Delta Tau GEO DIRECT PWM DRIVE User Manual

^1 INSTALLATION MANUAL

^2 Geo Direct PWM Amplifier

^3 Direct PWM Amplifier

^4 500-603700-xIxx

^5 November 15, 2013

Single Source Machine Control

……………………………………………..…...……………….

Power // Flexibility // Ease of Use

21314 Lassen St. Chatsworth, CA 91311 // Tel. [phone] Fax. [phone] // www.deltatau.com

Copyright Information

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 understanding or use of
the equipment. It follows the discussion of interest.

© 2013 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
directly exposed to hazardous or conductive materials and/or environments, we cannot
guarantee their operation.

REVISION HISTORY

REV.

DESCRIPTION

DATE

CHANGE

APPROVAL

1

Added Power On/Off procedures,
Power PMAC section,
Refurbished entire manual

11/15/2013

RN

RN

Geo Direct PWM Amplifier

Table of Contents

INTRODUCTION .....................................................................................................................6

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

PART NUMBER .............................................................................................................................7

ENVIRONMENTAL SPECIFICATIONS ...............................................................................................7

ELECTRICAL SPECIFICATIONS .......................................................................................................8

230 VAC Drives – Single Axis .................................................................................................8

230 VAC Drives – Dual Axis...................................................................................................9

480 VAC Drives – Single Axis ............................................................................................... 10

480 VAC Drives – Dual Axis................................................................................................. 11

RECEIVING AND UNPACKING ......................................................................................... 12

USE OF EQUIPMENT .................................................................................................................... 12

MOUNTING, PHYSICAL LAYOUT .................................................................................... 13

GPX012 ..................................................................................................................................... 14

Low Profile, Single Width, No Fan ....................................................................................... 14

GPL032 .................................................................................................................................... 15

Single Width, No Fan............................................................................................................ 15

GPX05X, GPX102, GPL101, GPH032 ........................................................................................ 16

Single Width with Fan .......................................................................................................... 16

GPX201, GPX301, GPX152, GPH102 ........................................................................................ 17

Double Width, Two Fans ...................................................................................................... 17

CONNECTOR PINOUTS AND WIRING ............................................................................. 18

J1: MAIN BUS POWER INPUT ...................................................................................................... 18

Recommended Main Bus Power Wiring/Protection ............................................................... 19

Recommended Bus Power Fuse and Wire Gauge ................................................................ .. 22

J4: 24 VDC LOGIC CONTROL ..................................................................................................... 23

J2 – J3: MOTOR WIRING ............................................................................................................. 24

Motor Cable, Noise Elimination ........................................................................................... 25

Motor Selection .................................................................................................................... 26

J5: EXTERNAL SHUNT RESISTOR ................................................................................................. 28

Recommended Shunt Resistors ................................ .............................................................. 29

Shunt Resistor Layout ................................................................................................ ........... 30

X1 – X2: PWM CONNECTORS .................................................................................................... 31

X3: DISCRETE I/O FOR MOTOR THERMALS ................................................................................. 32

X4: SAFETY RELAY.................................................................................................................... 33

POWER ON/OFF PROCEDURES ........................................................................................ 34

Cycling Main Bus Power ...................................................................................................... 34

Table Of Contents 4

Geo Direct PWM Amplifier

PWM FREQUENCY .............................................................................................................. 36

POWER PMAC3 DRIVE SETUP .......................................................................................... 37

KEY GATE PARAMETERS ............................................................................................................ 37

KEY CHANNEL PARAMETERS ..................................................................................................... 38

POWER PMAC2 DRIVE SETUP .......................................................................................... 40

KEY GATE PARAMETERS ............................................................................................................ 40

KEY CHANNEL PARAMETERS ..................................................................................................... 41

TURBO PMAC2 DRIVE SETUP ........................................................................................... 43

KEY GATE PARAMETERS ............................................................................................................ 43

KEY CHANNEL PARAMETERS ..................................................................................................... 44

DRIVE COMMAND STRUCTURE ...................................................................................... 46

DEFAULT MODE ......................................................................................................................... 46

ENHANCED MODE ...................................................................................................................... 47

TROUBLESHOOTING .......................................................................................................... 49

LED STATUS ............................................................................................................................. 49

7-SEGMENT DISPLAY ................................................................................................................. 49

Error Codes.......................................................................................................................... 50

APPENDIX A: CABLE/CONNECTOR KITS ...................................................................... 52

PWM CABLES ........................................................................................................................... 52

CONNECTOR KITS ...................................................................................................................... 52

CABLE KITS ............................................................................................................................... 53

Table Of Contents 5

Geo Direct PWM Amplifier

INTRODUCTION

The Geo Direct PWM amplifiers provide a 1- or 2-axis motor power using highly integrated IGBT based
power circuitry. They support a wide variety of motors and power ranges. The Geo Direct PWM
amplifiers interface directly with Delta Tau’s PMAC2 or PMAC3 style digital ASICs, typically found in
the axis expansion cards inside a Turbo or Power UMAC rack.

