Delta Tau GEO MACRO DRIVE User Manual

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^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: 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.

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

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

12/08/09 CP S. MILICI

Geo MACRO Drive User and Reference Manual

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

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Geo MACRO Drive User Manual

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

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Geo MACRO Drive User and Reference Manual

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

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Geo MACRO Drive User Manual

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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Geo MACRO Drive User and Reference Manual

MS{node},MI916 Output n Mode Select .......................................................................................................148

MS{node},MI917 Output n Invert Control....................................................................................................148

MS{node},MI918 Output n PFM Direction Signal Invert Control ...............................................................149

MS{node},MI919 Hardware 1/T ...................................................................................................................149

MS{node},MI921 Flag Capture Position (Read Only)..................................................................................150

MS{node},MI922 ADC A Input Value (Read Only) ......................................................................................150

MS{node},MI923 Compare Auto-Increment Value.......................................................................................150

MS{node},MI924 ADC B Input Value (Read Only) ......................................................................................150

MS{node},MI925 Compare A Position Value...............................................................................................151

MS{node},MI926 Compare B Position Value...............................................................................................151

MS{node},MI927 (Reserved for future use)......................................................................................................151

MS{node},MI928 Compare-State Write Enable............................................................................................151

MS{node},MI929 Compare-Output Initial State...........................................................................................151

General Hardware Setup MI-variables..................................................................................................................152

MS{anynode}, MI930 SSI Channel 1 Control Word .....................................................................................152

MS{anynode}, MI931 SSI Channel 2 Control Word ....................................................................................152

MS{anynode}, MI932 Resolver Excitation Frequency Divider....................................................................153

MS{anynode}, MI933 SSI Clock Frequency Divider ...................................................................................153

MS{anynode},MI934-MI939 (Reserved for future use)................................................................................153

MS{anynode}, MI940 Resolver Excitation Gain .........................................................................................153

MS{anynode}, MI941 Resolver Excitation Phase Offset.............................................................................154

MS{anynode},MI942 ADC Strobe Word Channel 1* & 2* ..........................................................................154

MS{node},MI943 Encoder Power control bit ...............................................................................................154

MS{node},MI944-MI949 (Reserved for future use) .....................................................................................154

Global & 2-Axis Board I-Variables ......................................................................................................................155

MS{node},MI992 MaxPhase Frequency Control..........................................................................................155

MS{node},MI993 Hardware Clock Control Handwheel Channels...............................................................155

MS{node},MI994 PWM Deadtime ...............................................................................................................157

MS{node},MI995 MACRO Ring Configuration/Status .................................................................................157

MS{node},MI996 MACRO Node Activate Control .......................................................................................158

MS{node},MI997 Phase Clock Frequency Control ......................................................................................160

MS{node},MI998 Servo Clock Frequency Control.......................................................................................160

ABSOLUTE POWER ON ONLINE COMMANDS.............................................................................................161

$$*.........................................................................................................................................................................161

$*...........................................................................................................................................................................161

APPENDIX A...........................................................................................................................................................166

Fiber Optic Cable Ordering Information...............................................................................................................166

Mating Connector and Cable Kits.........................................................................................................................166

Mating Connector and Cable Kits ....................................................................................................................166

Connector and pins Part numbers ....................................................................................................................168

Cable Drawings ................................................................................................................................................170

Regenerative Resistor: GAR78/48 .......................................................................................................................176

Type of Cable for Encoder Wiring........................................................................................................................177

APPENDIX B...........................................................................................................................................................180

Schematics.............................................................................................................................................................180

X3: Discrete I/O...............................................................................................................................................180

X6 and X7: Analog Inputs................................................................................................................................182

X8 and X9 Secondary Encoders (3 and 4)........................................................................................................183

APPENDIX C...........................................................................................................................................................184

Communication to the Geo MACRO via the USB Port........................................................................................184

APPENDIX D...........................................................................................................................................................186

MACRO Flag Transfer Location...........................................................................................................................186

Turbo PMAC2 Node Addresses............................................................................................................................187

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Geo MACRO Drive User Manual

ADC Register Table ..............................................................................................................................................189

Stepping through an Electrical Cycle....................................................................................................................190

Manually Stepping through an Electrical Cycle at 30 degree increments........................................................190

Example 1 of Hall Effect Values .......................................................................................................................191

Example 2 of Hall Effect Values .......................................................................................................................192

USEFUL NOTES.....................................................................................................................................................193

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Geo MACRO Drive User and Reference Manual

INTRODUCTION

The Geo Drive family of “bookcase”-style servo amplifiers provides many new capabilities for users. This family of 1- and 2-axis 3-phase amplifiers, built around a common core of highly integrated IGBTbased power circuitry, supports a wide variety of motors, power ranges, and interfaces. The 2-axis configurations share common power input, bus, and shunt for a very economical implementation.

Three command interfaces are provided: direct-PWM, MACRO-ring, and integrated PMAC controller, each described in following sections. In all three cases, fully digital “direct PWM” control is used. Direct PWM control eliminates D-to-A and A-to-D conversion delays and noise, allowing higher gains for more robust and responsive tuning without sacrificing stability.

All configurations provide these power-stage features:

• Direct operation off AC power mains (100 – 240 or 300 – 480 VAC, 50/60 Hz) or optional DC

power input (24 – 350 or 24 – 700 VDC)

• Integrated bus power supply including soft start and shunt regulator (external resistor required)

• Separate 24VDC input to power logic circuitry

• Complete protection: over voltage, under voltage, over temperature, PWM frequency limit,

minimum dead time, motor over temperature, short circuit, over current, input line monitor

• Ability to drive brushed and brushless permanent-magnet servo motors, or AC induction motors

• Single-digit LED display and six discrete LEDs for status information

• Optional safety relay circuitry. Please contact factory for more details and pricing.

• Easy setup with Turbo PMAC and UMAC controllers.

User Interface

The Geo Drive family is available in different versions distinguished by their user interface styles.

Geo MACRO Drives

The Geo MACRO Drive interfaces to the controller through the 125 Mbit/sec MACRO ring, with either a fiber-optic or Ethernet electrical medium, accepting numerical command values for direct PWM voltages and returning numerical feedback values for phase current, motor position, and status. It accepts many types of position feedback to the master controller, as well as axis flags (limits, home, and user) and general-purpose analog and digital I/O. Typically, the Geo MACRO Drives are commanded by either a PMAC2 Ultralite bus-expansion board, or a UMAC rack-mounted controller with a MACRO-interface card. This provides a highly distributed hardware solution, greatly simplifying system wiring, while maintaining a highly centralized software solution, keeping system programming simple.

• Choices for main feedback for each axis: A/B quadrature encoder, sinusoidal encoder with

• Secondary A/B quadrature encoder for each axis

• General-purpose isolated digital I/O: 4 in, 4 out at 24VDC

EnDat

or HiperfaceTM, SSI encoder, resolver

• 2 optional A/D converters, 12- or 16-bit resolution

Note:

Geo MACRO is not using the regular 8-axis or 16-axis MACRO station CPU.

A new MACRO CPU was developed for the Geo MACRO drive.

Introduction 1

Geo MACRO Drive User Manual

Geo PMAC Drives

The Geo PMAC Drive is a standalone-capable integrated controller/amplifier with a built-in full PMAC2 controller having stored-program capability. It can be operated standalone, or commanded from a host computer through USB2.0 or 100 Mbps Ethernet ports. The controller has the full software capabilities of a PMAC (see descriptions), with an internal fully-digital connection to the advanced Geo power-stage , providing a convenient, compact, and cost-effective installation for one and two-axis systems, with easy synchronization to other drives and controls.

• Choices for main feedback for each axis: A/B quadrature encoder, sinusoidal encoder with

• Secondary A/B quadrature encoder for each axis

• General-purpose isolated digital I/O: 8 in, 6 out at 24VDC

• 2 optional A/D converters 12- or 16-bit resolution

EnDat

or HiperfaceTM, SSI encoder, resolver

Geo Direct-PWM Drives

The direct-PWM interface versions accept the actual power-transistor on/off signals from the PMAC2 controller, while providing digital phase-current feedback and drive status to the controller for closedloop operation. Interface to the direct-PWM amplifier is through a standard 36-pin Mini-D style cable. The drive performs no control functions but has protection features. Drive installation, maintenance, and replacement are simplified because there is less wiring (position feedback and I/O are not connected to the drive) and there are no variables to set or programs to install in the drive.

• Fully centralized control means that all gains and settings are made in the PMAC; no software

setup of drive is required

• No position feedback or axis flags required at the drive

MACRO Defined

MACRO defined is a digital interface for connection of multi–axis motion controllers, amplifiers and other I/O devices on a fiber optic or twisted pair copper (RJ45 connector) ring.

MACRO operates in a ring topology. Data is transmitted serially. Each station on the ring has an in port for receiving data and an out port for transmitting data. Nodes, residing at a station can be amplifier axes, I/O banks, or communication interfaces to other devices. A station can have one or several nodes allowing for multi-axis amplifiers with a single in and single out port. Data packets, (groups of 96 bits of serial data) from the motion controller or master node are addressed to a specific amplifier or slave node. If the data packet is not for an amplifier, it is passed on unchanged. If it is for the node, it copies the contents of the data packet (typically commands), places feedback data into a packet, and transmits the data packet.

MACRO’s Advantages are:

• Single–plug connections between controls and amplifiers: A single fiber optic strand can provide a

controller with: position feedback, flag status (limits, home flag), amplifier status and machine input status. This same strand can communicate to the amplifier and other devices on the MACRO network (Amplifier enable and amplifier command signals, machine outputs, commands to D/A converters; all can be implemented with a single plug connection).

• Noise Immunity: Fiber–optic cable transmits light, not electricity. Unlike electricity light is immune

to electromagnetic noise, capacitive coupling, ground loops, and other wiring problems.

• Speed: MACRO’s operation is 125 Mbits/second. This is at least 25 times faster than other digital

motion control interfaces.

2 Introduction

Geo MACRO Drive User and Reference Manual

• One ring, multiple masters: In a ring network, several motion controllers (masters) can be on one

ring. Each controller controls several axes (up to 32 ea.).

• Simplicity: Transmission within the MACRO ring requires no software intervention. The

information sent to all nodes is written to a memory location and the MACRO hardware takes care of the rest.

Feedback Devices

Many motors incorporate a position feedback device. Devices are incremental encoders, resolvers, and sine encoder systems. The macro version of the Geo drive accepts feedback. In its standard form, it is set up to accept incremental encoder feedback. With the appropriate feedback option, it is possible to use either resolver or sinusoidal encoder feedback. Historically, the choice of a feedback device has been guided largely by cost and robustness. Today, feedbacks are relatively constant for the cost and picked by features such as size and feedback data. More feedback data or resolution provides the opportunity to have higher gains in a servo system.

Geo MACRO drives have standard secondary quadrature encoder feedback. One secondary encoder (X8) for one axis drive and two secondary encoders (X8 and X9) for dual axis drives (603542 rev-10A and above). Earlier versions of the Geo MACRO drive cannot use the secondary encoders.

Compatible Motors

The Geo drive product line is capable of interfacing to a wide variety of motors. The Geo drive can control almost any type of three-phase brushless motor, including DC brushless rotary, AC brushless rotary, induction, and brushless linear motors. Permanent magnet DC brush motors can also be controlled using two of the amplifiers three phases. Motor selection for an application is a science in itself and cannot be covered in this manual. However, some basic considerations and guidelines are offered. Motor manufacturers include a host of parameters to describe their motor.

Some basic equations can help guide an applications engineer to mate a proper drive with a motor. A typical application accelerates a load to a speed, running the speed for a while and then decelerating the load back into position.

Maximum Speed

The motor’s maximum rated speed is given. This speed may or may not be achievable in a given system. The speed could be achieved if enough voltage and enough current loop gain are available. Also consider the motor’s feedback adding limitations to achievable speeds. The load attached to the motor also limits the maximum achievable speed. In addition, some manufacturers will provide motor data with their drive controller, which is tweaked to extend the operation range that other controllers may be able to provide. In general, the maximum speed can be determined by input voltage line-to-line divided by Kb (the motor’s back EMF constant). It is wise to de-rate this a little for proper servo applications.

Torque

The torque required for the application can be viewed as both instantaneous and average. Typically, the instantaneous or peak torque is calculated as a sum of machining forces or frictional forces plus the forces required to accelerate the load inertia. The machining or frictional forces on a machine must be determined by the actual application. The energy required to accelerate the inertia follows the equation: T = JA, where T is the torque in Newton-meters or pound-feet required for the acceleration, J is the inertia in kilogram-meters-squared or pound-feet-second squared, and A is in radians per second per second. The required torque can be calculated if the desired acceleration rate and the load inertia reflected back to the motor are known. The T=JA equation requires that the motor’s inertia be considered as part of the inertia-requiring torque to accelerate.

Once the torque is determined, the motors specification sheet can be reviewed for its torque constant parameter (Kt). The torque required at the application divided by the Kt of the motor provides the peak current required by the amplifier. A little extra room should be given to this parameter to allow for good

Introduction 3

Geo MACRO Drive User Manual

servo control.

Most applications have a duty cycle in which the acceleration profile occurs repetitively over time. Calculating the average value of this profile gives the continuous rating required by the amplifier. Applications also concern themselves with the ability to achieve a speed. The requirements can be reviewed by either defining what the input voltage is to the drive, or defining what the voltage requirements are at the motor. Typically, a system is designed at a 230 or 480V input line. The motor must be able to achieve the desired speed with this voltage limitation. This can be determined by using the voltage constant of the motor (Kb), usually specified in volts-per-thousand rpm. The application speed is divided by 1000 and multiplied by the motor's Kb. This is the required voltage to drive the motor to the desired velocity. Headroom of 20% is suggested to allow for good servo control.

Peak Torque

The peak torque rating of a motor is the maximum achievable output torque. It requires that the amplifier driving it be able to output enough current to achieve this. Many drive systems offer a 3:1 peak-tocontinuous rating on the motor, while the amplifier has a 2:1 rating. To achieve the peak torque, the drive must be sized to be able to deliver the current to the motor. The required current is often stated on the datasheet as the peak current through the motor. In some sense, it can also be determined by dividing the peak amplifier's output rating by the motor's torque constant (Kt).

Continuous Torque

The continuous torque rating of the motor is defined by a thermal limit. If more torque is consumed from the motor than this on average, the motor overheats. Again, the continuous torque output of the motor is subject to the drive amplifier’s ability to deliver that current. The current is determined by the manufacturer’s datasheets stating the continuous RMS current rating of the motor and can also be determined by using the motor’s Kt parameter, usually specified in torque output per amp of input current.

