communications with Turbo PMAC ..................................................................................43

MACRO Ring Frequency Control Variables ......................................................................................................43

I7: Phase Cycle Extension ..................................................................................................................................43

I6840: MACRO IC 0 Master Configuration .......................................................................................................44

I6890/I6940/I6990: MACRO IC 1/2/3 Master Configuration ............................................................................44

I6841/I6891/I6941/I6991: MACRO IC 0/1/2/3 Node Activation Control...........................................................44

I70/I72/I74/I76: MACRO IC 0/1/2/3 Node Auxiliary Function Enable..............................................................45

I71/I73/I75/I77: MACRO IC 0/1/2/3 Node Protocol Type Control ....................................................................46

I78: MACRO Master/Slave Auxiliary Communications Timeout .......................................................................46

I79: MACRO Master/Master Auxiliary Communications Timeout.....................................................................46

I80, I81, I82: MACRO Ring Check Period and Limits .......................................................................................46

MACRO Node Addresses ....................................................................................................................................47

Using the Turbo PMAC Setup Program .............................................................................................................51

Using the PEWIN32PRO 2 MACRO Ring ASCII Feature..................................................................................58

PEWIN32PRO Suite 2 MACRO Status window..................................................................................................62

Ring Order Communications Method .................................................................................................................63

MACRO ASCII Communications........................................................................................................................64

How to Enable and Disable MACRO ASCII Communication Mode ..................................................................64

SETTING UP PRIMARY FEEDBACK..................................................................................................................67

Device Selection Control.........................................................................................................................................67

Setting up Digital Quadrature Encoders.................................................................................................................67

Setting up SSI Encoders..........................................................................................................................................67

Setting up Sinusoidal Encoders...............................................................................................................................69

Principle of PMAC Interpolation Operation ......................................................................................................69

Setting up Endat ......................................................................................................................................................72

Setting up Resolvers................................................................................................................................................72

Setting up the Phase Shift (MI941) Manually .....................................................................................................73

Setting up the Resolver for Power-On Absolute Position ...................................................................................73

Scaling the Feedback Units ................................................................................................................................74

SETTING UP SECONDARY ENCODERS............................................................................................................75

SETTING UP THE TURBO PMAC CONVERSION TABLE .............................................................................77

Geo MACRO Drive User and Reference Manual

Table of Contents iii

SETTING UP TURBO MOTOR OPERATION ....................................................................................................79

Turbo PMAC Basic Setup for Brushless Servo or Induction Motor .......................................................................79

Turbo PMAC Basic Setup for DC Brush Motors................................................................................................80

Instructions for Direct-PWM Control of Brush Motors ..........................................................................................85

PWM/ADC Phase Match ....................................................................................................................................85

Synchronous Motor Stepper Action ....................................................................................................................85

Current Loop Polarity Check..............................................................................................................................85

Troubleshooting..................................................................................................................................................86

Testing PWM and Current Feedback Operation .....................................................................................................86

Purpose...............................................................................................................................................................86

Preparation.........................................................................................................................................................87

Position Feedback and Polarity Test ..................................................................................................................87

Setting Up Hall Commutation Sensors....................................................................................................................88

Signal Format .....................................................................................................................................................88

Using Hall Effect Sensors for Phase Reference..................................................................................................89

Determining the Commutation Phase Angle.......................................................................................................89

Finding the Hall Effect Transition Points...........................................................................................................89

Calculating the Hall Effect Zero Point (HEZ) ....................................................................................................90

Determining the Polarity of the Hall Effects – Standard or Reversed................................................................92

Software Settings for Hall Effect Phasing...........................................................................................................92

Setting I2T Protection ..............................................................................................................................................96

Calculating Minimum PWM Frequency .................................................................................................................97

SETTING UP DISCRETE INPUTS AND OUTPUTS...........................................................................................99

Inputs and Outputs ..................................................................................................................................................99

Ring Break Output indicator MS{node},MI13 .....................................................................................................100

Setting up the Analog Inputs (X6 and X7)............................................................................................................100

Limit and Flag Circuit Wiring...............................................................................................................................102

Connecting Limits/Flags to the Geo Drive .......................................................................................................102

Setting up Position Compare (EQU) Outputs........................................................................................................103

Setting up for a Single Pulse Output.................................................................................................................103

Setting up for Multiple Pulse Outputs...............................................................................................................104

CONNECTORS.......................................................................................................................................................105

Connector Pinouts .................................................................................................................................................105

X1: Encoder Input 1.........................................................................................................................................105

X2: Encoder Input 2.........................................................................................................................................106

X3: General Purpose I/O..................................................................................................................................107

X4: Safety Relay (Optional) .............................................................................................................................108

X6: Analog IN 1 (Optional 3/4/5) ....................................................................................................................108

X7: Analog IN 2 (Optional 3/4/5) ....................................................................................................................108

X8: S. Encoder 1 ..............................................................................................................................................109

X9: S. Encoder 2 ..............................................................................................................................................109

X13: Discrete I/O.............................................................................................................................................109

J1: AC Input Connector Pinout .......................................................................................................................110