The Geo Direct PWM Drive takes the actual power-transistor on/off signals from PMAC, while providing
digital phase-current feedback and status for closed-loop operation. The interface to the direct PWM
amplifier is through a standard 36-pin Mini-D style cable.

The Geo Direct PWM amplifiers are capable of driving brush, brushless, or induction motors. They
operate in the 100 VAC – 480 VAC (156 – 678 DC) range at 50/60Hz, while providing full protection:

 Over voltage
 Under voltage
 Over temperature
 PWM frequency limit
 Motor over temperature input
 Short circuit (phase – phase)
 Over current
 Safety relay circuit

Introduction 6

Geo Direct PWM Amplifier

Main AC Voltage Input:
L = 115 - 230 VAC
H = 300 - 480 VAC

Number of Axes:
1 = Single Axis
2 = Dual Axis

P

Continuous/Peak Current Rating (Sinusoidal Amp rms)

G 0 0 0

0 = No Safety Relay
1 = Safety Relay

01 = 1.5 / 4.5
03 = 3 / 9
05 = 5 / 10
10 = 10 / 20
15 = 15 / 30
20 = 20 / 40
30 = 30 / 60

Description

Specifications

Operating Temperature

0 to 45°C
Above 45°C,de-rate current output by 2.5% per °C

Storage Temperature

-25°C to +70°C

Humidity

10% to 90% non-condensing

Operating Altitude

~3300 Feet (1000 m)
De-rate current output by 1.1% per additional 330 feet (100m)

Air Flow Clearances

~3 inches (76.2mm) above and below unit for air flow

Operating Environment

Pollution Degree 2 or equivalent

SPECIFICATIONS

Part Number

Environmental Specifications

Specifications 7

Geo Direct PWM Amplifier

230 VAC Drives – Single Axis

GxL051

GxL101

GxL151

GxL201

GxL301

Main Input Power

Main AC Input

[VAC rms]

110

-20%

– 240

+10%

(~87 – 264)

Rated Input Current @ 240VAC 3󰡆

[A rms]

3.3

6.6

9.9

13.2

19.8

Frequency

[Hz]

50/60 Hz

Rated Input Power

[Watts]

1315

2629

3944

5259

7888

Main Bus Capacitance

[µf]

3380

5020

6800

AC Input Phase Requirement

1Φ or 3Φ

3Φ

Output

Continuous Current Output per Axis

[A rms]

5

10

15

20

30

Peak Current Output per Axis @ 2 sec

[A rms]

10

20

30

40

60

Power Output per Axis

[Watts]

1195

2390

3585

4780

7171

Bus Protection

Nominal DC Bus

[VDC]

325

Over-Voltage Trip Level

[VDC]

410

Under-Voltage Lockout Level

[VDC]

137

Shunt Resistor

Shunt Turn-On Voltage

[VDC]

392

Shunt Turn-Off Voltage

[VDC]

372

Shunt Resistor (300 W max)

GAR78

GAR48

GAR48-3

Logic Power

Input Voltage

[VDC]

20 – 27

Input Current

[A rms] 2 Inrush Current

[A]

4

Current Feedback

Full Scale Reading

[A]

16.26

32.53

48.79

65.05

97.58

Resolution

[bits]

12

Transistor Control

Recommended PWM Frequency

[KHz]

12

10 8 Minimum Dead time

[µs]

1

Charge Pump Time (% of PWM Period)

5

Note

All values are at ambient temperature of 0 – 45°C (113 F) unless
otherwise stated.

