Delta 3Ax-602646-xUxx Quick Reference Guide
^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
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 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: support@deltatau.com
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.
Quad Amp Hardware Reference Manual
Table of Contents
INTRODUCTION.......................................................................................................................................................1
Related Technical Documentation ............................................................................................................................1
Safety Summary ........................................................................................................................................................1
Keep Away from Live Circuits..............................................................................................................................1
Live Circuit Contact Procedures..........................................................................................................................1
Quad Amp Basic Specifications................................................................................................................................2
Physical Specifications.........................................................................................................................................2
Electrical Specifications.......................................................................................................................................2
Bus Supply, Control Supply and Shunt Specifications..........................................................................................2
Protection ..................................................................................................................................................................6
Transient Voltage Filter........................................................................................................................................6
Transient Surge Suppressors................................................................................................................................6
Fly-Back Diode.....................................................................................................................................................6
Fuses.....................................................................................................................................................................6
Ground Fault (GF)...............................................................................................................................................6
Configurable Options ................................................................................................................................................7
GETTING STARTED.................................................................................................................................................9
Receiving and Handling ............................................................................................................................................9
Inspection upon Receipt........................................................................................................................................9
Storage Requirements...........................................................................................................................................9
Prior to Installation..............................................................................................................................................9
Equipment Required..................................................................................................................................................9
Installation Considerations and Options....................................................................................................................9
Option 3, 3A and 3B (External Mount).................................................................................................................9
Option 4 and 4A (Internal Mount).......................................................................................................................9
THEORY OF OPERATION....................................................................................................................................11
Operation.................................................................................................................................................................11
Configuration ..........................................................................................................................................................11
Logic Board........................................................................................................................................................11
Current Sense Board...........................................................................................................................................12
Firing Boards .....................................................................................................................................................12
Soft Start and Shunt Regulator ...........................................................................................................................12
DC Bus Power Supply ........................................................................................................................................12
Heat Dissipation.................................................................................................................................................13
Shunt Considerations..........................................................................................................................................13
INSTALLATION.......................................................................................................................................................15
Wiring the Quad Amplifier System.........................................................................................................................15
Quad Amplifier Channel Connections................................................................................................................15
Two Quad Amplifier Example.............................................................................................................................15
Typical Quad Amplifier Setup.............................................................................................................................15
Non-Standard Quad Amplifier Setup ......................................................................................................................16
Accessory Terminal Board (Acc-8F, Acc-24E2).................................................................................................16
PWM Input Cables..............................................................................................................................................16
Connectors..........................................................................................................................................................16
Connecting Power Devices .....................................................................................................................................16
Main AC Input Power.........................................................................................................................................19
Control AC Input Voltage...................................................................................................................................19
Bus Power Enable/Emergency Stop....................................................................................................................21
Shunt and Bus.....................................................................................................................................................21
Bus......................................................................................................................................................................21
Bus Filter/Indicator............................................................................................................................................21
Motor Wiring......................................................................................................................................................21
Motor Over-Temp Sensor...................................................................................................................................21
Table of Contents i
Quad Amp Hardware Reference Manual
Jumpers, Potentiometers, Test Points, and LEDs...............................................................................................21
Grounding ...............................................................................................................................................................25
General...............................................................................................................................................................25
Main Power Supply (DC Bus) ............................................................................................................................25
Motor..................................................................................................................................................................25
PMAC2 I-Variables Setup.......................................................................................................................................25
Ix00.....................................................................................................................................................................25
Ix01.....................................................................................................................................................................25
Ix02.....................................................................................................................................................................25
Ix25.....................................................................................................................................................................25
Ix82.....................................................................................................................................................................25
I900.....................................................................................................................................................................25
I9n6.....................................................................................................................................................................26
Start-Up Procedures ................................................................................................................................................26
Power On Sequence............................................................................................................................................26
P2Setup...............................................................................................................................................................26
TROUBLESHOOTING............................................................................................................................................29
Logic Fault Detection and Fault Codes...................................................................................................................29
Axis-Specific Faults............................................................................................................................................29
Global Faults......................................................................................................................................................29
Fault Reporting........................................................................................................................................................29
Serial Fault/Status Data.....................................................................................................................................29
LED Fault Indicator...........................................................................................................................................30
Global Fault Only...............................................................................................................................................30
Global and Axis-Specific Faults .........................................................................................................................30
Axis-Specific Fault Only.....................................................................................................................................30
ILLUSTRATED REPAIR PARTS LIST................................................................................................................33
Purpose....................................................................................................................................................................33
Scope.......................................................................................................................................................................33
How to Use the Repair Parts List ............................................................................................................................33
Table of Contents
ii
Quad Amp Hardware Reference Manual
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 brushless or AC induction motors. All control parameters
including switching frequency and dead time are determined by software set-up of the controller, not in
the amplifier.