Motor Poles

Usually, the number of poles in the motor is not a concern to the actual application. However, it should be noted that each pole-pair of the motor requires an electrical cycle. High-speed motors with high motor pole counts can require high fundamental drive frequencies that a drive amplifier may or may not be able to output. In general, drive manufacturers with PWM switching frequencies (16kHz or below) would like to see commutation frequencies less than 400 Hz. The commutation frequency is directly related to the number of poles in the motor.

Motor Inductance

PWM outputs require significant motor inductance to turn the on-off voltage signals into relatively smooth current flow with small ripple. Typically, motor inductance of servomotors is 1 to 15 mH. The Geo drive product series can drive this range easily. On lower-inductance motors (below 1mH), problems occur due to PWM switching where large ripple currents flow through the motor, causing excessive energy waste and heating. If an application requires a motor of less than 1mH, external inductors are recommended to increase that inductance. Motors with inductance in excess of 15mH can still be driven, but are slow to react and typically are out of the range of high performance servomotors.

Motor Resistance

Motor resistance is not really a factor in determining the drive performance, but rather, comes into play more with the achievable torque or output horsepower from the motor. The basic resistance shows up in the manufacturer's motor horsepower curve.

Motor Back EMF

The back EMF of the motor is the voltage that it generates as it rotates. This voltage subtracts from the bus voltage of the drive and reduces the ability to push current through the motor. Typical back EMF

4 Introduction

Geo MACRO Drive User and Reference Manual

ratings for servomotors are in the area of 8 to 200 volts-per-thousand rpm. The Geo drive product series can drive any range of back EMF motor, but the back EMF is highly related to the other parameters of the motor such as the motor inductance and the motor Kt. It is the back EMF of the motor that limits the maximum achievable speed and the maximum horsepower capability of the motor.

Motor Torque Constant

Motor torque constant is referred to as Kt and usually it is specified in torque-per-amp. It is this number that is most important for motor sizing. When the load that the motor will see and knowing the motor’s torque constant is known, the drive amplifier requirements can be calculated to effectively size a drive amplifier for a given motor. Some motor designs allow Kt to be non-linear, in which Kt will actually produce less torque per unit of current at higher output speeds. It is wise to de-rate the systems torque producing capability by 20% to allow headroom for servo control.

Motor Inertia

Motor inertia comes into play with motor sizing because torque to accelerate the inertia of the motor is effectively wasted energy. Low inertia motors allow for quicker acceleration. However, consider the reflected inertia from the load back to the motor shaft when choosing the motor’s inertia. A high ratio of load-to-motor inertia can limit the achievable gains in an application if there is compliance in the transmission system such as belt-drive systems or rubber-based couplings to the systems. The closer the rotor inertia matches the load’s reflected inertia to the motor shaft, the higher the achievable gains will be for a given system. In general, the higher the motor inertia, the more stable the system will be inherently. Mechanical gearing is often placed between the load and the motor simply to reduce the reflected inertia back to the motor shaft.

Motor Cabling

Motor cables are an integral part of a motor drive system. Several factors should be considered when selecting motor cables. First, the PWM frequency of the drive emits electrical noise. Motor cables must have a good-quality shield around them. The motor frame must also have a separate conductor to bring back to the drive amplifier to help quench current flows from the motor due to the PWM switching noise. Both motor drain wire and the cable shield should be tied at both ends to the motor and to the drive amplifier.

Another consideration in selecting motor cables is the conductor-to-conductor capacitance rating of the cable. Small capacitance is desirable. Longer runs of motor cable can add motor capacitance loading to the drive amplifier causing undesired spikes of current. It can also cause couplings of the PWM noise into the earth grounds, causing excessive noise as well. Typical motor cable ratings would be 50 pf per foot maximum cable capacitance.

Another factor in picking motor cables is the actual conductor cross-sectional area. This refers to the conductors ability to carry the required current to and from the motor. When calculating the required cable dimensions, consider agency requirements, safety requirements, maximum temperature that the cable will be exposed to, the continuous current flow through the motor, and the peak current flow through the motor. Typically, it is not suggested that any motor cable be less than 14 AWG.

The motor cable’s length must be considered as part of the application. Motor cable length affects the system in two ways. First, additional length results in additional capacitive loading to the drive. The drive’s capacitive loading should be kept to no more than 1000pf. Additionally, the length sets up standing waves in the cable, which can cause excessive voltage at the motor terminals. Typical motor cable length runs of up to 60 meters (200 feet) for 230V systems and 15 meters (50 feet) for 480V systems are acceptable. Exceeding these lengths may put other system requirements in place for either a snubber at the motor end or a series inductor at the drive end. The series inductor at the drive end provides capacitance loading isolation from the drive and slows the rise time of the PWM signal into the cable, resulting in less voltage overshoot at the motor.

Introduction 5

Geo MACRO Drive User Manual

6 Introduction

Geo MACRO Drive User and Reference Manual

SPECIFICATIONS

Part Number

Geo MACRO Drive

Model Number Definition

GL03 1 0

Voltage Rating (Direct M ains ) L = 110 - 240 VAC H = 300 - 480 VAC

Continuous/Peak Current Rating (Sinusoidal RMS)

01 = 1.5/4.5 Amp (one or 3 03 = 3/9 Amp (one or 3 05 = 5/10 Amp (3 10 = 10/20 Amp (3 15 = 15/30 Amp (3 20 = 20/40 Amp (3 30 = 30/60 Amp (3 *For single phase input, need to derate 30%

Product Width According to Ratings Single -Width U nits :

1.5/4.5 Dual Axis 10/20 Dual Axis (480VAC) 3/9 Dual Axis 15/30 Dual Axis 5/10 Single and Dual Axis 20/40 Single Axis 10/20 Single Axis and Dual Axis (240VAC) 30/60 Single Axis 15/30 Single Axis

φ φ φ φ

operation )

input, for single φ need to derate 20%)

input*) input*) input*) input*)

Number of Axes 1 = Single Axis 2 = Dual Axis

Double-Width Units:

Feedback Options 0 = No options, Default; Standard feedback

per axis is quadrature differential encoder with hall effect inputs or SSI absolute encoder .

1 = Analog Feedback including:

• Option 0 Standard Feedback

• 4096x Sin/Cos interpolator

• Resolver Interface

2 = Absolute Feedback including :

• Option 1 Analog Feedback

• Endat™

• Hiperface™

3, 4, 5 = Same as Options 0, 1 and 2 described above but with two 16-bit analog-to-digital converter inputs

Note: Any available method can be used for feedback but only one method can be used at any time . Feedback method is selected by wiring.

MACRO Link Options: F = Fiber Optic R = RJ/45 (Default)

GMx012xx

GMx051xx

GMx101xx

GMx151xx

GMx032xx

GMx052xx

GML102xx

GMx201xx

GMx301xx

GMH102xx

GMx152xx

Single axis

Dual Axis

Single Width

Size Axis

Double width

√ √ √ √ √

√ √ √ √ √ √

√* √ √ √ √ √ √

√ √ √ √

* Low Profile Unit, No heatsink, no Fan

Specifications 7

Geo MACRO Drive User Manual

Geo MACRO Feedback Options

Model Default Configuration:

Quadrature Encoders Or SSI Absolute Encoders And Hall Effect inputs

GMxxxxx0 GMxxxxx1 GMxxxxx2 GMxxxxx3 GMxxxxx4 GMxxxxx5

√

√ √

√ √ √ √

Analog (Sin/Cos) Encoders: x4096 Interpolator Resolver to Digital Converters

Absolute Encoder Interfaces: EnDat Hiperface

Addition of two channels of 16-bit A/D converters with each feedback option

Package Types

Geo package types provide various power levels and one or two axis capability with three different package types.

The Geo Drive has a basic package size of 3.3"W x 11"H x 8.0"D(84mm W x 280mm H x 203mm D). This size includes the heat sink and fan. In this package size, Single Width, the Geo can handle one or two low-to-medium power axes or only a single axis for medium to high power.

The mechanical design of the Geo drive is such that it allows two heat sinks to be easily attached together to provide two high power axes in a double width configuration. This double package size is 6.5" W x 11" H x 8.0" D (165 mm W x 280 mm H x 203 mm D). It provides a highly efficient package size containing two axes of up to about 10kW each thus driving nearly 24kW of power, but using a single interface card. This results in a highly cost effective package.

There is also one more package type only for the low power (1.5A/4.5A) single width Geo drive, model Gxx012xx. This package substitutes the heatsink and the fan with a smaller plate which has the same mounting pattern as the regular single width drive, making the units depth 2.2inches (56mm) less than the single width drive, 5.8" D (148mm D).

• Low Profile: GMx012xx (only)

3.3" wide (84 mm) (no heatsink, no fan), Maximum Power Handling ~1200 watts Package Dimensions: 3.3" W x 11" H x 5.8" D (84 mm W x 280 mm H x 148 mm D) Weight: 4.3 lbs. (1.95kgs)

• Single Width: GMx051xx, GMx101xx, GMx151xx, GMH032xx, GMx052xx and GML102xx.

3.3" wide (84 mm)(with heatsink and fan), Maximum Power Handling ~12000 watts GML032xx Single Width, with heatsink, no Fan (Weight 5.4lbs/2.45kgs) Package Dimensions: 3.3" W x 11" H x 8.0" D (84 mm W x 280 mm H x 203 mm D) Weight: 5.5 lbs. (2.50kgs)

• Double Width: GMx201xx, GMx301xx, GMH102xx and GMx152xx.

6.5” wide (164mm)(with heatsink and fan), Maximum Power Handling ~24,000 watts Package Dimensions: 6.5" W x 11" H x 8.0" D (164 mm W x 280 mm H x 203 mm D) Weight: 11.6lbs (5.3kgs)

8 Specifications

Geo MACRO Drive User and Reference Manual

Electrical Specifications

230VAC Input Drives

Main Input

Power

Output

Power

Bus

Protection

Shunt

ulator

Ratings

Control

Power

Current

Feedback

Transistor

Control

GxL051 GxL101 GxL151 GxL201 GxL301

Nominal Input Voltage (VAC) Rated Input Voltage (VAC) Rated Continuous Input Current (A

)

RMS

Rated Input Power (Watts) Frequency (Hz) Phase Requirements Charge Peak Inrush Current (A) Main Bus Capacitance (µf) Rated Output Voltage (V) Rated Cont. Output Current per Axis Peak Output Current (A) for 2 seconds Rated Output Power per Axis (Watts) Nominal DC Bus Over-voltage Trip Level (VDC) Under-voltage Lockout Level (VDC) Turn-On Voltage (VDC) Turn-Off Voltage (VDC) 372 Delta Tau Recommended Load Resistor

(300 W Max.) Input Voltage (VDC)

Input Current (A)

Inrush Current (A) Resolution (bits) Full-scale Signed Reading (±A) Delta Tau Recommended PWM

Frequency (kHz) @rated current

Minimum Dead Time (µs) Charge Pump Time (% of PWM period.)

230

97-265

3.3 6.6 9.9 13.2 19.8

1315 2629 3944 5259 7888

50/60

1Φ or 3Φ 3Φ

3380 5020 6800

138

5 10 15 20 30

10 20 30 40 60

1195 2390 3585 4780 7171

325

410

392

GAR78 GAR48 GAR48-3

20-27

16.26 32.53

12 10 8

48.79 65.05 97.58

Note:

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

Specifications 9

Geo MACRO Drive User Manual

Main Input

Power

Output

Power

Bus

Protection

Shunt

ulator

Ratings

Control

Power

Current

Feedback

Transistor

Control

GxL012 GxL032 GxL052 GxL102 GxL152

Output Circuits (axes)

Nominal Input Voltage (VAC) Rated Input Voltage (VAC) Rated Continuous Input Current (A

)

RMS

Rated Input Power (Watts) Frequency (Hz) Phase Requirements

Charge Peak Inrush Current (A) Main Bus Capacitance (µf)

Rated Output Voltage (V) Rated Cont. Output Current per Axis Peak Output Current (A) for 2 seconds Rated Output Power per Axis (Watts)

Nominal DC Bus Over-voltage Trip Level (VDC) Under-voltage Lockout Level (VDC)

Turn-On Voltage (VDC) Turn-Off Voltage (VDC) Delta Tau Recommended Load Resistor

(300 W Max.) Input Voltage (VDC)

Input Current (A) Inrush Current (A)

Resolution (bits) Full-scale Signed Reading (±A)

Delta Tau Recommended Maximum PWM Frequency (kHz) Minimum Dead Time (µs)

Charge Pump Time (% of PWM period.)

1.98 3.96 6.6 13.2 19.8

789 1578 2629 5259 7888

1Φ or 3Φ 1Φ or 3Φ 3Φ

1.5 3 5 10 15

4.5 9 10 20 30

359 717 1195 2390 3585

GAR78 GAR48

7.32 14.64

16 12 10

230

97-265

50/60

3380 5020

138

325

410

392

372

20-27

16.26 32.53

48.79

Note:

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

10 Specifications

Geo MACRO Drive User and Reference Manual

480VAC Input Drives

Main Input

Power

Bus

Protection

Shunt

ulator

Ratings

Control

Power

Current

Feedback

Transistor

Control

GxH051 GxH101 GxH151 GxH201 GxH301

Output Circuits (axes) Nominal Input Voltage (VAC) Rated Input Voltage (VAC) Rated Continuous Input Current (A

)

RMS

Rated Input Power (Watts) Frequency (Hz) Phase Requirements Charge Peak Inrush Current (A) Main Bus Capacitance (µf) Rated Output Voltage (V) @ Rated

Current Rated Cont. Output Current per Axis

Peak Output Current (A) for 2 seconds Rated Output Power per Axis (Watts) Nominal DC Bus Over-voltage Trip Level (VDC) Under-voltage Lockout Level (VDC) Turn-On Voltage (VDC) Turn-Off Voltage (VDC) 744 Delta Tau Recommended Load

Resistor (300 W Max.) Input Voltage (VDC)

Input Current (A)

Inrush Current (A) Resolution (bits) Full-scale Signed Reading (±Amperes) Delta Tau Recommended PWM

Frequency (KHz) @ rated current Minimum Dead Time (µs)

Charge Pump Time (% of PWM period.)