Electrical Specifications

Specifications 8

Geo Direct PWM Amplifier

230 VAC Drives – Dual Axis

GxL012

GxL032

GxL052

GxL102

GxL152

Main Input Power

Main AC Input

[VAC rms]

110

-20%

– 240

+10%

(~87 – 264)

Rated Input Current @ 240VAC 3󰡆

[A rms]

1.98

3.96

6.6

13.2

19.8

Frequency

[Hz]

50/60 Hz

Rated Input Power

[Watts]

789

1578

2629

5259

7888

Main Bus Capacitance

[µf]

3380

5020

AC Input Phase Requirement

1Φ or 3Φ

3Φ

Output

Continuous Current Output per Axis

[A rms]

1.5 3 5

10

15

Peak Current Output per Axis @ 2 sec

[A rms]

4.5 9 10

20

30

Power Output per Axis

[Watts]

359

717

1195

2390

3585

Bus Protection

Nominal DC Bus

[VDC]

325

Over-Voltage Trip Level

[VDC]

410

Under-Voltage Lockout Level

[VDC]

137

Shunt Resistor

Shunt Turn-On Voltage

[VDC]

392

Shunt Turn-Off Voltage

[VDC]

372

Shunt Resistor (300 W max)

GAR78

GAR48

Logic Power

Input Voltage

[VDC]

20 – 27

Input Current

[A rms] 2 Inrush Current

[A]

4

Current Feedback

Full Scale Reading

[A]

7.32

14.64

16.26

32.53

48.79

Resolution

[bits]

12

Transistor Control

Recommended PWM Frequency

[KHz]

16

12

10

Minimum Dead time

[µs]

1

Charge Pump Time (% of PWM Period)

5

Note

All values are at ambient temperature of 0–45°C (113 F) unless
otherwise stated.

Specifications 9

Geo Direct PWM Amplifier

480 VAC Drives – Single Axis

GxH051

GxH101

GxH151

GxH201

GxH301

Main Input Power

Main AC Input

[VAC rms]

375

-20%

– 480

+10%

(~300 – 525)

Rated Input Current

[A rms]

3.3

6.6

9.9

13.2

19.8

Frequency

[Hz]

50/60 Hz

Rated Input Power

[Watts]

2744

5487

8231

10974

16461

Main Bus Capacitance

[µf]

845

1255

1700

AC Input Phase Requirement

1Φ or 3Φ

3Φ

Output

Continuous Current Output per Axis

[A rms]

5

10

15

20

30

Peak Current Output per Axis @ 2 sec

[A rms]

10

20

30

40

60

Power Output per Axis

[Watts]

2494

4988

7482

9977

14965

Bus Protection

Nominal DC Bus

[VDC]

678

Over-Voltage Trip Level

[VDC]

828

Under-Voltage Lockout Level

[VDC]

137

Shunt Resistor

Shunt Turn-On Voltage

[VDC]

784

Shunt Turn-Off Voltage

[VDC]

744

Shunt Resistor (300 W max)

GAR78

GAR48

GAR48-3

Logic Power

Input Voltage

[VDC]

20 – 27

Input Current

[A rms] 2 Inrush Current

[A]

4

Current Feedback

Full Scale Reading

[A]

16.26

32.53

48.79

65.05

97.58

Resolution

[bits]

12

Transistor Control

Recommended PWM Frequency

[KHz]

12

10 8 Minimum Dead time

[µs]

1.6

Charge Pump Time (% of PWM Period)

5

Note

All values are at ambient temperature of 0–45°C (113 F) unless
otherwise stated.

Specifications 10

Geo Direct PWM Amplifier

480 VAC Drives – Dual Axis

GxH012

GxH032

GxH052

GxH102

GxH152

Main Input Power

Main AC Input

[VAC rms]

375

-20%

– 480

+10%

(~300 – 525)

Rated Input Current @ 240VAC 3󰡆

[A rms]

1.98

3.96

6.6

13.2

19.8

Frequency

[Hz]

50/60 Hz

Rated Input Power

[Watts]

1646

3292

5487

10974

16461

Main Bus Capacitance

[µf]

845

1255

AC Input Phase Requirement

1Φ or 3Φ

3Φ

Output

Continuous Current Output per Axis

[A rms]

1.5 3 5

10

15

Peak Current Output per Axis @ 2 sec

[A rms]

4.5 9 10

20

30

Power Output per Axis

[Watts]

748

1496

2494

4988

7482

Bus Protection

Nominal DC Bus

[VDC]

678

Over-Voltage Trip Level

[VDC]

828

Under-Voltage Lockout Level

[VDC]

137

Shunt Resistor

Shunt Turn-On Voltage

[VDC]