The Quad Amp is designed to work in conjunction with the Delta Tau PMAC2 motion controller, which
supports up to eight axes of motion control. The PMAC2 delivers Pulse Width Modulated (PWM) on/off
signals to the Quad Amp power transistors. The Quad Amp simply isolates and level-shifts these signals,
at the required frequency and magnitude, to obtain the desired torque, velocity, and position.
All feedback is processed by the PMAC2. The Quad Amp measures motor phase currents, digitizes them,
and transmits them back to PMAC2 as a serial data stream. Position feedback data is sent directly back to
the PMAC2 via the Acc-8F Digital Interface Board. The Quad Amp does not use or require any position
data.
Related Technical Documentation
The following technical manuals are required to successfully install and operate the Delta Tau Quad Amp.
These manuals should be included in the technical documentation package received with the Quad Amp.
If any of these manuals are missing, contact Delta Tau before attempting installation.
Manual Number Manual Title
3A0-602204-363 PMAC User Manual and Software Reference with PMAC2 Addendum
3A0-602775-363 Acc-8F Digital Interface Board User Manual
3A0-602598-363 PMAC2 PC and PMAC2 Lite Hardware Reference Manual
3A0-602413-363 PMAC2 VME Hardware Reference Manual
3A0-602643-363 PMAC2 VME Ultralite Hardware Reference Manual
Safety Summary
The following are general safety precautions not related to any specific procedures and therefore may not
appear elsewhere in this publication. These are recommended precautions that personnel must
understand, apply, and adhere to during the phases of installation, operation, and maintenance.
Keep Away from Live Circuits
Do not replace components or make adjustments inside equipment with power applied. Under certain
conditions, dangerous potentials may exist when power has been turned off due to charges retained by
capacitors. To avoid casualties, always remove power and allow 10 to 12 minutes for the bus capacitors
to discharge before removing the cover.
Live Circuit Contact Procedures
Never attempt to remove a person from a live circuit with bare hands. To do so is to risk sure and sudden
death. If a person is connected to a live circuit, the following steps should be taken:
• Call for help immediately
• De-energize the circuit, if possible.
• Use wooden or fiberglass hot stick to pull the person free of the circuit.
• Apply cardiopulmonary resuscitation (CPR) if the person has stopped breathing or is in cardiac arrest.
• Obtain immediate medical assistance.
Introduction 1
Quad Amp Hardware Reference Manual
Quad Amp Basic Specifications
Physical Specifications
Size (See Figure 1)
• Height: 22.0 Inches
• Width: 10.5 Inches
• Length:
5.125 Inches (without mounting option)
9.031 Inches (with mounting option)
Weight
• 60 lb. (27.3 kg)
Temperature
Storage: -20 degrees C to +85 degrees C
Operating: 0 degrees C to +60 degrees C (Unit is disabled if heat sink temperature exceeds 80 degrees C)
Relative Humidity
10% to 95%, non-condensing
Electrical Specifications
Switching Frequency
7.5 kHz (Nominal)
15 kHz (Maximum)
Cooling
Options 3B, 4, and 4A: Forced Air (Internal)
Options 3 and 3A: Customer supplied (external)
Protection
Fuses:
F201 - Shunt Regulator IGBT and Shunt Resistors
F202 - Logic Power Supply
3-Phase In-Line Circuit Breaker (Optional)
Bus Supply, Control Supply and Shunt Specifications
120V/208V/230V Quad Amplifier Specifications
Main AC Input Voltage/Current (L1, L2, L3)
Input voltage
Input current/phase, continuous.