480

300-525

3.3 6.6 9.9 13.2 19.8

2744 5487 8231 10974 16461

50/60

1Φ or 3Φ 3Φ

845 1255 1700

288

5 10 15 20 30

10 20 30 40 60

2494 4988 7482 9977 14965

678

828

784

GAR78 GAR48 GAR48-3

20-27

16.26 32.53 48.79 65.05 97.58

12 10 8

1.6

Note:

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

Specifications 11

Geo MACRO Drive User Manual

Main Input

Power

Bus

Protection

Shunt

ulator

Ratings

Control

Power

Current

Feedback

Transistor

Control

GxH012 GxH032 GxH052 GxH102 GxH152

Output Circuits (axes)

Nominal Input Voltage (VAC) Rated Input Voltage (VAC) Rated Continuous Input Current (A

)

RMS

Rated Input Power (Watts) Frequency (Hz) Phase Requirements Charge Peak Inrush Current (A) Main Bus Capacitance (µf)

Rated Output Voltage (V) @ Rated Current Rated Cont. Output Current per Axis

Peak Output Current (A) for 2 seconds Rated Output Power per Axis (Watts)

Nominal DC Bus Over-voltage Trip Level (VDC) Under-voltage Lockout Level (VDC)

Turn-On Voltage (VDC)

1.98 3.96 6.6 13.2 19.8

1646 3292 5487 10974 16461

1Φ or 3Φ 3Φ

1.5 3 5 10 15

4.5 9 10 20 30

748 1496 2494 4988 7482

480

300-525

50/60

845 1255

288

678

828

784

Turn-Off Voltage (VDC) 744 Delta Tau Recommended Load Resistor

(300 W Max.) Input Voltage (VDC)

Input Current (A) Inrush Current (A)

Resolution (bits) Full-scale Signed Reading (±Amperes)

Delta Tau Recommended PWM Frequency (KHz) @ rated current

Minimum Dead Time (µs) Charge Pump Time (% of PWM period.)

7.32 14.64 16.26 32.53 48.79

GAR78 GAR48

20-27

12 10 8

1.6

Note:

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

12 Specifications

Geo MACRO Drive User and Reference Manual

Environmental Specifications

Description Unit Specifications

Operating Temperature °C +0 to 45°C. Above 45°C, derate the continuous peak output current by

2.5% per °C above 45°C. Maximum Ambient is 55°C Rated Storage Temperature °C -25 to +70 Humidity % 10% to 90% non-condensing Shock Call Factory Vibration Call Factory Operating Altitude Feet

(Meters)

Air Flow Clearances in (mm) 3" (76.2mm) above and below unit for air flow

To 3300 feet (1000meters). Derate the continuous and peak output current by 1.1% for each 330 feet (100meters) above the 3300feet

Recommended Fusing and Wire Gauge

Model Recommended Fuse (FRN/LPN) Recommended Wire Gauge*

GxL012xx 15 14 AWG GxL032xx 20 12 AWG GxL051xx 20 12 AWG GxL052xx 20 12 AWG GxL101xx 20 12 AWG GxL102xx 20 12 AWG GxL151xx 25 10 AWG GxL152xx 25 10 AWG GxL201xx 25 10 AWG GxL301xx 30 8 AWG

GxH012xx 15 14 AWG GxH032xx 20 12 AWG GxH051xx 20 12 AWG GxH052xx 20 12 AWG GxH101xx 20 12 AWG GxH102xx 20 12 AWG GxH151xx 25 10 AWG GxH152xx 25 10 AWG GxH201xx 25 10 AWG GxH301xx 30 8 AWG

* See local and national code requirements

Wire Sizes

Geo Drive electronics create a DC bus by rectifying the incoming AC electricity. The current flow into the drive is not sinusoidal but rather a series of narrow, high-peak pulses. Keep the incoming impedance small so that these current pulses are not hindered. Conductor size, transformer size, and fuse size recommendations may seem larger than normally expected. All ground conductors should be 8AWG minimum using wires constructed of many strands of small gauge wire. This provides the lowest impedance to high-frequency noises.

Specifications 13

Geo MACRO Drive User Manual

14 Specifications

Geo MACRO Drive User and Reference Manual

RECEIVING AND UNPACKING

Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the Geo Drive is received, do the following immediately.

1. Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered the drive.

2. Remove the drive from the shipping container and remove all packing materials. Check all shipping material for connector kits, documentation, diskettes, CD ROM, or other small pieces of equipment. Be aware that some connector kits and other equipment pieces may be quite small and can be discarded accidentally if care is not used when unpacking the equipment. The container and packing materials can be retained for future shipment.

3. Verify that the part number of the drive received is the same as the part number listed on the purchase order.

4. Inspect the control for external physical damage that may have been sustained during shipment and report any damage immediately to the commercial carrier that delivered the controller.

5. Electronic components in this amplifier are design-hardened to reduce static sensitivity. However, use proper procedures when handling the equipment.

6. If the Geo 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 stated in this manual.

Use of Equipment

The following guidelines describe the restrictions for proper use of the Geo Drive:

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

of such equipment.

• The Geo Drives are to be used only on grounded three-phase industrial mains supply networks (TN-

system, TT-system with grounded neutral point).

• The Geo Drives must not be operated on power supply networks without a ground or with an

asymmetrical ground.

• If the Geo Drives are used in residential areas, or in business or commercial premises, implement

additional filter measures.

• The Geo Drives 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 Drives with the standards for industrial areas stated in this manual, only if Delta Tau components (cables, controllers, etc.) are used.

Receiving and Unpacking 15

Geo MACRO Drive User Manual

16 Receiving and Unpacking

Geo MACRO Drive User and Reference Manual

MOUNTING

The location of the controller 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 the performance of the controller.

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

• For effective cooling and maintenance, the controller should be mounted on a smooth, non-flammable

vertical surface.

• At least 3 inches (76mm) top and bottom clearance must be provided for airflow. At least 0.4 inches

(10mm) clearance is required between controls (each side).

• Temperature, humidity and vibration specifications should also be considered.

The Geo Drives can be mounted with a traditional 4-hole panel mount, two U shape/notches on the bottom and two pear shaped holes on top. This keeps the heat sink and fan (single width and double width drives), inside the mounting enclosure. On the low profile units (low power), the heat sink and fan are replaced with a flat plate and the mounting enclosure itself is used as a heat sink. This reduces the depth of the Geo amplifier by about 2.2 inches (~56 mm) to a slim 5.8 inch D (150 mm D). Mounting is also identical to the single and double width drives through the 4-hole panel mount.

If multiple Geo drives are used, they can be mounted side-by-side, leaving at least to of a 0.4 inch clearance between drives. This means a 3.7 inch center-to-center distance (94 mm) with the single width and low profile Geo drives. Double width Geo amplifiers can be mounted side by side at 6.9 inch centerto-center distance (175 mm).

It is extremely important that the airflow is not obstructed by the placement of conduit tracks or other devices in the enclosure.

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. Make sure that all metal chips are cleaned up before the drive is mounted so there is no risk of getting metal chips inside the drive.

The drive is mounted to the back panel with 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).

Caution:

Units 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]).

Note:

For more detail drawings (SolidWorks, eDrawings, DXF) visit our website under

the product that you are looking for.

Mounting 17

Geo MACRO Drive User Manual

Low Profile

Gxx012xx

Mounting dimensions 3.30in./ 84mm 11.00in./ 280mm 5.79in./ 147.1mm 4.3lbs/ 1.95kgs

Width Height Depth Weight

MACRO Version, No Heatsink, No Fan

(5.79)

(2.70)

(11.00)

(10.625)

(3.30)

18 Mounting

Geo MACRO Drive User and Reference Manual

Single Width

Gxx051xx, Gxx101xx, Gxx151xx, Gxx032xx, Gxx052xx and GxL102xx

Mounting dimensions 3.30in./ 84mm 11.00in./ 280mm 8.00in./ 203mm 5.5lbs/ 2.5kgs

Width Height Depth Weight

Mounting 19

Geo MACRO Drive User Manual

Double Width

Gxx201xx, Gxx301xx, GxH102xx and Gxx152xx

Mounting dimensions 6.50in./ 165mm 11.00in./ 280mm 8.00in./ 203mm Call the factory

Width Height Depth Weight

20 Mounting

Geo MACRO Drive User and Reference Manual

CONNECTIONS

System (Power) Wiring

MAIN POWER

GARxx

SHUNT

RESISTOR

24V POWER SUPPLY

EARTH FRAME

+24 V

Red

Blk 24V RET

WHT

LOGIC

Twisted Wires

RE GEN -

SHU NT

Geo

MACRO

+24 VDC

24 VDC RET

BLK

RED

RE GEN +

GRN\Y EL

SC RE W HE AD

BLK

BLU

MOTOR 2

WHT

MOTOR 1

AC IN PUT

L2L

L 1

BLK

BLU

GRN\Y EL

WHT

WVUWVU

SCREW HEAD

X1X2

SCREW HEAD

t e xt

8AWG to Main

Earth Block

t e xt

e xt

OPTI ONAL

EMI FILTER

EARTH BLOCK

BLK

MCR

Fusing

WARNING:

Installation of electrical control equipment is subject to many regulations including national, state, local, and industry guidelines and rules. General recommendations can be stated but it is important that the installation be carried out in accordance with all regulations pertaining to the installation.

Motor 2

Motor 1

Encoders

Fuse and Circuit Breaker Selection

In general, fusing must be designed to protect the weakest link from fire hazard. Each Geo drive is designed to accept more than the recommended fuse ratings. External wiring to the drive may be the weakest link as the routing is less controlled than the drive’s internal electronics. Therefore, external circuit protection, be it fuses or circuit breakers, must be designed to protect the lesser of the drive or external wiring.

High peak currents and high inrush currents demand the use of slow blow type fuses and hamper the use of circuit breakers with magnetic trip mechanisms. Generally, fuses are recommended to be larger than what the rms current ratings require. Remember that some drives allow three times the continuous rated current on up to two axis of motion. Time delay and overload rating of protection devices must consider this operation.

Use of GFI Breakers

Ground Fault Interrupter circuit breakers are designed to break the power circuit in the event that outgoing currents are not accompanied by equal and opposite returning currents. These breakers assume that if outgoing currents are not returning then there is a ground path in the load. Most circuit breakers of this type account for currents as low as 10mA PWM switching in servo drives coupled with parasitic capacitance to ground in motor windings and long cables generate ground leakage current. Careful

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Geo MACRO Drive User Manual

installation practices must be followed. The use of inductor chokes in the output of the drive will help keep these leakage currents below breaker threshold levels.

Transformer and Filter Sizing

Incoming power design considerations for use with Geo Drives require some over rating. In general, it is recommended that all 3-phase systems using transformers and incoming filter chokes be allotted a 25% over size to keep the impedances of these inserted devices from affecting stated system performance. In general, it is recommended that all single-phase systems up to 1kW be designed for a 50% overload. All single-phase systems over 1kW should be designed for a 200% overload capacity.

Noise Problems

When problems do occur often it points to electrical noise as the source of the problem. When this occurs, turn to controlling high-frequency current paths. If following the grounding instructions does not work, insert chokes in the motor phases. These chokes can be as simple as several wraps of the individual motor leads through a ferrite ring core (such as Micrometals T400-26D). This adds high-frequency impedance to the outgoing motor cable thereby making it harder for high-frequency noise to leave the control cabinet area. Care should be taken to be certain that the core’s temperature is in a reasonable range after installing such devices.

Operating Temperature

It is important that the ambient operating temperature of the Geo Drive be kept within specifications. The Geo Drive is installed in an enclosure such as a NEMA cabinet. The internal temperature of the cabinet must be kept under the Geo Drive Ambient Temperature specifications. It is sometimes desirable to roughly calculate the heat generated by the devices in the cabinet to determine if some type of ventilation or air conditioning is required. For these calculations the Geo Drive’s internal heat losses must be known. Budget 100W per axis for 1.5A drives, 150W per axis for 3A drives, 200W per axis for 5A drives, 375W per axis for 10A drives, 500W per axis for 15A drives, 650W per axis for 20A drives.

From 0°C to 45°C ambient no derating required. Above 45°C, derate the continuous and peak output current by 2.5% per °C above 45°C. Maximum ambient is 55°C.

Single Phase Operation

Due to the nature of power transfer physics, it is not recommended that any system design attempt to consume more than 2kW from any single-phase mains supply. Even this level requires careful considerations. The simple bridge rectifier front end of the Geo Drive, as with all other drives of this type, require high peak currents. Attempting to transfer power from a single-phase system getting one charging pulse each 8.3 milliseconds causes excessively high peak currents that can be limited by power mains impedances. The Geo Drive output voltage sags, the input rectifiers are stressed, and these current pulses cause power quality problems in other equipment connected to the same line. While it is possible to operate drives on single-phase power, the actual power delivered to the motor must be considered. Never design expecting more than 1.5 HP total from any 115V single-phase system and never more than

2.5 HP from any 230V single-phase system.

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Geo MACRO Drive User and Reference Manual

Wiring AC Input, J1

The main bus voltage supply is brought to the Geo drive through connector J1. 1.5A continuous and 3A continuous Geo drives can be run off single-phase power. It is acceptable to bring the single-phase power into any two of the three input pins on connector J1. Higher-power drive amplifiers require three-phase input power. It is extremely important to provide fuse protection or overload protection to the input power to the Geo drive amplifier. Typically, this is provided with fuses designed to be slow acting, such as FRN-type fuses. Due to the various regulations of local codes, NEC codes, UL and CE requirements, it is very important to reference these requirements before making a determination of how the input power is wired.

Additionally, many systems require that the power be able to be turned on and off in the cabinet. It is typical that the AC power is run through some kind of main control contact within the cabinet, through the fuses, and then fed to a Geo drive. If multiple Geo drives are used, it is important that each drive has its own separate fuse block.

Whether single- or three-phase, it is important that the AC input wires be twisted together to eliminate noise radiation as much as possible. Additionally, some applications may have further agency noise reduction requirements that require that these lines be fed from an input filtering network.

The AC connections from the fuse block to the Geo drive are made via a cable that is either purchased as an option from Delta Tau (CABKITxx) or made with the appropriate connector kit (CONKITxx). (Appendix A)

J1: AC Input Connector Pinout

Pin # Symbol Function Description Notes

1 L3 Input Line Input Phase 3 2 L2 Input Line Input Phase 2 3 L1 Input Line Input Phase 1 (not used for single Phase Input)

On Gxx201xx and Gxx301xx, there is a fourth pin for Ground connection. If DC bus is used, use L3 for DC+ and L2 for DC return. Connector is located at the bottom side of the unit.

Wiring Earth-Ground

Panel wiring requires that a central earth-ground location be installed at one part of the panel. This electrical ground connection allows for each device within the enclosure to have a separate wire brought back to the central wire location. Usually, the ground connection is a copper plate directly bonded to the back panel or a copper strip with multiple screw locations. The Geo drive is brought to the earth-ground via a wire connected to the M4 stud (5mm thread) on the top of the location through a heavy gauge, multi-strand conductor to the central earth-ground location. On some models, a fourth pin is provided on the 3-phase AC input connector (J1) and on the motor output connectors to provide a ground connection.