784

Shunt Turn-Off Voltage

[VDC]

744

Shunt Resistor (300 W max)

GAR78

GAR48

Logic Power

Input Voltage

[VDC]

20 – 27

Input Current

[A rms] 2 Inrush Current

[A]

4

Current Feedback

Full Scale Reading

[A]

7.32

14.64

16.26

32.53

48.79

Resolution

[bits]

12

Transistor Control

Recommended PWM Frequency

[KHz]

12

10 8 Minimum Dead time

[µs]

1.6

Charge Pump Time (% of PWM Period)

5

Note

All values are at ambient temperature of 0–45°C (113 F) unless
otherwise stated.

Specifications 11

Geo Direct PWM Amplifier

RECEIVING AND UNPACKING

Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the
Geo Direct PWM Drive is received, there are several things to be done immediately:

 Observe the condition of the shipping container and report any damage immediately to the

commercial carrier that delivered the drive.

 Remove the drive from the shipping container and remove all packing materials. Check all shipping

material for connector kits, documentation, or other small pieces of equipment. Be aware that some
connector kits and other equipment pieces may be quite small and can be accidentally discarded if
care is not used when unpacking the equipment. The container and packing materials may be retained
for future shipment.

 Verify that the part number of the drive received is the same as the part number listed on the purchase

order.

 Inspect the drive for external physical damage that may have been sustained during shipment and

report any damage immediately to the commercial carrier that delivered the drive.

 Electronic components in this product are design-hardened to reduce static sensitivity. However, use

proper procedures when handling the equipment.

 If the Geo Direct PWM Drive is to be stored for several weeks before use, be sure that it is stored in a

location that conforms to published storage humidity and temperature specifications.

Use of Equipment

The following restrictions will ensure the proper use of the Geo Direct PWM Drive:

 The components built into electrical equipment or machines can be used only as integral components

of such equipment.

 The Geo Direct PWM Drive must not be operated on power supply networks without a ground or

with an asymmetrical ground.

 If the Geo Direct PWM Drive is used in residential areas, or in business or commercial premises,

implement additional filtering measures.

 The Geo Direct PWM Drive may be operated only in a closed switchgear cabinet, taking into account

the ambient conditions defined in the environmental specifications.

Delta Tau guarantees the conformance of the Geo Direct PWM Drives with the standards for industrial
areas stated in this manual, only if Delta Tau components (cables, controllers, etc.) are used.

Receiving and Unpacking 12

Geo Direct PWM Amplifier

Caution

Unit must be installed in an enclosure that meets the environmental IP
rating of the end product (ventilation or cooling may be necessary to
prevent enclosure ambient from exceeding 45° C [113° F]).

MOUNTING, PHYSICAL LAYOUT

The location of the Geo Direct PWM Drive is important. Installation should be in an area that is
protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and other
contaminants. Exposure to these can reduce the operating life and degrade performance of the drive.

Several other factors should be carefully evaluated when selecting a location for installation:

 For effective cooling and maintenance, the Geo Direct PWM Drive should be mounted on a

smooth, non- flammable vertical surface.

 At least 76 mm (3 inches) top and bottom clearance must be provided for air flow. At least 10

mm (0.4 inches) clearance is required between units (each side).

 Temperature, humidity and Vibration specifications should also be taken in account.

The Geo Direct PWM Drive can be mounted with a traditional 4-hole panel mount, two U shape/notches
on the bottom and two pear shaped holes on top.

If multiple Geo Direct PWM Drives are used, they can be mounted side-by-side, leaving at least a 122
mm clearance between drives. This means a 122 mm center-to-center distance (0.4 inches) with the 4­axis Drives. 8- and 6-axis Geo Direct PWM Drives can be mounted side by side at 214 mm center-to­center distance (8.4 inches). It is extremely important that the airflow is not obstructed by the placement
of conduit tracks or other devices in the enclosure.
If the drive is mounted to a back panel, the back panel should be unpainted and electrically conductive to
allow for reduced electrical noise interference. The back panel should be machined to accept the
mounting bolt pattern of the drive.

The Geo Direct PWM Drive can be mounted to the back panel using four M4 screws and internal-tooth
lock washers. It is important that the teeth break through any anodization on the drive’s mounting gears
to provide a good electrically conductive path in as many places as possible. Mount the drive on the back
panel so there is airflow at both the top and bottom areas of the drive (at least three inches).