J2: Motor 1 Output Connector Pinout.............................................................................................................110

J3: Motor 2 Output Connector Pinout (Optional) ...........................................................................................110

J4: 24VDC Input Logic Supply Connector .......................................................................................................110

J5: External Shunt Connector Pinout ..............................................................................................................110

MACRO Link Connectors.....................................................................................................................................111

X5: MACRO I/O, MACRO Fiber Optic Transceiver (Optional).......................................................................111

X10 and X11 MACRO RJ-45 Copper Connectors ............................................................................................111

USB Connector .....................................................................................................................................................111

X12: USB Universal Serial Bus Port ...............................................................................................................112

TROUBLESHOOTING..........................................................................................................................................113

Error Codes ...........................................................................................................................................................113

Geo MACRO Drive User Manual

iv Table of Contents

D1: Geo MACRO Drive Status Display Codes.................................................................................................113

MACRO Network Errors...................................................................................................................................114

Status LEDs ......................................................................................................................................................115

Geo MACRO Drive Ring Status Error Codes.......................................................................................................116

MS{node},MI4 Geo MACRO Status Word (Read Only) ...............................................................................116

MS{node},MI6 Status Word Control.............................................................................................................117

Status Word.......................................................................................................................................................117

TURBO PMAC2 RELATED I-VARIABLE REFERENCE ...............................................................................119

Ixx10: Motor xx Power-On Servo Position Address............................................................................................119

Ixx25, Ixx24: Flag Address and Mode ..................................................................................................................121

Ixx70, Ixx71: Commutation Cycle Size ...............................................................................................................123

Ixx72: Commutation Phase Angle.........................................................................................................................123

Ixx75: Absolute Phase Position Offset.................................................................................................................123

Ixx81: Motor xx Power-On Phase Position Address and Mode...........................................................................124

Ixx82: Current Loop Feedback Address................................................................................................................125

Ixx83: Commutation Feedback Address ..............................................................................................................126

Ixx91: Motor xx Power-On Phase Position Format .............................................................................................126

Ixx95: Motor xx Power-On Servo Position Format .............................................................................................129

Ixx97 Motor xx Position Capture and Trigger Mode ...........................................................................................131

GEO MACRO DRIVE MI-VARIABLE REFERENCE......................................................................................133

Global MI-Variables .............................................................................................................................................133

MS{node},MI0 Geo MACRO drive Firmware Version (Read Only)............................................................133

MS{node},MI1 Geo MACRO drive Firmware Date (Read Only) ................................................................133

MS{node},MI2 and MI3 (Reserved for future use).......................................................................................133

MS{node},MI4 Geo MACRO drive Status Word (Read Only) ......................................................................134

MS{node},MI5 Ring Error Counter .............................................................................................................134

MS{node},MI6 Status Word Control............................................................................................................135

MS{node},MI7 Geo MACRO Error Counter ...............................................................................................135

MS{node},MI8 Geo MACRO Ring Check Period ........................................................................................135

MS{node},MI9 Geo MACRO Ring Error Shutdown Count..........................................................................135

MS{node},MI10 Geo MACRO Sync Packet Shutdown Count......................................................................136

MS{node},MI11 Station Order Number.......................................................................................................136

MS{node},MI12 Card Identification (Read Only)........................................................................................137

MS{node},MI13 Ring Break Output indicator .............................................................................................137

MS{node},MI100 Motor Activation Control word .......................................................................................138

MS{node},MI101-102 Primary Feedback Selection .....................................................................................138

MS{node},MI103 Sin Encoder/ Resolver #1 bias..........................................................................................139

MS{node},MI104 Sin Encoder/ Resolver #2 bias..........................................................................................139

MS{node},MI105 Cosine Encoder/ Resolver #1 bias....................................................................................139

MS{node},MI106 Cosine Encoder/ Resolver #2 bias....................................................................................139

MS{node},MI107 Motor 1 Encoder-Loss Mask ............................................................................................140

MS{node},MI108 Motor 2 Encoder-Loss Mask ............................................................................................140

Primary Channel Node-Specific Gate Array MI-variables....................................................................................142

MS{node},MI910 Primary Encoder/Timer n Decode Control ......................................................................142

MS{node},MI911 Primary Enc. Position Compare n Channel Select ..........................................................143

MS{node},MI912 Primary Encoder n Capture Control................................................................................143

MS{node},MI913 Primary Encoder Capture n Flag Select Control.............................................................144

MS{node},MI914 Primary Encoder n Gated Index Select ............................................................................144

MS{node},MI915 Primary Encoder Index Gate State/Demux Control.........................................................145

MS{node},MI910 Secondary Encoder Decode Control ................................................................................146

MS{node},MI911 Secondary Encoder counter Direction .............................................................................146

MS{node},MI912 Secondary Encoder Index Capture Control ....................................................................147

MS{node},MI913 Secondary Encoder Home Flag Capture Control ...........................................................147

MS{node},MI914 Secondary Encoder Filter Control ...................................................................................147

MS{node},MI915 Secondary Encoder Capture Flag Select Control ............................................................148

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