Frequency
Control AC Input Voltage/Current (Connector
C3)
(Dependent on Option Ordered)
Input voltage (Selectable)
Min. required input current (RMS)
Frequency
120 VAC, single phase
208 VAC, three phase
230 VAC, three phase
25 A @ 12.5 HP continuous output
60 A @ 25 HP continuous output
72 A @ 33 HP continuous output
50/60 Hz ±2
120 VAC (+/- 10 %), single phase
208 VAC (+/- 10 %), single phase
230 VAC (+/- 10 %), single phase
3 A @ 120VAC
1.5 A @ 230 VAC
50/60 Hz ±2
For demo only
Introduction
2
Quad Amp Hardware Reference Manual
Main DC bus Voltage
Internal Shunt Resistor
Resistance
Resistor power
External Shunt Resistor (Optional)
Resistance
Resistor power
Soft Start charge time
Minimum output inductance
380/460/480V Quad Amplifier Specifications
Main AC Input Voltage/Current (L1, L2, L3)
Input voltage
Input current/phase, continuous.
Frequency
Control AC Input Voltage/Current (Connector
C3)
(Dependent on Option Ordered)
Input voltage (Selectable)
Min. required input current (RMS)
Frequency
Main DC bus Voltage
Internal Shunt Resistor
Resistance
Resistor power
External Shunt Resistor
Resistance
Resistor power
Soft Start charge time
Minimum output inductance
170 VDC (120 VAC line input)
(L1, L2)
300 VDC (208 VAC line input)
(L1, L2, L3)
325 VDC (230 VAC line input)
(L1, L2, L3)
15 Ohm
1.8 kW
8.5 Ohm
2.8 kW
1 Sec
3 mH
380 VAC, three phase
460 VAC, three phase
480 VAC, three phase
10 A @ 12.5 HP continuous output
25 A @ 25 HP continuous output
36 A @ 33 HP continuous output
50/60 Hz ±2
120 VAC (+/- 10 %), single phase
208 VAC (+/- 10 %), single phase
230 VAC (+/- 10 %), single phase
380 VAC (+/- 10 %), single phase
460 VAC (+/- 10 %), single phase
480 VAC (+/- 10 %), single phase
3 A @ 120VAC
1.5 A @ 230 VAC
1A @ 380VAC
0.75 A @ 460 VAC
50/60 Hz ±2
537 VDC (380 VAC line input) (L1,
L2, L3)
650 VDC (460 VAC line input) (L1,
L2, L3)
680 VDC (480 VAC line input) (L1,
L2, L3)
30 Ohm
0.6 kW
12.75 Ohm
4.2 kW
1 Sec
3 mH
For demo only
Introduction 3
Quad Amp Hardware Reference Manual
AIR FLOW
USE 1/4-INCH
MOUNTING
HARDWARE
(4 PLACES)
Figure 1 Quad Amp Specifications
Output Specifications for 120/208/230 VAC Amplifier
Up to four blocks (options) can be selected in any power combination. The total power cannot exceed 33
HP.
Note:
When 30HP is selected only two additional axes may be used (three total instead of
four).
Introduction
4
Quad Amp Hardware Reference Manual
Opt 5 Opt 6 Opt 7 Opt 8 Opt 9 Opt 10 Opt 11 Opt 12 Opt 13 Opt 14
Continuous
HP(100%)
Continuous
0.75 HP
0.56 kW
2 A 4 A 5 A 7 A 15 A 20 A 25 A 35 A 50 A 75 A
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
current
(RMS)
Continuous 2
min
1.5 HP
1.1 kW
3 HP
2.2 kW
4 HP
3 kW
6 HP
4.5 kW
10 HP
7.5 kW
15 HP
11 kW
20 HP
15 kW
30 HP
22 kW
40 HP
30 kW
60 HP
45 kW
HP(200%)
Peak 2 sec
HP(300%)
Peak 2 sec
2.25 HP
1.7 kW
5 A 12 A 15 A 21 A 36 A 54 A 75 A 100 A 150 A 200 A
4.5 HP
3.4 kW
6 HP
4.5 kW
9 HP
6.7 kW
15 HP
11 kW
22.5 HP
17 kW
30 HP
22 kW
45 HP
34 kW
60 HP
45 kW
90 HP
67 kW
current
PWM dead
time
2.3 s(PMAC2default)
PMAC2 programmable
Output Specifications for 380/460 VAC Amplifier
Up to four blocks (options) can be selected in any power combination.