Earth Grounding Paths

High-frequency noises from the PWM controlled power stage will find a path back to the drive. It is best that the path for the high-frequency noises be controlled by careful installation practices. The major failure in problematic installations is the failure to recognize that wire conductors have impedances at high frequencies. What reads 0 ohms on a handheld meter may be hundreds of ohms at 30MHz. Consider the following during installation planning:

1. Star point all ground connections. Each device wired to earth ground should have its own conductor brought directly back to the central earth ground plate.

2. Use unpainted back panels. This allows a wide area of contact for all metallic surfaces reducing high frequency impedances.

3. Conductors made up of many strands of fine conducts outperform solid or conductors with few strands at high frequencies.

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Geo MACRO Drive User Manual

4. Motor cable shields should be bonded to the back panel using 360-degree clamps at the point they enter or exit the panel.

5. Motor shields are best grounded at both ends of the cable. Again, connectors using 360-degree shield clamps are superior to connector designs transporting the shield through a single pin. Always use metal shells.

6. Running motor armature cables with any other cable in a tray or conduit should be avoided. These cables can radiate high frequency noise and couple into other circuits.

Wiring 24 V Logic Control, J4

An external 24VDC power supply is required to power the logic portion of the Geo drive. This power can remain on, regardless of the main AC input power, allowing the signal electronics to be active while the main motor power control is inactive. The 24V is wired into connector J4. The polarity of this connection is extremely important. Carefully follow the instructions in the wiring diagram. This connection can be made using 16 AWG wire directly from a protected power supply. In situations where the power supply is shared with other devices, it may be desirable to insert a filter in this connection.

The power supply providing this 24V must be capable of providing an instantaneous current of at least

1.5A to be able to start the DC-to-DC converter in the Geo drive. In the case where multiple drives are driven from the same 24V supply, it is recommended that each drive be wired back to the power supply terminals independently. It is also recommended that the power supply be sized to handle the instantaneous inrush current required to start up the DC-to-DC converter in the Geo drive.

J4: 24VDC Input Logic Supply Connector

Pin # Symbol Function Description Notes

2 +24VDC Input Control power input 24V+/-10%, 2A

Connector is located at the bottom side of the unit.

24VDC RET Common Control power return

Wiring the Motors

The cable wiring must be shielded and have a separate conductor connecting the motor frame back to the drive amplifier. The cables are available in cable kits (CABKITxx) from Delta Tau. (See Appendix A.)

Motor phases are conversed in one of three conventions. Motor manufacturers will call the motor phases A, B, or C. Other motor manufacturers call them U, V, W. Induction motor manufacturers may call them L1, L2, and L3. The drive’s inputs are called U, V, and W. Wire U, A, or L1 to the drive’s U terminal. Wire V, B, or L2 to the drive’s V terminal. Wire W, C, or L3 to the drive’s W terminal.

The motor’s frame drain wire and the motor cable shield must be tied together at the mounting stud (5mm thread) on top of the Geo drive product.

J2: Motor 1 Output Connector Pinout

Pin # Symbol Function Description Notes

1 U Output Axis 1 Phase1 2 V Output Axis 1 Phase2

3 W Output Axis 1 Phase3 On Gxx201xx and Gxx301xx, there is a fourth pin for Ground connection. Connector is located at the top side of the unit.

J3: Motor 2 Output Connector Pinout

Pin # Symbol Function Description Notes

1 U Output Axis 2 Phase1 2- Axis drives only

2 V Output Axis 2 Phase2 2- Axis drives only

3 W Output Axis 2 Phase3 2- Axis drives only

Connector is located at the top side of the unit.

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Geo MACRO Drive User and Reference Manual

Wiring the Motor Thermostats

Some motor manufacturers provide the motors with integrated thermostat overload detection capability. Typically, it is in one or two forms: a contact switch that is normally closed or a PTC. These sensors can be wired into the Geo drive’s front panel at connector X1 and X2.

Motor 1 thermostat output is wired to pin 23 of X1, In_Therm_Mot1, and referenced to the GND pin13 or 25. In addition, if dual axis drive is ordered, Motor 2 thermostat output is wired to pin 23 of X2, In_Therm_Mot2, and referenced to the GND pin 13 or 25.

Function Pin #

In_Therm_Mtr 23

GND 13,25

Wiring the Motor Thermostats

X1/X2

In_Therm_Mot

GND

MS{node},MI100 has special functions for Geo MACRO drives ( firmware 1.006 and above) to enable the motor over-temperature function of the drive, default this function is disabled (firmware 1.006 and above). If someone wants to enable the motor #1 over-temperature input to his Geo then he needs to set MS{node},MI100= $4. For motor #2 over-temperature input to be enabled MS{node},MI100=$8 and if the user wants both motor over-temperature inputs enable then MS{node},MI100=$C.

For earlier drives (firmware 1.005 and before) If the motor over-temperature protection is not required, In_Therm_Mot1/2 should be connected to GND, pin 13 or 25. Otherwise, the drive status display will

show a warning error code 5 for motor #1 over -temperature, or an A for motor 2 over -temperature. If both pins are not shorted to GND, display will show 5 (the first error gets triggered)

Wiring the Regen (Shunt) Resistor, J5

The Geo Drive family offers compatible regen resistors as optional equipment. The regen resistor is used as a shunt regulator to dump excess power during demanding deceleration profiles. The GAR48 and GAR78 resistors are designed to dump the excess bus energy very quickly.

The regen circuit is also known as a shunt regulator. Its purpose is to dump power fed back into the drive from a motor acting as a generator. Excessive energy can be dumped via an external load resistor. The Geo product series is designed for operation with external shunt resistors of 48 Ω for the 10 and 15 amp versions or 78 Ω for the 1.5, 3, and 5 amp versions. These are available directly from Delta Tau as GAR48 and GAR78, respectively. These resistors are provided with pre-terminated cables that plug into connector J5.

Each resistor is the lowest ohm rating for its compatible drive and is limited for use to 200 watts RMS. There are times the regen design might be analyzed to determine if an external Regen resistor is required or what its ratings can be. The following data is provided for such purpose.

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Geo MACRO Drive User Manual

Caution:

The black wires are for the thermostat and the white wires are for the regen resistor on the external regen resistor (pictured below). These resistors can reach temperatures of up to 200 degrees C. These resistors must be mounted away from other devices and near the top of the cabinet. Additionally, precautions must be made to ensure the resistors are enclosed and cannot be touched during operation or anytime they are hot. Sufficient warning labels should be placed prominently near these resistors.

The regen resistors incorporate a thermal overload protection thermostat that opens when the core temperature of the resistor exceeds 225 degrees C. This thermostat is available through the two black leads exiting the resistor. It is important that these two leads be wired in a safety circuit that stops the system from operating should the thermostat open.

J5: External Shunt Connector Pinout

Pin # Symbol Function

1 Regen2 Regen+ Output

Connector is located at the top side of the unit DT Connector part number #014-000F02-HSG and pins part number #014-043375-001 Molex Crimper tool p/n#63811-0400

For the high Current Drives, Gxx201xx and Gxx301xx , this connector is a 3 pin Large Molex connector

1 CAP2 Regen- Output

3 Regen+ Output Connector is located at the top side of the unit. DT Connector part number #014-H00F03-049 and pins part number #014-042815-001. Molex Crimper tool p/n#63811-1500

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Output

Geo MACRO Drive User and Reference Manual

Shunt Regulation

When the motor is used to slow the moving load, this is called regenerative deceleration. Under this operation, the motor is acting as a generator consuming energy from the load while passing the energy into the DC Bus storage capacitors. Left unchecked, the DC Bus voltage can raise high enough to damage the drive. For this reason there are protection mechanisms built into the Geo Drive product such as shunt regulation and over-voltage protection.

The shunt regulator monitors the DC Bus voltage. If this voltage rises above a present threshold (Regen Turn On Voltage), the Geo Drive will turn on a power device intended to place the externally mounted regen resistor across the bus to dump the excessive energy. The power device keeps the regen resistor connected across the bus until the bus voltage is sensed to be below the Regen Turn Off voltage at which time the power device removes the resistor connection.

Minimum Resistance Value

The regen resistor selection requires that the resistance value of the selected resistor will not allow more current to flow through the Geo Drive’s power device than specified.

Maximum Resistance Value

The maximum resistor value that will be acceptable in an application is one that will not let the bus voltage reach the drive’s stated over voltage specification during the deceleration ramp time. The following equations defining energy transfer can be used to determine the maximum resistance value.

Energy Transfer Equations

Regen, or shunt, regulation analysis requires study of the energy transferred during the deceleration profile. The basic philosophy can be described as follows:

• The motor and load have stored kinetic energy while in motion.

• The drive removes this energy during deceleration by transferring to the DC bus.

• There are losses during this transfer, both mechanical and electrical, which can be significant in some

systems.

• The DC bus capacitors can store some energy.

• The remaining energy, if any, is transferred to the regen resistor.

Kinetic Energy

The first step is to ascertain the amount of kinetic energy in the moving system, both the motor rotor and the load it is driving. In metric (SI) units, the kinetic energy of a rotating mass is:

where:

is the kinetic energy in joules, or watt-seconds (J, W-s)

J is the rotary moment of inertia in kilogram-meter

ω is the angular velocity of the inertia in radians per second (1/s)

If the values are not in these units, first convert them. For example, if the speed is in revolutions per minute (rpm), multiply this value by 2π/60 to convert to radians per second.

When English mechanical units are used, there are additional conversion factors must be included to get the energy result to come out in joules. For example, if the rotary moment of inertia J is expressed in lb-

, the following equation should be used:

ft-sec

If the rotary moment of inertia J is expressed in lb-in-sec

In standard metric (SI) units, the kinetic energy of a linearly moving mass is:

Connections 27

(kg-m2)

J678.0

, the following equation should be used:

J0565.0

Geo MACRO Drive User Manual

E =

where:

is the kinetic energy in joules (J)

m is the mass in kilograms (kg) v is the linear velocity of the mass in meters/second (m/s)

Here also, to get energy in Joules from English mechanical units, additional conversion factors are required. To calculate the kinetic energy of a mass having a weight of W pounds, the following equation can be used:

E ==

678.0 g

Wv0211.0

where:

is the kinetic energy in joules (J)

W is the weight of the moving mass in pounds (lb) g is the acceleration of gravity (32.2 ft/sec

)

v is the linear velocity of the mass in feet per second (ft/sec)

Energy Lost in Transformation

Some energy will be lost in the transformation from mechanical kinetic energy to electrical energy. The losses will be both mechanical due to friction and electrical due to resistance. In most cases, these losses will comprise a small percentage of the transformed energy and can be safely ignored especially because ignoring losses leads to a conservative design. However, if the losses are significant and the system should not be over-designed, calculate these losses.

In metric (SI) units, the mechanical energy lost due to Coulomb (dry) friction in a constant deceleration to stop of a rotary system can be expressed as:

dtf

where:

is the lost energy in joules (J)

is the resistive torque due to Coulomb friction in newton-meters (N-m)

ω is the starting angular velocity of the inertia in radians per second (1/s)

is the deceleration time in seconds (s)

If the frictional torque is expressed in the common English unit of pound-feet (lb-ft), the comparable expression is:

T678.0

In metric (SI) units, the mechanical energy lost due to Coulomb (dry) friction in a constant deceleration to stop of a linear system can be expressed as:

dvtf

where:

is the lost energy in joules (J)

is the resistive force due to Coulomb friction in newtons (N)

v is the starting linear velocity in meters/second (m/s) t

is the deceleration time in seconds (s)

If the frictional force is expressed in the English unit of pounds (lb) and the velocity in feet per second (ft/sec), the comparable expression is:

F678.0

dvtf

The electrical resistive losses in a 3-phase motor in a constant deceleration to stop can be calculated as:

where:

rms

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Geo MACRO Drive User and Reference Manual

−−−

(

ELE is the lost energy in joules (J) i

is the current required for the deceleration in amperes (A), equal to the required deceleration torque

rms

divided by the motor’s (rms) torque constant K

is the phase-to-phase resistance of the motor, in ohms (Ω)

is the deceleration time in seconds (s)

Capacitive Stored Energy in the Drive

The energy not lost during the transformation is initially stored as additional capacitive energy due to the increased DC bus voltage. The energy storage capability of the drive can be expressed as:

where:

is the additional energy storage capacity in joules (J)

E −=

regen

nom

)

C is the total bus capacitance in Farads V

is the DC bus voltage at which the regeneration circuit would have to activate, in volts (V)

regen

is the normal DC bus voltage, in volts (V)

nom

Evaluating the Need for a Regen Resistor

Any starting kinetic energy that is not lost in the transformation and cannot be stored as bus capacitive energy must be dumped by the regeneration circuitry in to the regen (shunt) resistor. The following equation can be used to determine whether this will be required:

If E

excess

in this equation is greater than 0, a regen resistor will be required.

excess

Regen Resistor Power Capacity

A given regen resistor will have both a peak (instantaneous) and a continuous (average) power dissipation limit. It is therefore necessary to compare the required peak and continuous regen power dissipation requirements against the limits for the resistor.

The peak power dissipation that will occur in the regen resistor in the application will be:

peak

Note:

regen

% timeon

100

where:

is peak power dissipation in watts (W)

peak

is the DC bus voltage at which the regeneration circuit activates, in volts (V)

regen

peak

R is the resistance value of the regen resistor, in ohms (Ω)

However, this power dissipation will not be occurring all of the time, and in most applications, only for a small percentage of the time. Usually, the regen will only be active during the final part of a lengthy deceleration, after the DC bus has charged up to the point where it exceeds the regen activation voltage. The average power dissipation value can be calculated as:

where:

is average power dissipation in watts (W)

avg

P−=

avg

%on-time is the percentage of time the regen circuit is active

The Turn-on voltage for the shunt circuitry for all Low power Geo drives is 392V (high power is 784V). There is a Hysteresis of 20V, so if the regen turns on @ 392V (784V) it will not turn off until it drops to 372V (744V).

Bonding

The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing immunity levels. The bonding effect is to reduce the impedance between the cable shield and the back

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Geo MACRO Drive User Manual

panel.

Power input wiring does not require shielding (screening) if the power is fed to the enclosure via metal conduit. If metal conduit is not used in the system, shielded cable is required on the power input wires along with proper bonding techniques.

Filtering

CE Filtering

Apply proper bonding and grounding techniques, described earlier in this section, when incorporating EMC noise filtering components to meet this standard.

Noise currents often occur in two ways. The first is conducted emissions passed through ground loops. The quality of the system-grounding scheme inversely determines the noise amplitudes in the lines. These conducted emissions are of a common-mode nature from line-to-neutral (ground). The second is radiated high-frequency emissions that usually are capacitively coupled from line-to-line and are differential in nature.