Mounting, Physical Layout 13

Geo Direct PWM Amplifier

Width

Height

Depth

Weight

3.30 in. / 84 mm

11.00 in. / 280 mm

5.80 in. / 147 mm

4.2 lbs / 1.9 kgs

GATE ENABLE

DELTA TAU

Data Systems, Inc.

24VDC INPUT (J4)

L2

AC INPUT (J1)

L1

24VDC

+24VDC

RET

L3

DISCRETE I/O (X3)

Wait 5 minutes after

N/A

(X4)

SAFETY RELAY (X4)

before servicing unit.

removing power

WARNING:

HIGH VOLTAGE!

RELAY COMM
RELAY WB
RELAY WA

RELAY N/O

NOT USED

MTR1 PTC RET

MTR2 PTC RET

24V RET

MTR1 PTC

MTR2 PTC

Residual Voltage.

WARNING!

INPUT 1

DC BUS

AMP

STATUS

(D1)

SHUNT

ENABLE 1

+5V

ENABLE 2

(X1)

PWM

INPUT 2

PWM

(X2)

EXT SHUNT (J5)

REGEN -

REGEN +

MOTOR 2 (J3)

W V U

MOTOR 1 (J2)

W V U

10.625”

(269.875 mm)

2.7”

(68.6 mm)

9.875”

(250.825 mm)

3.3”

(83.82 mm)

5.79”

(147.066 mm)

GPx012

Low Profile, Single Width, No Fan

Mounting, Physical Layout 14

Geo Direct PWM Amplifier

Width

Height

Depth

Weight

3.30 in./ 84 mm

11.00 in./ 280 mm

8.00 in./ 203 mm

5.4 lbs/ 2.45 kgs

L1

24VDC

+24VDC

24VDC INPUT (J4)

L2

AC INPUT (J1)

L3

RET

EXT SHUNT (J5)

REGEN +

REGEN -

MOTOR 2 (J3)

W V

MOTOR 1 (J2)

U W UV

GATE ENABLE

DELTA TAU

Data Systems, Inc.

DISCRETE I/O (X3)

Wait 5 minutes after

N/A

(X4)

SAFETY RELAY (X4)

before servicing unit.

removing power

WARNING:

HIGH VOLTAGE!

RELAY COMM
RELAY WB
RELAY WA

RELAY N/O

NOT USED

MTR1 PTC RET

MTR2 PTC RET

24V RET

MTR1 PTC

MTR2 PTC

Residual Voltage.

WARNING!

INPUT 1

DC BUS

AMP

STATUS

(D1)

SHUNT

ENABLE 1

+5V

ENABLE 2

(X1)

PWM

INPUT 2

PWM
(X2)

10.625”

(269.875 mm)

2.7”

(68.6 mm)

9.875”

(250.825 mm)

3.3”

(83.82 mm)

5.79”

(147.066 mm)

GPL032

Single Width, No Fan

Mounting, Physical Layout 15

Geo Direct PWM Amplifier

Width

Height

Depth

Weight

3.30 in./ 84 mm

11.00 in./ 280 mm

8.00 in./ 203 mm

5.5 lbs/ 2.5 kgs

AC INPUT (J1)

L2

L1

24VDC INPUT (J4)

+24VDC

RET

24VDC

L3

EXT SHUNT (J5)

REGEN -

REGEN +

MOTOR 2 (J3)

W V U

MOTOR 1 (J2)

W V U

GATE ENABLE

DELTA TAU

Data Systems, Inc.

DISCRETE I/O (X3)

Wait 5 minutes after

N/A

(X4)

SAFETY RELAY (X4)

before servicing unit.

removing power

WARNING:

HIGH VOLTAGE!

RELAY COMM
RELAY WB
RELAY WA

RELAY N/O

NOT USED

MTR1 PTC RET

MTR2 PTC RET

24V RET

MTR1 PTC

MTR2 PTC

Residual Voltage.

WARNING!

INPUT 1

DC BUS

AMP

STATUS

(D1)

SHUNT

ENABLE 1

+5V

ENABLE 2

(X1)

PWM

INPUT 2

PWM
(X2)

10.625”

(269.875 mm)

2.7”

(68.6 mm)

9.875”

3.3”

(83.82 mm)

5.79”

(147.066 mm)

GPx05x, GPx102, GPL101, GPH032

Single Width with Fan

Mounting, Physical Layout 16