The total power cannot exceed 35 Hp.
Note:
When 30HP is selected, only two additional axes may be used (three total instead
of four).
Opt 15 Opt 16 Opt 17 Opt 18 Opt 19 Opt 20
Continuous HP
2 HP 3 HP 5 HP 10 HP 20 HP 30 HP
(100 %)
Continuous current
2.5 A 3.5 A 6 A 12.5 A 25 A 35 A
(RMS)
Continuous 2 min
HP (200%)
Peak 2 sec HP
(300%)
Peak 2 sec current
PWM dead-time
4 HP
3 kW
6 HP
4.5 kW
7.5 A 10.5 A 18 A 40 A 75 A 100 A
2.3 µs (PMAC2 default) PMAC2 programmable
6 HP
4.5 kW
9 HP
6.7 kW
10 HP
7.5 kW
15 HP
11 kW
20 HP
15 kW
30 HP
22 kW
40 HP
30 kW
60 HP
45 kW
60 HP
45 kW
90 HP
67 kW
Introduction 5
Quad Amp Hardware Reference Manual
6
Protection
There are several layers of protection built into the amplifier, 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.
Transient Voltage Filter
The transient voltage RC filter is used as a means of suppressing inductive transients and is located across
the single phase Control AC input voltage connector C3.
Transient Surge Suppressors
Transient surge suppressors (also referred to as metal oxide varistors or MOVs) are connected across all
three input phases (L1, L2, L3) of the Main AC input power. They are located on a circuit board attached
to the top of the bridge power rectifier. The primary function of these devices is to absorb high-level
energy pulses (spikes).
Fly-Back Diode
The fly-back diode clamps inductive spikes that may be generated across the external shunt resistors
when the shunt IGBT is turned off. The diode is connected across the external shunt resistor terminals.
Fuses
The primary hardware protection is fuses, which are mounted within the Quad Amplifier chassis.
Fuse F201
F201 is a 30 Amp long delay fuse, located externally on the top cover of the Quad Amplifier. Fuse F201
is connected to the output of the shunt regulator IGBT and to the internal shunt regulator resistors. Fuse
F201 protects the shunt regulator IGBT and the internal shunt resistors from over current damage.
Fuse F202
F202 is a 4-Amp Slo-Blo fuse located under the Quad Amplifier cover, next to the control AC input
power supply transformer. This fuse is connected between incoming AC control input power connector
C3 and control input AC power transformer T201. Fuse F202 protects the primary input windings of the
control power supply transformer against overloads.
Ground Fault (GF)
The Ground Fault Detector is a self-powered circuit that continuously samples the AC line currents via a
toroid around the incoming three phase lines. If there is more current flowing into the amplifier than out,
the ground fault circuit will activate and shut down the Quad Amplifier with a soft start fault.
Introduction
Quad Amp Hardware Reference Manual
Configurable Options
Each Quad Amplifier is shipped with an Identification 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 Quad Amplifier is a custom unit, Delta Tau would like
to emphasize that each user should inspect the equipment and see that the correct unit has been supplied.
Contact Delta Tau immediately if there are questions regarding the shipment. The following tables define
the Delta Tau part numbers, for the Delta Tau Digital Quad Amplifier and its configurable options.
Part No. Item Description Note
500-602645-102 Basic Quad Amplifier. Basic Quad Amplifier includes: Fans,
built-in shunt and soft start circuits.
301-QADAMP-OPT Quad Amplifier Basic P.S.
Option 1
302-QADAMP-OPT Quad Amplifier upgrade
Option 2
3A2-QADAMP-OPT Quad Amplifier High
voltage upgrade Option 2A
For 10 HP or less
Power supply 50 amp and small HS
Over 10 HP up to 33 HP
Power supply 100 amp and large HS
380/460 VAC version
Power supply 75 amp and large HS
Power Blocks Item Description Note
305-QADAMP-OPT Power Block Option 5 10 Amp, 600V *** Block, 0.75 HP Cont.