When mounting the filters, make sure the enclosure has an unpainted metallic surface. This allows more surface area to be in contact with the filter housing and provides a lower impedance path between the housing and the back plane. The back panel should have a high frequency ground strap connection to the enclosure frame and earth ground.

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Geo MACRO Drive User and Reference Manual

Input Power Filtering

Caution:

To avoid electric shock, do not touch filters for at least 10 seconds after removing the power supply.

The Geo Drive electronic system components require EMI filtering in the input power leads to meet the conducted emission requirements for the industrial environment. This filtering blocks conducted-type emissions from exiting onto the power lines and provides a barrier for power line EMI.

Adequately size the system. The type of filter must be based on the voltage and current rating of the system and whether the incoming line is single or three-phase. One input line filter may be used for multi-axis control applications. These filters should be mounted as close to the incoming power as possible so noise is not capacitively coupled into other signal leads and cables. Implement the EMI filter according to the following guidelines:

• Mount the filter as close as possible to the incoming cabinet power.

• When mounting the filter to the panel, remove any paint or material covering. Use an unpainted

metallic back panel.

• Filters are provided with a ground connection. All ground connections should be tied to ground.

• Filters can produce high leakage currents; they must be grounded before connecting the supply.

• Do not touch filters for a period of ten seconds after removing the power supply.

Motor Line Filtering

Motor filtering may not be necessary for CE compliance of Geo Drives. However, this additional filtering increases the reliability of the system. Poor non-metallic enclosure surfaces and lengthy, unbonded (or unshielded) motor cables that couple noise line-to-line (differential) are some of the factors that may lead to the necessity of motor lead filtering.

Motor lead noise is either common-mode or differential. The common-mode conducted currents occur between each motor lead and ground (line-to-neutral). Differential radiated currents exist from one motor lead to another (line-to-line). The filtering of the lines feeding the motor provides additional attenuation of noise currents that may enter surrounding cables and equipment I/O ports in close proximity.

Differential mode currents commonly occur with lengthy motor cables. As the cable length increases, so does its capacitance and ability to couple noise from line-to-line. While every final system is different and every application of the product causes a slightly different emission profile, it may become necessary to use differential mode chokes to provide additional noise attenuation to minimize the radiated emissions. The use of a ferrite core placed at the Geo Drive end on each motor lead attenuates differential mode noise and lowers frequency (30 to 60 MHz) broadband emissions to within specifications. Delta Tau recommends a Fair-Rite P/N 263665702 (or equivalent) ferrite core.

Common mode currents occur from noise spikes created by the PWM switching frequency of the Geo Drive. The use of a ferrite or iron-powder core toroid places common mode impedance in the line between the motor and the Geo Drive. The use of a common mode choke on the motor leads may increase signal integrity of encoder outputs and associated I/O signals.

I/O Filtering

I/O filtering may be desired, depending on system installation, application, and integration with other equipment. It may be necessary to place ferrite cores on I/O lines to avoid unwanted signals entering and disturbing the Geo.

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Geo MACRO Drive User Manual

Connecting Main Feedback Sensors (X1 & X2)

X1 is for motor #1 and X2 for motor #2.

Digital Quadrature Encoders

Quadrature encoders provide two digital signals that are a function of the position of the encoder, each nominally with 50% duty cycle, and nominally one-quarter cycle apart. This format provides four distinct states per cycle of the signal, or per line of the encoder. The phase difference of the two signals permits the decoding electronics to discern the direction of travel, which would not be possible with a single signal.

Typically, these signals are at 5V TTL/CMOS levels, whether single-ended or differential. The input circuits are powered by the main 5V supply for the controller, but they can accept up to +/-12V between the signals of each differential pair, and +/-12V between a signal and the GND voltage reference.

Differential encoder signals can enhance noise immunity by providing common-mode noise rejection. Modern design standards virtually mandate their use for industrial systems, especially in the presence of PWM power amplifiers, which generate a great deal of electromagnetic interference.

Hardware Setup

The Geo Drive accepts inputs from two digital encoders and provides encoder position data to the motion processor. X1 is encoder 1 and X2 is encoder 2. The differential format provides a means of using twisted pair wiring that allows for better noise immunity when wired into machinery.

Geo Drives encoder interface circuitry employs differential line receivers. The wiring diagram on the right shows an example of how to connect the Geo drive to a quadrature encoder.

Function Pin #

ChA+ 1 ChA- 14 ChB+ 2 ChB- 15 ChC+ 3 ChC- 16

X1/ X2

CHA+

CHA-

CHB+

CHB-

CHC+

CHC-

Shield

GND

Quadrature

Encoder

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Geo MACRO Drive User and Reference Manual

Digital Hall Commutation Sensors

Many motor manufactures now give the consumer the option of placing both Hall effect sensors and quadrature encoders on the end shaft of brushless motors. This will allow the controller to estimate the rotor magnetic field orientation and adjusts the command among the motor phases properly without rotating the motor at power-up. If this is not done properly, the motor or amplifier could be damaged.

Note:

These digital hall-effect position sensors should not be confused with analog halleffect current sensors used in many amplifiers to provide current feedback data for the current loop.

Hardware Setup

The Geo Drive accepts digital hall sensor inputs. X1 is for motor #1 and X2 for motor #2.

The wiring diagram on the right shows an example of how to connect the Geo drive to Digital Hall sensors.

Function Pin #

U 8 V 21

W 9

T 22

5V 12/24

GND 13/25

X1/ X2

GND

Shield

Hall Sensors

SSI Encoders

Geo Drive was designed to work with either Gray Code or Binary Style SSI Encoders. The Geo Drive takes the gray/binary code information and converts it into a parallel binary word for absolute and ongoing position data.

Hardware Setup

The differential format provides a means of using twisted pair wiring that allows for better noise immunity when wired into machinery.

The wiring diagram to the right shows an example of how to connect the Geo Drive to an SSI encoder.

Function Pin#

CLK+ 6

DATA+ 7

CLK- 19

DATA- 20

ENCPWR/5V 12/24

GND 13/25 Note: We assume the SSI Encoder power requirements are for 5V, else use of an external power supply for the SSI encoder is required. Tie together the Geo Drive GND and the power supply for noise immunity

X1/X2

CLK+

CLK-

DAT+

DAT-

Shield

SSI

encoder

+5V

GND

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Geo MACRO Drive User Manual

Sinusoidal Encoders

The Geo Drive with the Interpolator option accepts inputs from two sinusoidal or quasi-sinusoidal encoders and provides encoder position data to the motion processor. This interpolator creates 4,096 steps per sine-wave cycle. User needs to order the option.

Be sure to use shielded, twisted pair cabling for sinusoidal encoder wiring. Double insulated is the best. The sinusoidal signals are very small and must be kept as noise free as possible. Avoid cable routing near noisy motor or driver wiring. Refer to the appendix for tips on encoder wiring.

It is possible to reduce noise in the encoder lines of a motor-based system by the use of inductors that are placed between the motor and the amplifier. Improper grounding techniques may also contribute to noisy encoder signals.

Note:

Voltage mode encoders are becoming the more popular choice for machine designs

due to their lower impedance outputs. Lower impedance outputs represent better

noise immunity, and therefore more reliable encoder interfaces.

The Geo Drive uses 1 Vp-p voltage mode encoders only.

Hardware Setup

The differential format provides a means of using twisted pair wiring that allows for better noise immunity when wired into machinery.

Sinusoidal encoders operate on the concept that there are two analog signal outputs 90 degrees out of phase.

Geo Drives can be used only with the voltage mode encoder type, and the lines have to be differential. The wiring diagram to the right shows an example of how to connect the Geo drive to a sinusoidal encoder.

Function Pin#

Sin+ 1

Cos+ 2

Cos- 15

Index+ 3

Index- 16

Sin- 14

X1/X2

Cos+

In_Therm_Mot

+5V

GND

Sin+

Index+

Sin-

Cos-

Index-

Sinusoidal

Encoder

1Vpp A

1Vpp B

index

Up Power 0V Supply

Shield

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Geo MACRO Drive User and Reference Manual

Hiperface® Interface

The Geo Drive will read the absolute data from the Hiperface® interface only if the appropriate option is ordered. (Not yet released firmware).

Hardware Setup

The differential format provides a means of using twisted pair wiring that allows for better noise immunity when wired into machinery.

• Safe data transmission

• Absolute positioning

• Only 8 leads

The wiring diagram to the right shows an example of how to connect the Geo Drive with Hiperface.

Function Pin#

Sin+/ ChA+ 1 Cos+/ChB+ 2

Sin-/ChA- 14

Cos-/ChB- 15

DATA+ 7

DATA- 20

ENCPWR/5V 12/24

GND 13/25 Note: We assume the Hiperface Interface power requirements are for 5V, else use of an external power supply for the Hiperface is required. Tie together the Geo Drive GND and the power supply GND for noise immunity.

X1/X2

Cos+

In_Ther m_Mot

+5V

GND

Hiperface® Interface

Sin+

Sin-

Cos-

DATA+

DATA-.

Shield

Hiperface Interface

1Vpp A

1Vpp B

Up Power 0V Supply

DATA DATA

Connections 35

Geo MACRO Drive User Manual

EnDat Interface

The Geo Drive will read the absolute data from the EnDat (Encoder Data) interface only if the appropriate option is ordered. (Not yet released firmware)

Hardware Setup

The differential format provides a means of using twisted pair wiring that allows for better noise immunity when wired into machinery.

The wiring diagram to the right shows an example of how to connect the Geo Drive to an EnDat interface.

Function Pin#

Sin+/ ChA+ 1 Cos+/ChB+ 2

Sin-/ChA- 14

Cos-/ChB- 15

CLK+ 6

DATA+ 7

CLK- 19

DATA- 20

ENCPWR/5V 12/24

GND 13/25 Note: We assume the EnDat Interface power requirements are for 5V, else use of an external power supply for the EnDat is required. Tie together the Geo Drive GND and the power supply GND for noise immunity.

X1/X2

Cos+

In_Therm_Mot

+5V

GND

EnDat Interface

Sin+

Sin-

Cos-

CLK+

CLK-

DATA+

DATA-.

Shield

1Vpp A

1Vpp B

Up Power 0V Supply

DATA

EnDat Interface

DATA

CLOCK CLOCK

36 Connections

Geo MACRO Drive User and Reference Manual

Resolvers

The Geo Drive can interface to most industry standard resolvers if the appropriate option is ordered. Typical resolvers requiring 5 to 10 kHz excitation frequencies with voltages ranging from 5 to 10V peakto-peak are compatible with this drive.

Fundamentally, the Geo Drive connects three differential analog signal pairs to each resolver: a single excitation signal pair, and two analog feedback signal pairs. The wiring diagram below shows an example of how to connect the Geo drive to the Resolver

Hardware Setup

The differential format provides a means of using twisted pair wiring that allows for better noise immunity when wired into machinery.

The wiring diagram to the right shows an example of how to connect the Geo Drive to a Resolver.

Function Pin #

ResSin+ 4

ResSin- 17

ResCos+ 5

ResCos- 18

ResOut 11

GND 13,25

Geo Drive Resolver Wiring Diagram

Sin+

Sin-

Twisted pair Screened

Cable

Cos+

Cos-

ResOut

GND

Notes:

Terminate shields on pins 13 and 25

Shield

ResSin+

ResSinResCos+

ResCos-.

ResOut

GND

X1 or X2

Connections 37

Geo MACRO Drive User Manual

Connecting Secondary Quad. Encoders (X8 & X9)

Secondary encoders in the Geo MACRO Amplifier are standard since logic board revision -10A and above, and are found on Db-connectors X8 and X9. They must be Quadrature TTL encoders.

Hardware Setup

The Geo Drive also accepts inputs from two digital quadrature encoders and provides encoder position data to the motion processor. X8 is secondary encoder #1 and X9 is secondary encoder #2. The differential format provides a means of using twisted pair wiring that allows for better noise immunity when wired into machinery.

Geo Drives encoder interface circuitry employs differential line receivers. The wiring diagram on the right shows an example of how to connect the Geo drive to a quadrature encoder.

Function Pin #

ChA+ 1 ChA- 6 ChB+ 2 ChB- 7 ChC+ 3 ChC- 8 ENCPWR 5V 4 GND 5

Secondary Encoders

Quadrature

X8 / X9

CHA+

CHA-

CHB+

CHB-

CHC+

CHC-

GND

Shield

Fl oat

Shield

Encoder

38 Connections

Geo MACRO Drive User and Reference Manual

Connecting General Purpose I/O & Flags (X3)

X3 provides the connector for general purpose I/O (12-24VDC) and the input flags for each axis (Positive Limit, Negative Limit, Home Switch and USER flag input). The outputs are rated for 0.5A and have to be set up all sinking or all sourcing, no mixing topologies. Same is true for the inputs, no mixing topologies, all sinking or all sourcing.

24V

Flag Supply

12-24VDC

Flag

Return

Sample wiring the I/O

Sourcing Inputs and Sourcing Outputs

Function Pin #

GP_OUT 1 EMT 2 GP_OUT 2 EMT 4 GP_OUT 3 EMT 6 GP_OUT 4 EMT 8

COM COL 9

GP IN 1 11 GP IN 2 12 GP IN 3 13 GP IN 4 14

I/O RTN 15

Sourcing Separate

Supply

Flag Supply

12-24VDC

24V

Return

Flag

Sinking

Separate

Supply

Geo MACRO

Sourcing Inputs

Sourcing Outputs

Input Return

Input4 Input3

Input2 Input1

Com_Col

Output4

Output3

Output2

Output1

24V Supply

0V 24V

Connections 39

Geo MACRO Drive User Manual

Sinking Inputs and Sinking Outputs

Function Pin #

GP_OUT 1 COL 1 GP_OUT 2 COL 3 GP_OUT 3 COL 5 GP_OUT 4 COL 7

COM EMT 10

GP IN 1 11 GP IN 2 12 GP IN 3 13 GP IN 4 14

I/O RTN 15

Sample Wiring the Flags

Geo MACRO

Sourcing Flags

24V Supply

24V 0V

Geo MACRO

Sinking Inputs

Sinking Outputs

Input Return

Input4

Input3

Input2

Input1

Com_EMT

Geo MACRO

Sinking Flags

Output4

Output3

Output2

Output1

24V Supply

24V 0V

24V Supply

0V 24V

USER 2

Home 2

Neg.Limit 2

Pos .Lim it 2

USER 1

Home 1

Neg.Limit 1

Pos .Lim it 1

FLG_RTN

USER 2

Home 2

Neg.Limit 2

Pos .Lim it 2

USER 1

Home 1

Neg.Limit 1

Pos .Lim it 1

FLG_RTN

Function Pin #

FLG_RTN 16

PLIM1 17 NLIM1 18

HOME1 19

USER1 20 PLIM2 21 NLIM2 22

HOME2 23

USER2 24

40 Connections

Geo MACRO Drive User and Reference Manual

Connecting MACRO Ring

Fiber Optic MACRO connections (X5)

Output

ACC-5E

Turbo Ultralite/

Input

RJ-45 Copper MACRO connections (X10 &X11)

MACRO

(X5)

Geo MACRO

Input

I/O

Output

Geo MACRO

Output

ACC-5E

Turbo Ultralite/

Input

Output

Input

RJ45

Out

(X11)

RJ45

(X12)

Connections 41

Geo MACRO Drive User Manual

Connecting optional Analog Inputs (X6 & X7)

The MACRO Geo Drive can be ordered with two analog to digital converters (option 3/4/5). These A/D converters are 16-bit devices that are ready to be used without any software setup. Delta Tau uses the Burr Brown ADS8343 for this circuit.

