Delta Tau 4Ax-603397-xUxx User Manual

^1 USER MANUAL

^2 3U DIGITAL PWM AMPLIFIER

^3 3U Digital PWM Amplifier

^4 4Ax-603397-xUxx

^5 January 28, 2003

Single Source Machine Control Power // Flexibility // Ease of Use

21314 Lassen Street Chatsworth, CA 91311 // Tel. [phone] Fax. [phone] // 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: [phone]
Fax: [phone]
Email: [e-mail]
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 exposed to hazardous or conductive
materials and/or environments, we cannot guarantee their operation.

3U Digital PWM Amplifier User Manual

Table of Contents

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

Theory of Operation..................................................................................................................................................1

Power Supply Considerations ...................................................................................................................................1

Specifications............................................................................................................................................................2

Power Stage..........................................................................................................................................................2

Environmental ......................................................................................................................................................2

3U Power Supply..................................................................................................................................................2

Amplifier Display Codes...........................................................................................................................................2

CONNECTIONS.........................................................................................................................................................3

3U Amplifier Faceplate Connections........................................................................................................................3

Power Supply Faceplate............................................................................................................................................4

Hardware Connections to the Assembly ...................................................................................................................4

Hardware Connections to the Assembly ...................................................................................................................5

Power-DC Bus......................................................................................................................................................5

Power-AC Input....................................................................................................................................................6

Amplifier Power Section Pinout (603391-10x).....................................................................................................7

3U Power Supply Layout......................................................................................................................................8

3U AMPLIFIER BACKPLANE BOARD (603435-10X) .........................................................................................9

Front Side Connectors ..........................................................................................................................................9

Back Side Connectors.........................................................................................................................................10

3U Amplifier Backplane Layout (Back)..............................................................................................................11

3U Amplifier Backplane Layout (Front).............................................................................................................11

TROUBLESHOOTING............................................................................................................................................13

USEFUL NOTES.......................................................................................................................................................15

Table of Contents i

3U Digital PWM Amplifier User Manual

ii Table of Contents

3U Digital PWM Amplifier User Manual

INTRODUCTION

The 3U Digital PWM Amplifier board is a 3U-size amplifier designed to drive AC Induction, Permanent
Magnet Brushless, DC Brushed type motors. This amplifier unit comes in two packages: Two 680W
continuous power amplifiers or one 1360W continuous power amplifier. The 3U Digital PWM Amplifier
may be interfaced conveniently to the PMAC controller via ACC-24E2 or ACC-8F.

Typically, the amplifier is purchased with the Delta Tau 3U power supply and backplane interface card to
distribute the power to the unit.

Part Number Description

603428-10x 170V Power Supply for 3U Amplifiers
603435-10x Backplane Assembly for 3U Amplifiers

Theory of Operation

The 3U Digital PWM Amplifier is a 3-phase direct PWM drive, utilizing the latest in smart power
technology from the world’s leading vendors and the cutting edge algorithms of the PMAC2/UMAC
controller family. The 3U Digital PWM Amplifier can drive all of the motor types commonly used in
programmable motion control in both rotary and linear forms.

The 3U Digital PWM Amplifier is based on PWM (Pulse Width Modulation), a technique employing
both frequency and phase to approximate sinusoidal currents and to control AC and DC motors.

Each axis of the 3U Digital PWM Amplifier uses a three H-bridge legs scheme. Each leg employs a top
and bottom IGBT transistor. The motor windings are connected between the center points of top and
bottom pairs. When two appropriate IGBT transistors in the bridge are turned on, the current flows
through any two motor windings. Any two (top and bottom) bridge transistors are turned on by a logic
from PMAC2 with no other conditioning necessary, except an optical isolation. The 3U Digital PWM
Amplifier performs no control functions itself; it simply accepts direct PWM commands from the
PMAC2. PMAC2 requires the position feedback and the feedback about the current fed to the motors to
commutate each controlled axis.

The current feedback is provided in digital form as a part of a serial data stream of 18 bits (12 bits report
the current feedback and remaining 6 bits report fault conditions) from the current feedback A/D
converters which are located in the 3U Digital PWM Amplifier. Each axis has its own “mask” word that
tells the PMAC2 how many bits to expect from the A/D converter. The clock and the strobe for the digital
feedback are programmable at the PMAC2.

The position feedback is generally fed to PMAC2/UMAC via ACC 8F or ACC-24E2. The position
feedback is not connected to the Quad Amp in any way.

Power Supply Considerations

The 3U Digital PWM Amplifier requires a single power supply of +50V to +170V max. The current
requirement can vary depending on the load, but should not exceed 8A (4A per channel) continuous and
16A peak (8A per channel) for a 1-second period.

The logic power for the amplifier is derived from the BUS voltage. Typically, the BUS voltage can be
brought in from the amplifier backplane assembly card.

Any shunt resistors connected to the amplifiers are connected to the amplifier backplane assembly.

Introduction 1

Specifications

Power Stage

BUS Voltage (standard unit) 60V DC minimum

Max Continuous Current (per amp) 4A (RMS)

MAX ADC Current Loop Feedback 12A

Environmental

3U Power Supply

3U Digital PWM Amplifier User Manual

Description Specification

170V DC maximum

Peak Current (per amp) 8A

Maximum PWM Frequency 15 KHz

Description Specification

Operating Temperature

Storage Temperature

Humidity 0% to 95%, Non-Condensing

0°C to 55°C (32°F to 135°F)

-12°C to 82°C (10°F to 180°F)

Description Specification

Main AC Input Voltage 120V AC

Frequency 50/60 Hz

Main BUS Voltage 170V

Amplifier Display Codes

The amplifier is protected against severe electrical and temperature conditions. See the table below for a
code, and explanation.

Code Description

0 Everything is OK
1 2 sec over current, axis #1
2 Short circuit, axis # 1
3 Motor over temperature fault, axis #1
4 2 sec over current, axis # 2
5 Short circuit, axis #2
6 Motor over temperature fault, axis #2
8 Under voltage, global
9 High PWM fault, global

C Over voltage, global

2 Introduction