306-QADAMP-OPT Power Block Option 6 15 Amp, 600V*** Block, 1.5 HP Cont.
307-QADAMP-OPT Power Block Option 7 20 Amp, 600V*** Block, 2 HP Cont.
308-QADAMP-OPT Power Block Option 8 30 Amp, 600V*** Block, 3 HP Cont.
309-QADAMP-OPT Power Block Option 9 50 Amp, 600V*** Block, 5 HP Cont.
310-QADAMP-OPT Power Block Option10 ** 50 AMP, 600V*** Block, 7.5 HP Cont.
311-QADAMP-OPT Power Block Option11 ** 75 Amp, 600V*** Block, 10 HP Cont.
312-QADAMP-OPT Power Block Option12 ** 100 Amp, 600V*** Block, 15 HP Cont.
313-QADAMP-OPT Power Block Option13 ** 150 Amp, 600V*** Block, 20 HP Cont.
314-QADAMP-OPT Power Block Option14 ** 200 Amp, 600V*** Block, 30 HP Cont. *
315-QADAMP-OPT Power Block Option15 10 Amp, 1200V*** Block, 2 HP Cont.*
316-QADAMP-OPT Power Block Option16 15 Amp, 1200V*** Block, 3 HP Cont.*
317-QADAMP-OPT Power Block Option17 25 Amp, 1200V*** Block, 5 HP Cont.*
318-QADAMP-OPT Power Block Option18 ** 50 Amp, 1200V*** Block, 10 HP Cont.*
319-QADAMP-OPT Power Block Option19 ** 75 Amp, 1200V*** Block, 20 HP Cont.*
320-QADAMP-OPT Power Block Option 20 ** 100 Amp, 1200V*** Block, 30 HP. Cont. *
Mounting Options Item Description Note
303-QADAMP-OPT External mounting opt
Option 3
3A3-QADAMP-OPT External mounting opt
Option 3A
3B3-QADAMP-OPT External mounting opt
Option 3B
304-QADAMP-OPT Internal mounting opt
Option 4
3A4-QADAMP-OPT Internal mounting opt
Option 4A
Used with basic (Opt 1) Quad Amplifier,
under 10 HP. Includes Fan and Shunt R.
Used with up-graded (Opt 2) Quad
Amplifier over 10 HP. Same as above
Does not include cooling fans or internal
shunt resistor.
Used with basic (Opt 1) Quad Amplifier,
under 10 HP.
Used with up-graded (Opt2) Quad
Amplifier, over 10 HP.
Must choose either option 1, 2
or 2A with basic quad P/N.
Control Voltage is Selectable:
120 VAC
208 VAC
230 VAC
380 VAC
460 VAC
480 VAC
For use when mounting HS
external to cabinet
Same as above.
For use when mounting
Amplifier HS in plenum.
Foot Mounting to cabinet panel
Same as above.
Introduction 7
Quad Amp Hardware Reference Manual
N
Accessories Item Description Note
3A1-602582-100 Circuit Breaker 50 Amps 450 VAC 3 Phase With external trip
3A2-602582-100 Circuit Breaker 70 Amps 250 VAC 3 Phase
200-602739-024 PWM Input Cables 36” long cable with DB36 pin mini
connectors at each end
3A0-602757-100 External Shunt Resistor 4.25 Ohms 1400 Watts each.
25” long 2” diameter Edge-Power resistor.
Open Frame
3AO-602775-10X ACC8F Interface Circuit Board
Used to connect Encoders to PMAC.
* When 30 HP is selected, only two additional axes may be used (three total, not four).
** When a total of 7.5 HP or greater is selected, use Acc-4 (external shunt resistors).
*** 600V/1200V indicates VDC rating of the igbt and has no connection to the main AC input (operating) voltage.
A
Two required per Acc-8F.
Connects between Quad
Amplifier and Acc-8F
Two required for 208/230 Quad
Amplifier. Three required for
380/460 Quad Amplifier.
Connected in series.
Two required per Quad
Amplifier. Not required if
PWM MACRO station is used.
Introduction
8
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