The analog signals for analog input #1 are wired in to pins 5 (ADC1+) and 9 (ADC1-) of X6, and for analog input #2 into pins 5 (ADC2+) and 9 (ADC2-) of X7.

Bipolar Analog Input

Function Pin #

GND 4

ANALOG+ 5

ANALOG- 9

Unipolar Analog Input

Function Pin #

GND 4

ANALOG+ 5

ANALOG- 9

X6/X7

-5VDC to 5VDC

Source

ANALOG- .

ANALOG+

-10VDC to 10VDC

Source

GND

ANALOG-.

ANALOG+

42 Connections

Geo MACRO Drive User and Reference Manual

SOFTWARE SETUP FOR GEO MACRO DRIVES

Introduction

Turbo PMAC2 controllers can command axes and I/O over the MACRO ring. Most commonly, this is done with an Ultralite board-level Turbo PMAC2 controller that is installed as an expansion card in the host computer, communicating to MACRO Stations, MACRO-based drives, and/or MACRO peripheral devices over the MACRO ring. However, it is also possible for a UMAC Turbo with the ACC-5E MACRO interface, to command devices over the MACRO ring.

It is advisable to the user to use the Turbo Setup program to set up his Geo MACRO application(MACRO communications, feedback setup, commutation, and motor setup), or to use the MACRO Ring ASCII setup tool which comes with the PEWIN32PRO2 and sets up the MACRO communications, and displays to the user some useful information about his system. Sample screens and procedures for these programs are shown in the following section

Establishing MACRO Communications with Turbo PMAC

Several variables must be set up properly for proper ring operation. Usually, this is done automatically through use of the Turbo Setup program or with the new application tool PEWIN32PRO2 MACRO Ring ASCII on a PC. The following instructions permit direct manual setting of these variables.

MACRO Ring Frequency Control Variables

The MACRO ring update frequency is the phase clock frequency of the ring master controller. If there is more than one Turbo PMAC2 controller on the ring, only one of them can be the ring master controller (others are masters, but not ring masters). Of course, if there is only one Turbo PMAC2 controller on the ring, it will be the ring master controller. Determining which Turbo PMAC2 (technically, which MACRO IC on a Turbo PMAC2) is ring master is explained below.

While the ring master has the capability to force the clock generation of other devices on the ring into synchronization, it is strongly recommended that all devices on the ring, both other Turbo PMAC2 controllers, and any slave devices, be set up for the same phase clock frequency. Determining which IC sets the phase clock frequency and the actual setting the phase clock frequency for a Turbo PMAC2 controller is explained above.

For a Turbo PMAC2 driving a MACRO ring, MACRO IC 0 should generate the phase clock signal. This means that I19 should be set to 6807 (which it will be by default on virtually any Turbo PMAC2 capable of driving a MACRO ring), and that I6800 and I6801 set the phase clock frequency.

I7: Phase Cycle Extension

On the Turbo PMAC2 board, it is possible to skip hardware phase clock cycles between executions of the phase update software. A Turbo PMAC2 board will execute the phase update software – commutation and/or current-loop closure – every (I7+1) hardware phase clock cycles. The default value for I7 is 0, so normally Turbo PMAC2 executes the phase update software every hardware phase clock cycle.

If the Turbo PMAC2 board is closing the current loop for direct PWM control over the MACRO ring, it is desirable to have two hardware ring update cycles (which occur at the hardware phase clock frequency) per software phase update. This eliminates one ring cycle of delay in the current loop, which permits slightly higher gains and performance. To do this, I7 would be set to 1, so the phase update software would execute every second hardware phase clock cycle, and ring update cycle.

Normally it is desirable to close the current loop at an update rate of about 9 kHz (the default rate). If two ring updates were desired per current loop update, the ring update frequency would need to be set to 18 kHz. This is possible if there are no more than 40 total active nodes on the ring. To implement this, I6800 would be set to one-half of the default value, and I6801 to the default value of 0.

Software Setup 43

Geo MACRO Drive User Manual

Note:

When making this change, change the Turbo PMAC2’s I6800 variable first, then the MACRO Station’s MI992. Changing the MACRO Station’s MI992 alone, followed by an MSSAVE<node> command and an MS$$$<node>, could cause the Station’s watchdog timer to trip.

I6840: MACRO IC 0 Master Configuration

Any MACRO IC on a Turbo PMAC2 talking to a MACRO Station must be configured as a master on the ring. For purposes of the MACRO protocol, each MACRO IC is a separate logical master with its own master number, even though there may be multiple MACRO ICs on a single physical Turbo PMAC2.

Each ring must have one and only one ring controller (synchronizing master). This should be the MACRO IC 0 one and only one of the Turbo PMAC2 boards on the ring.

On a Turbo PMAC2, set I6840 to $30 to make the card’s MACRO IC 0 the ring controller. This sets bits 4 and 5 of the variable to 1. Setting bit 4 to 1 makes the IC a master on the ring; setting bit 5 to 1 makes the IC the ring controller” starting each ring cycle by itself.

On a Turbo PMAC2 whose MACRO IC 0 will be a master but not ring controller, I6840 should be set to $90. This sets bits 4 and 7 of the variable to 1. Setting bit 4 to 1 makes the IC a master on the ring; setting bit 7 to 1 will cause this IC to be synchronized to the ring controller IC every time it receives a ring packet specified by I6841.

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

A Turbo PMAC2 Ultralite may have additional MACRO ICs if Options 1U1, 1U2, and/or 1U3 are ordered. A UMAC Turbo system may have additional MACRO ICs if Option 1 on an Acc-5E is ordered, or if multiple Acc-5E boards are ordered. These additional ICs should be set to be masters but not ring controllers by setting I6890, I6940, and I6990, respectively to $10. This sets bit 4 of the variable to 1, making the IC a master on the ring. These ICs should never be synchronizing masters, and since they do not control the clock signals on their own board, their internal clocks do not need to be synchronized to the ring (only MACRO IC 0 needs to do this).

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

I6841, I6891, I6941, and I6991 on Turbo PMAC2 control which of the 16 MACRO nodes for MACRO ICs 0, 1, 2, and 3, respectively, on the card are activated. They also control the master station number for their respective ICs, and the node number of the packet that creates a synchronization signal. The bits of these I-variables are arranged as follows:

Bits 0-15: Activation of MACRO Nodes 0 to 15, respectively (1 = active, 0 = inactive). These 16 bits (usually read as four hex digits) individually control the activation of the MACRO nodes in the MACRO IC on a Turbo PMAC2. Each node that is active on the matching MACRO Station, whether for servo, I/O, or auxiliary communications, should have its node activation bit set to 1.

When working with a Delta Tau MACRO Station, Node 15 of each MACRO IC on a Turbo PMAC2 must be activated to permit auxiliary communications, so bit 15 of this variable should always be set to 1 if the IC is used to communicate with a MACRO Station.

Bits 16-19: Packet Sync Node Slave Number. These four bits together (usually read as one hex digit) form the slave number (0 to 15) of the packet whose receipt by the PMAC2 will set the Sync Packet Received status bit in the MACRO IC. Usually, this digit is set to $F (15), because Node 15 is always activated.

Turbo PMAC2 must see this bit set regularly; otherwise it will assume ring problems and shut down servo and I/O outputs on the ring. Bit 7 of I6840 must be set to 1 on the MACRO IC 0 of all Turbo PMAC2s that are not ring controllers to enable the synchronization of their phase clocks to that of the ring controller based on receipt of the sync packet.

44 Software Setup

Geo MACRO Drive User and Reference Manual

Bits 20-23: Master Number. These four bits together form the master number (0 to 15) of the MACRO IC on the MACRO ring. Each MACRO IC acting as a master on the ring, whether on the same card or different cards, must have its own master number, and acts as a separate master station for the purposes of the ring protocol. This master number forms half of the address byte with each packet sent by the PMAC2 over the MACRO ring.

The master number can be the same number as the MACRO IC number (e.g. MACRO IC 0 has master number 0, MACRO IC 1 has master number 1, and so on), and if there is only one Turbo PMAC2 in the ring, this probably will be the case. However, this is not required. The MACRO IC that is the ring controller must have master number 0 if Type 1 master-to-master auxiliary communications are to be used.

Hex ($) 000

Bit

Slavenode Enables

000

Sync nodeAddress

MasterAddress (0-15)

(0-15)

The table shown in an above section and in the Hardware Reference Manual for the 3U MACRO Station’s SW1 switch setting provides a starting point for the Turbo PMAC2’s I6841/I6891/I6941/I6991 value. Additional bits of these I-variables may be set to 1 if I/O nodes are enabled or if more than one 3U MACRO station is commanded from a single MACRO IC.

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

I70, I72, I74, and I76 are 16-bit I-variables (bits 0 - 15) in which each bit controls the enabling or disabling of the auxiliary flag function for the MACRO node number matching the bit number for MACRO ICs 0, 1, 2, and 3, respectively. A bit value of 1 enables the auxiliary flag function; a bit value of 0 disables it. If the function is enabled, PMAC automatically copies information between the MACRO interface flag register and RAM register $00344n, $00345n, $00346n, and $00347n (where n is the IC’s node number 0 – 15) for MACRO ICs 0, 1, 2, and 3, respectively.

Note that Turbo PMAC MACRO node numbers (as opposed to individual MACRO IC node numbers) go from 0 to 63, with board nodes 0 – 15 on MACRO IC 0, board nodes 16 – 31 on MACRO IC 1, board nodes 32 – 47 on MACRO IC 2, and board nodes 48 – 63 on MACRO IC 3.

Each MACRO node n that is used for servo functions should have the corresponding bit n of I70, I72, I74, or I76 set to 1. Ixx25 for the Motor x that uses Node n should then address $00344n, $00345n, $00346n, or $00347n, not the address of the MACRO register itself (see below). If Register 3 of a MACRO node n is used for other purposes, such as direct I/O, the corresponding bit n of I70, I72, I74, or I76 should be set to 0, so this copying function does not overwrite these registers.

Typically, non-servo I/O functions with a MACRO Station do not involve auxiliary flag functions, so this flag copy function should remain disabled for any node used to transmit I/O between the Turbo PMAC2 and the MACRO Station. If any auxiliary communications is done between the Turbo PMAC2 and the MACRO Station on Nodes 14 and/or 15, bits 14 and 15 of these variables must be set to 0.

Examples:

I70=$3 ; Enabled for MACRO IC 0, Nodes 0 and 1

I72=$30 ; Enabled for MACRO IC 1, Nodes 4 and 5

I74=$3300 ; Enabled for MACRO IC 2, Nodes 8,9,12,13

Software Setup 45

Geo MACRO Drive User Manual

I76=$3333 ; Enabled for MACRO IC 3, Nodes 0,1,4,5,8,9,12,13

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

I71, I73, I75, and I77 are 16-bit I-variables (bits 0 - 15) in which each bit controls whether PMAC uses the uses MACRO Type 0 protocol or the MACRO Type 1 protocol for the node whose number matches the bit number for the purposes of the auxiliary servo flag transfer for MACRO ICs 0, 1, 2, and 3, respectively. A bit value of 0 sets a Type 0 protocol; a bit value of 1 sets a Type 1 protocol.

All 3U MACRO Station nodes use the Type 1 protocol, so each MACRO node n used for servo purposes with a MACRO Station must have bit n of I1002 set to 1. Generally I71 = I70, I73 = I72, I75 = I74, and I77 = I76 on a Turbo PMAC2 communicating with a MACRO Station.

Remember that if servo nodes for more than one MACRO Station are commanded from a single MACRO IC, the protocol must be selected for all of the active servo nodes on each station.

I78: MACRO Master/Slave Auxiliary Communications Timeout

If I78 is set greater than 0, the MACRO Type 1 Master/Slave Auxiliary Communications protocol using Node 15 is enabled. Turbo PMAC implements this communications protocol using the MACROSLAVE (MS), MACROSLVREAD (MSR), and MACROSLVWRITE (MSW) commands.

If this function is enabled, I78 sets the timeout value in PMAC servo cycles. In this case, if PMAC does not get a response to a Node 15 auxiliary communications command within I78 servo cycles, it will stop waiting and register a MACRO auxiliary communications error, setting Bit 5 of global status register X:$000006.

I78 must be set greater than 0 if any auxiliary communications is desired with a MACRO Station. This reserves Node 15 for the Type 1 Auxiliary Communications. A value of 32 is suggested. If I78 is set greater than 0, bit 15 of I70, I72, I74, and I76 must be set to 0, so Node 15 is not used for flag transfers also.

I79: MACRO Master/Master Auxiliary Communications Timeout

If I79 is set greater than 0, the MACRO Type 1 Master/Master Auxiliary Communications protocol using Node 14 is enabled. Turbo PMAC implements this communications protocol using the MACROMASTER (MM), MACROMSTREAD (MMR), and MACROMSTWRITE (MMW) commands. Only the Turbo PMAC that is the “ring controller” can execute these commands; other Turbo PMACs that are masters on the ring can respond to these commands from the ring controller.

If this function is enabled, I79 sets the “timeout” value in PMAC servo cycles. In this case, if the Turbo PMAC does not get a response to a Node 14 master/master auxiliary communications command within I79 servo cycles, it will stop waiting and register a “MACRO auxiliary communications error,” setting Bit 5 of global status register X:$000006.

I79 must be set greater than 0 if any auxiliary communications is desired with a MACRO Station. A value of 32 is suggested. If a value of I79 greater than 0 has been saved into PMAC’s non-volatile memory, then at subsequent power-up/resets, bit 14 of I70 is set to 0, the node-14 broadcast bit (bit 14 of I6840) is set to 1, and activation bit for node 14 (bit 14 of I6841) is set to 1, regardless of the value saved for these variables. This reserves Node 14 of MACRO IC 0 for the Type 1 Master/Master Auxiliary Communications.

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

If I80 is set to a value greater than zero, Turbo PMAC will monitor for MACRO ring breaks or repeated MACRO communications errors automatically. A non-zero value sets the error detection cycle time in Turbo PMAC servo cycles. Turbo PMAC checks to see that “sync node” packets (see I6840 and I6841) are received regularly, and that there have not been regular communications errors.

The limits for these checks can be set with variables I81 and I82. If less than I82 sync node packets have been received and detected during this time interval, or if I81 or more ring communications errors have

46 Software Setup

Geo MACRO Drive User and Reference Manual

been detected in this interval, Turbo PMAC will assume a major ring problem, and all motors will be shut down. Turbo PMAC will set the global status bit “Ring Error” (bit 4 of X:$000006) as an indication of this error.

Turbo PMAC looks for receipt of sync node packets and ring communications errors once per real-time interrupt – every (I8 + 1) servo cycles). The time interval set by I80 must be large enough that I82 realtime interrupts in PMAC can execute within the time interval, or false ring errors will be detected. Remember that long motion program calculations can cause skips in the real-time interrupt. Typically values of I80 setting a time interval of about 20 milliseconds are used. I80 can be set according to the formula:

I80 = Desired cycle time (msec) * Servo update frequency (kHz) For example, with the default servo update frequency of 2.26 kHz, to get a ring check cycle interval of 20

msec, I80 would be set to 20 * 2.26 ≅ 45.

MACRO Node Addresses

The MACRO ring operates by copying registers at high speed across the ring. Therefore, each Turbo PMAC2 master controller on the ring communicates with its slave stations by reading from and writing to registers in its own address space. MACRO hardware handles the data transfers across the ring automatically.

Starting in Turbo firmware version 1.936, the base addresses of the up to 4 MACRO ICs must be specified in I20 – I23, for MACRO IC 0 – 3 respectively. Before this, the base addresses were fixed at $078400, $079400, $07A400, and $07B400, respectively. Only UMAC Turbo systems can support any other configuration, and only rarely will another configuration be used.

The following table gives the addresses of the MACRO ring registers for Turbo PMAC2 controllers.

Note:

It is possible, although unlikely, to have other addresses in a UMAC Turbo system. In these systems, the fourth digit does not have to be 4; it can also take the values 5, 6, and 7.

Software Setup 47

Geo MACRO Drive User Manual

Turbo PMAC2 Addresses: MACRO IC 0

Node # Reg. 0 Reg. 1 Reg. 2 Reg. 3

0 Y:$078420 Y:$078421 Y:$078422 Y:$078423

1 Y:$078424 Y:$078425 Y:$078426 Y:$078427

2 X:$078420 X:$078421 X:$078422 X:$078423

3 X:$078424 X:$078425 X:$078426 X:$078427

4 Y:$078428 Y:$078429 Y:$07842A Y:$07842B

5 Y:$07842C Y:$07842D Y:$07842E Y:$07842F

6 X:$078428 X:$078429 X:$07842A X:$07842B

7 X:$07842C X:$07842D X:$07842E X:$07842F

8 Y:$078430 Y:$078431 Y:$078432 Y:$078433

9 Y:$078434 Y:$078435 Y:$078436 Y:$078437

10 X:$078430 X:$078431 X:$078432 X:$078433

11 X:$078434 X:$078435 X:$078436 X:$078437

12 Y:$078438 Y:$078439 Y:$07843A Y:$07843B

13 Y:$07843C Y:$07843D Y:$07843E Y:$07843F

14 X:$078438 X:$078439 X:$07843A X:$07843B

15 X:$07843C X:$07843D X:$07843E X:$07843F

Turbo PMAC2 Addresses: MACRO IC 1

Node # Reg. 0 Reg. 1 Reg. 2 Reg. 3

0 Y:$079420 Y:$079421 Y:$079422 Y:$079423

1 Y:$079424 Y:$079425 Y:$079426 Y:$079427

2 X:$079420 X:$079421 X:$079422 X:$079423

3 X:$079424 X:$079425 X:$079426 X:$079427

4 Y:$079428 Y:$079429 Y:$07942A Y:$07942B

5 Y:$07942C Y:$07942D Y:$07942E Y:$07942F

6 X:$079428 X:$079429 X:$07942A X:$07942B

7 X:$07942C X:$07942D X:$07942E X:$07942F

8 Y:$079430 Y:$079431 Y:$079432 Y:$079433

9 Y:$079434 Y:$079435 Y:$079436 Y:$079437

10 X:$079430 X:$079431 X:$079432 X:$079433

11 X:$079434 X:$079435 X:$079436 X:$079437

12 Y:$079438 Y:$079439 Y:$07943A Y:$07943B

13 Y:$07943C Y:$07943D Y:$07943E Y:$07943F

14 X:$079438 X:$079439 X:$07943A X:$07943B

15 X:$07943C X:$07943D X:$07943E X:$07943F

48 Software Setup

Geo MACRO Drive User and Reference Manual

Turbo PMAC2 Addresses: MACRO IC 2

Node # Reg. 0 Reg. 1 Reg. 2 Reg. 3

0 Y:$07A420 Y:$07A421 Y:$07A422 Y:$07A423

1 Y:$07A424 Y:$07A425 Y:$07A426 Y:$07A427

2 X:$07A420 X:$07A421 X:$07A422 X:$07A423

3 X:$07A424 X:$07A425 X:$07A426 X:$07A427

4 Y:$07A428 Y:$07A429 Y:$07A42A Y:$07A42B

5 Y:$07A42C Y:$07A42D Y:$07A42E Y:$07A42F

6 X:$07A428 X:$07A429 X:$07A42A X:$07A42B

7 X:$07A42C X:$07A42D X:$07A42E X:$07A42F

8 Y:$07A430 Y:$07A431 Y:$07A432 Y:$07A433

9 Y:$07A434 Y:$07A435 Y:$07A436 Y:$07A437

10 X:$07A430 X:$07A431 X:$07A432 X:$07A433

11 X:$07A434 X:$07A435 X:$07A436 X:$07A437

12 Y:$07A438 Y:$07A439 Y:$07A43A Y:$07A43B

13 Y:$07A43C Y:$07A43D Y:$07A43E Y:$07A43F

14 X:$07A438 X:$07A439 X:$07A43A X:$07A43B

15 X:$07A43C X:$07A43D X:$07A43E X:$07A43F

Turbo PMAC2 Addresses: MACRO IC 3

Node # Reg. 0 Reg. 1 Reg. 2 Reg. 3

0 Y:$07B420 Y:$07B421 Y:$07B422 Y:$07B423

1 Y:$07B424 Y:$07B425 Y:$07B426 Y:$07B427

2 X:$07B420 X:$07B421 X:$07B422 X:$07B423

3 X:$07B424 X:$07B425 X:$07B426 X:$07B427

4 Y:$07B428 Y:$07B429 Y:$07B42A Y:$07B42B

5 Y:$07B42C Y:$07B42D Y:$07B42E Y:$07B42F

6 X:$07B428 X:$07B429 X:$07B42A X:$07B42B

7 X:$07B42C X:$07B42D X:$07B42E X:$07B42F

8 Y:$07B430 Y:$07B431 Y:$07B432 Y:$07B433

9 Y:$07B434 Y:$07B435 Y:$07B436 Y:$07B437

10 X:$07B430 X:$07B431 X:$07B432 X:$07B433

11 X:$07B434 X:$07B435 X:$07B436 X:$07B437

12 Y:$07B438 Y:$07B439 Y:$07B43A Y:$07B43B

13 Y:$07B43C Y:$07B43D Y:$07B43E Y:$07B43F

14 X:$07B438 X:$07B439 X:$07B43A X:$07B43B

15 X:$07B43C X:$07B43D X:$07B43E X:$07B43F

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Note:

With the MACRO station, only nodes that map into Turbo PMAC2 Y registers (0, 1, 4, 5, 8, 9, 12, and 13) can be used for servo control. These nodes are unshaded in the above table. The nodes that map into X registers (2, 3, 6, 7, 10, 11, and 14) can be used for I/O control. Node 15 is reserved for Type 1 auxiliary communications. Node 14 is often reserved for broadcast communications.

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Using the Turbo PMAC Setup Program

The following captured screens are taken from the Turbo Setup program.

First the user needs to start the Turbo Setup Application. From the Menu Bar move the mouse over the “Tools” and select with double click the “Turbo/UMAC Setup Pro (2)”

Another way to start the Turbo Setup Application the user can double click the Turbo Setup shortcut on the desktop.

So as to use the Geo MACRO drive: Turbo Ultralite, UMAC MACRO or QMAC with MACRO option needs to be used, and if they do then at the first pop up window, user needs to click Yes. If your system doesn’t use any of the above Controllers then Turbo Setup cannot be used, click No

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Then the first step is to select the kind of communications you have established with your PMAC device that would be used as your Controller.

• UMAC and QMAC controllers can communicate to the PC via Serial Port, USB and Ethernet

• Turbo PMAC2 Ultralite controllers have two versions: the older ISA Bus and the newer PCI bus

o The ISA boards

can communicate to the PC via Serial Port and ISA Bus (manual

registration).

o The PCI boards

can communicate to the PC via Serial Port and PCI Bus. (Plug and

Play)

If there are no Devices on the list, then the user needs to Insert new devices.

For more information and details about the Communication of the devices, please read the appropriate manual:

• PEWIN32 PRO

http://www.deltatau.com/fmenu/PEWIN32%20PRO.PDF

• PEWIN32 PRO Suite 2

http://www.deltatau.com/fmenu/PEWIN%2032%20PRO%202%20SOFTWARE.PDF

After you select the communications scheme, double click on the Test button and if everything is set correct then a pop-up window will show saying that “the PMAC was successfully founded”. Press ok and the Turbo Setup Application starts.

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The first setup screen is to set some information about your PMAC controller and the ACCessories that are used. Currently there are only two options that can be used with Geo MACRO drives.

Turbo/UMAC MACRO or QMAC

On the same setup screen the user needs to select how many MACRO ICs the used Turbo Ultralite or ACC-5E have installed, and how many MACRO Stations will be controlled. If UMAC MACRO is used then the user needs to know if he has in his UMAC rack an ACC-24E or/and ACC-51E. After selecting all the correct options (appropriate to your system) click the Next button.

A pop up window will show asking you if your Geo MACRO drive is a 16-axis MACRO station. Geo MACRO drives are neither 16-axis nor 8-axis MACRO stations. Geo MACRO drives use special MACRO CPU. So click on the N

o button.

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The next window that will appear is to set up your PWM frequency.

After you select the dominant PWM frequency, click on Next.

A new setup screen will appear to Assign your MACRO Master number to the MACRO IC’s. For most of the systems default values are good.

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The following screen of the Setup program selects which method to use to bind the MACRO stations to the MACRO controller.

Geo MACRO drives are using the Ring Order Method. After clicking the Next button the program will use some time for its calculations.

The setup program will come back with any MACRO stations that were found with the Ring order Method. MS<node>,MI996 needs to be set manually

on this screen to enable the nodes.

MI996 controls which of the MACRO nodes on the Geo MACRO Station are activated. It also controls the master station number, and the node number of the packet that creates a synchronization signal.

Bits 0 to 15 are individual control bits for the matching node number 0 to 15. If the bit is set to 1, the node is activated; if the bit is set to 0, the node is de-activated. Node 15 should always be activated to support the Type 1 auxiliary communications.

Bits 16-19 specify the slave number of the packet which will generate the “sync pulse” on the Geo MACRO Station. This is always set to 15 ($F) on the Geo MACRO Station.

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Bits 20-23 specify the master number (0-15) for the Geo MACRO Station. At power-up/reset, these bits get the value set by SW2. The number must be specified whether the card is a master station or a slave station.

Hex ($) 000

Bit

Slave node Enables

Sync nodeAddress

MasterAddress (0-15)

000

(0-15)

After setting the correct value to the MI996, click the Next button to move on.

The Setup software will come up with a new pop-up window asking if it is a Geo MACRO drive. You should reply by clicking the Yes button.

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All the screens following are the Steps to setup your motors, so check the boxes and enter the correct data to the questions, to setup, phase and tune your motors. There are 23 steps.

Note:

Geo Drives are using Digital Current Loop, with PWM outputs

User needs with the current version of Turbo Setup (before 9/1/05) to manually

edit at the terminal window MI101 and MI102 for the Encoders

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Using the PEWIN32PRO 2 MACRO Ring ASCII Feature

With the new PEWIN32PRO Suite2 a new configuration application has been added to initiate the MACRO Ring ASCII communication between the Ring Controller and other Slave stations and/or secondary Masters/Slaves. This new application allows the user to setup the Ring Controller, detect or reinitialize all other stations on the Ring, set up all communication parameters, save these parameters in a backup file, and can start or stop MACRO Ring ASCII communication to any station on the Ring.

So as to start the application you need to start your PEWIN32 PRO Suite2 and with the mouse on the Menu Bar select the Configure Menu and click on the MACRO Ring ASCII

The new application starts, make sure you have selected which PMAC device the PEWIN32PRO communicates to, else with the right click on the application click on the Select PMAC.

Detect MACRO Ring

Detects all MACRO IC’s that are connected to the Ring.

• Ring Controller

• MACRO Station #n

Setup Ring Controller

It will re-initialize the MACRO controller (Turbo PMAC), and all clocks and nodes will be reset. It gives the option of a re-initialize and a reset.

Reinit. MACRO Ring

The program will reinitialize the MACRO stations on the ring.

Ring Check

A small troubleshooting tool for the MACRO ring communications

The first thing the user needs to do when he starts the program is to make sure that everything is

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connected and powered up. Then if it is the first time he tries to setup his system, its advisable to click on the Setup Ring Controller and Click Yes on the pop-up window to do a global re-initialization of the Turbo PMAC controller.

If the user wants just to do some change of values, troubleshooting or setup some new MACRO Stations then he should just press the No in the above window or not even press on the Setup Ring Controller and press on Detect MACRO Ring button. If the user wants to reinitialize every I-variable on the Turbo PMAC will be set back to factory default.

Note

If by accident or error the user pressed the Yes button on the reinitialize of the controller, and he wants to reverse, then he needs issue a reset “$$$” or a couple of seconds powercycle. This will load the last saved I-variables before the re initialization.

Do NOT issue a save after the re-initialize if you want to reverse; if Save is issued

then there is no way to reverse unless the user restores with a backup file.

If the user chooses to Detect MACRO Ring, the program will automatically show how many Stations were detected.

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The user has to first setup his Ring Controller and save any changes and then Setup each of his MACRO stations. So select at the Stations Detected window the Ring Controller. The Application automatically gives the user a Description online

commands that the Application send to the controller.

of his Motion Controller Card. The window below the description, are the

• User can select which MACRO

IC he would like to setup.

• Set the I-variables for the systems

frequencies. And mainly set I6841. Then issue a Save Changes, I70 & I71 will automatically be set according to the I6841 value.

If the user clicks on his Right mouse button on the Ring Controller Window, a new menu window will show up on screen.

*All the I-variables on this screen are in detail explained at the Appendix of this manual

Reset All Stations to Default, sends the command MS$$$**255 and re-initializes all MACRO stations on the ring.

Reset all Stations to Last Saved, sends the online command “MS$$$255” and does a reset to the last saved by the user values. It is the same with Power cycle at all the units.

Save All Station Variables, saves all the MI-variables at the MACRO Stations.

Clear All Stations Faults, mainly sends the command “CLRF255”

Backup MACRO Ring creates a backup file with all the MACRO I-variables from all the MACRO stations on the ring.

Restore MACRO Ring downloads the backup file with all the MACRO I-variables to all the MACRO stations on the ring.

After the Ring Controller is set up the user needs to setup his MACRO Stations.

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First the user needs to select which MACRO station to start with. Set the MI-variables (MI : MACRO Station I-variables), and enable the nodes with MI996.

Note

MI996 and I6841 need to comply

Then the user should click on the Save Changes button.

If the user clicks on his Right mouse button on the Station Window, a new menu window will show up on screen.

Start MACRO ASCII, it starts MACRO ASCII communications. Sends the online command “MACSTA<node>”

Stop MACRO ASCII, it stops MACRO ASCII communications. Sends the online command “^T” (Ctrl+T)

Station Specific Commands

Reset Station to Default, sends the

command MS$$$**<node> and reinitializes the MACRO station #n on the ring.

Reset Station to Last Saved, sends the online command “MS$$$<node>” and does a reset to the last saved by the user values. It is the same with Power cycle at all the units.

Save Station Variables, it saves all the MIvariables of the station that the application currently is communicating to. The online command is “MSSAVE<node>”

Clear Station Faults, it clears all the faults, unless there is a hardware fault. The online command is “CLRF<node>”

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PEWIN32PRO Suite 2 MACRO Status window

One more new addition to the new PEWIN32PRO (Suite2) is the MACRO Status window.

So as to open it, the user needs to select the View Menu from the Menu Bar and click on the MACRO Status.

A new window will open showing the Status at the Geo MACRO Station, which is the same with MS<node>,MI4

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Ring Order Communications Method

The Ring Order Method has been developed to allow MACRO Devices to be set up with software. Since the Geo MACRO drive has no hardware switches (SW1 and SW2) to activate nodes and assign it to a master, the ring order method is necessary. The Turbo Setup program can do this automatically for you; thi section tells you how to do it manually.

Factory default state for the I-Variables to the Turbo Ultralite ($$$***) and that firmware version 1.939 or above are necessary. In addition, the Geo MACRO drive should have version 1.004 and above firmware.

1. To initiate the Ring Order Method, start with the new hardware and then enable the MACRO ASCII Communication Mode by typing MACSTA255 in the terminal window. At this point, the Software Interface will seek the first device that has not been setup (i.e. MI11=0). Once communicating with the device, activate the nodes with MI996 and set up any critical MI-variables that need to be set for the application. Upon completion of these MI-variable settings, assign a Station Number to the device with the STN=n command where n can be set from 1 to 254. As soon a station number is assigned to the device, the system will look for the next device that has not been set up (MI11=0). If assigning a MACRO device as Station Number 20, type STN=20 in the terminal window and MI11 will be set to 20.

• If a Macro I/O error is received, make sure I6840, I6841 and I79 are set correctly. Also, make

sure that the unit has not been already assigned a station number.

• If the Station has been assigned a Station number already, there are two options:

a) Find out the station number n by typing the STN command and enter MACSTA<n>, where n is

the station number, to initiate MACRO ASCII communication with the Station.

b) Reset the station number of all the stations by entering MACSTA0 and then STN=0. Exit

MACRO ASCII communications by typing <Control-T> (^T). Then enter MACSTA255 to access the first Station. Now assign it a Station number by entering STN=n where n is the Station number. Enter (^T) to exit MACRO ASCII Communications. Enter MACSTA255 again to access the next station and repeat this process until a MACRO I/O error is received stating that there are no further unassigned stations.

2. Enter MACSTA<n> where n is the Station number. Enter I996=$F4004. (Binds to Ring Controller 0 and Node2)

3. Enter ^T. (Control-T terminates MACRO ASCII Communications.)

4. Enter MSCLRF2. (Clears any faults at Node 2.)

5. Enter I6841= $0FC004. (Enable Node 2.)

Issue the SAVE and MSSAVE{node} commands to save the parameters in memory

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MACRO ASCII Communications

MACRO ASCII Communication Mode allows direct access to the MACRO Device. This mode of communication allows the Master controller to set up all MACRO devices in the ring one at a time using the Ring Order Method. One other benefit to this method of communications is that it allows direct communication to the MACRO device without having to issue MS commands as in the traditional PEWIN Terminal window.

At a minimum, the following I-variables must be set to the Turbo PMAC to enable MACRO ASCII mode communications.

I6840=$4030 ; to enable MACRO IC0 as sync-master and node 14 for auxiliary communications I6841=$0FCxxx ; to enable node 15 and 14. If activating nodes 0,1,4,5 set I6841=$0FC033 I79=32 ; Timeout value for Node 14 Auxiliary communications

If using more than one MACRO IC, set up I6890, I6891, I6940, I6941, I6990, and I6991 appropriately. Once the communication variables are modified, save them to the memory of the controller with the SAVE command and then reset the controller with either a $$$ command or power cycle the controller.

Note:

The PMAC controller can communicate to the MACRO Device in MACRO ASCII communication mode after the unit has been restarted with the changes saved to its memory.

How to Enable and Disable MACRO ASCII Communication Mode

To start the MACRO ASCII Mode, issue the MACSTAn (n stands for the assigned station number for the device) command to the device in the ring.

Note:

For MACRO ASCII communication via PEWIN 32 Pro, close all other windows of the PEWIN other than the terminal window.

HyperTerminal also can be used for MACRO ASCII communication to the Geo MACRO drive. PEWIN32 Pro must be totally closed.

In many cases, there will be only one device and a number may not be assigned to the device. In that case, use the MACSTA255 or MACSTA0 commands. The actual number that is assigned to the device resides in MI11 of the MACRO Device and the default value is 0. If there are multiple MACRO devices in the ring and communication is in MACRO ASCII mode, set up the systems with the Ring Order Method and assign station numbers to each device. If the assigned station number is not known, check MI11.

Once in MACRO ASCII Mode, communicate to the MACRO device is done directly. To change/monitor an MI-variable, write directly to the Variable in the terminal window.

MI996=$0F803F ;To activate Nodes 0,1,2,3,4,5 at the MACRO Device

To exit or disable MACRO ASCII Communication mode, issue the <CTRL>T command.

Note:

The MACSTA255 command will look for the first MACRO device that does not have a station number assigned to it (MI11=0). As soon as MI11 is changed to a value greater than zero, then it will look immediately for the next device with MI11 set to zero.

MACRO ASCII Communication global commands

1. VID Vendor ID (Delta Tau = 1, Range=1- 65535)

2. CID Vendor Card ID, Part Number, (Range=1- 4,294,967,295) 32 bit unsigned.

Delta Tau: Turbo PMAC2 VME = 602413 (MACRO Master)

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Delta Tau: Turbo PMAC2 Ultralite = 603182 (MACRO Master) Delta Tau: UMAC Turbo = 603382 (MACRO Master) Delta Tau: UMAC MACRO 8 = 602804 (MACRO Slave) Delta Tau: UMAC MACRO 16 = 603719 (MACRO Slave) Delta Tau: Geo MACRO Drive = 603542 (MACRO Slave) Delta Tau: ACC-65M = 603740 (MACRO Slave) Delta Tau: ACC-68M = 603747 (MACRO Slave)

3. SID Serial ID (Range = 64 bit unsigned, 0=Serial ID not available)

4. $$$** - Station to reset to default parameter with no station number and ready for Ring location

identification.

Note

Do not use $$$***.

5. SAVE – Save station number and initialization parameters.

6. $$$ – Reset Station to saved station number and initialization parameters.

7. STN=n <n=0-254> – Assigns the MACRO station number. Normally, this would be its order in

the Ring. A STN=0 resets the station number and is reserved for the Ring Controller Master.

8. Commands with STN=0 is a broadcast to all stations in the ring.

9. Commands with STN=255 is a request for communication with the first station in the ring with its

STN=0.

10. Commands with STN=1-254 is a request for communication with the station in the ring with

STN=1-254.

11. STN – The addressed MACRO Station responds with its station number (n).

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SETTING UP PRIMARY FEEDBACK

Device Selection Control

Geo Drives with the appropriate options can handle Quadrature Encoder Input (Shift / No Shift), Resolver Feedback, Sinusoidal Encoder Input, SSI Absolute Encoders, ENDAT Interface (future release) and Hiperface Interface (future release).

The main encoder input channels for the Geo PMAC Drive supports a variety of encoder feedback types. 5V supply to power the encoder is provided from each encoder connector.

Encoder #1 Encoder #2 Value Decode Function

MS{node},MI101 MS{node},MI102 0 Quadrature Encoder, Normal Shifting (1/T) (5-bits) MS{node},MI101 MS{node},MI102 1 Quadrature Encoder, No shifting MS{node},MI101 MS{node},MI102 2 SSI encoder, CW MS{node},MI101 MS{node},MI102 3 SSI encoder, CCW MS{node},MI101 MS{node},MI102 4 Resolver CW MS{node},MI101 MS{node},MI102 5

MS{node},MI101 MS{node},MI102 6 Sinusoidal Encoder x4096 MS{node},MI101 MS{node},MI102 12 Write the arctangent value of the Sin and Cos to the

MS{node},MI101 MS{node},MI102 13 Write the arctangent value of the Sin and Cos to the

MS{node},MI101 MS{node},MI102 14 Write the Sin and Cos values to the MACRO IO node

Resolver CCW

MACRO IO node (Resolver CCW +8)

MACRO IO node (Resolver CW +8)

(Sin enc.) For troubleshooting

Setting up Digital Quadrature Encoders

Digital quadrature encoders are the most common position sensors used with Geo Drives. Interface circuitry for these encoders comes standard on board-level Turbo PMAC controllers, UMAC axisinterface boards, Geo drives, and QMAC control boxes.

User needs to set up his MS<node>, MI101 equal to 0 for channel #1 of his Geo MACRO drive for normal quadrature encoder with 5-bit shifting (1/T). If the user doesn’t want to use the 1/T shifting then he needs to set MS<node>, MI101 equal to 1.

For the second channel use MS<node>, MI102 and the same with channel #1.

So as to change the direction of the encoder feedback the user can either swap the cable leads or an easier way would be to set MS<node>, MI910 equal to 3, clockwise, or equal to 7 for counterclockwise. MI910 can be set to more values for different options, please look at the Software Reference Appendix.

Setting up SSI Encoders

The Geo Drive will take the data from the SSI encoder and process it as a binary parallel word (12 or 24 bits). This data can then be processed in the PMAC encoder conversion table for position and velocity feedback. With proper setup, the information can also be used to commutate brushless and AC induction motors.

Caution:

Geo Drive was designed to work with either Gray Code or Binary Style SSI

Encoders. The Geo Drive takes the gray/binary code information and converts it

into a parallel binary word for absolute and ongoing position data

User needs to set up his MS<node>, MI101 equal to 2 (CW) or 3 (CCW) and then set 2 I-variables per channel.

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The user needs to set the control word MS<node>,MI930 (channel#1) and MS<node>,MI931 (channel#2) depending on the SSI encoder that the system uses, the control word specifies the mode that the data are coming back to the PMAC (binary or gray code) and the length of the word.

• A 12-bit numeric binary encoder would mean the control word (MI930/MI931) need to be set equal

to $2, if the encoder is outputting gray code then the control word needs to be set equal to $3.

• A 16-bit numeric binary encoder would mean the control word (MI930/MI931) need to be set equal

to $6, if the encoder is outputting gray code then the control word needs to be set equal to $7.

• A 20-bit numeric binary encoder would mean the control word (MI930/MI931) need to be set equal

to $A, if the encoder is outputting gray code then the control word needs to be set equal to $B.

• A 24-bit numeric binary encoder would mean the control word (MI930/MI931) need to be set equal

to $E, if the encoder is outputting gray code then the control word needs to be set equal to $F.

And the second I-variable the user needs to set is the clock output (frequency) to the SSI- encoder interface (MS<node>, MI933). A value of 0 sets the Clock output @ 153.6 KHz. If higher clock frequency required then MI933 can be set equal to 1 which sets the clock output @ 307.2 KHz, while a value of 2 sets the clock output @ 614.4 KHz to the SSI-encoder interface. And the highest value the clock can be set would be when MI933=3 setting the clock output @1.23MHz. MI933 is setting the clock output for both channels #1 and #2, so user can not have different excitation frequencies for his two SSIinterface encoders.

SSI encoders (especially multi-turn) generally provide absolute position information that eliminates the need for a homing-search move to establish a position reference.

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Setting up Sinusoidal Encoders

The Geo Drive with the Interpolator option accepts inputs from two sinusoidal or quasi-sinusoidal encoders and provide encoder position data to the motion processor. This interpolator creates 4,096 steps per sine-wave cycle.

The Geo MACRO drive so as to read the sinusoidal encoders needs the device control variable MS<node>, MI101 (for the first channel #1) or MS<node>, MI102 (for the second channel #2) equal to 6. Also the user can reverse the direction of the sinusoidal encoder by setting the MS<node>, MI910 equal to 3 (ClockWise) or 7 (CounterClockWise)

If the direction decode variable is changed, the user must save the setting, MSSAVE{node} and reset the card MS$$${node} before the fractional direction sense matches.

Note

Home Capture with high resolution feedback requires bit 11 of Ixx24 on the Turbo

PMAC to be set to one (value $800 or 2,048). Bit 12 of Ixx24 enables the Sub-

count Capture while the Geo MACRO’s: MS<node>, MI7mn9 is set to one.

Principle of PMAC Interpolation Operation

Decoder /

Counter

Comparator

1 - Bit A/D

Analog

Photo

Current

Differential

Amplifier

Sin / Cos

Signals

Encoder

n-bit

A/D

n-bit

A/D

Controller

The sine and cosine signals from the encoder are processed in two ways in the Geo Drive board (see above diagram). First, they are sent through comparators that square up the signals into digital quadrature and sent into the quadrature decoding and counting circuit of the Servo IC on the Geo Drive. The units of the hardware counter, which are called hardware counts, are thus ¼ of a line. For most users, this fact is an intermediate value, an internal detail that does not concern them. However, this is important in two cases. First, if the sinusoidal encoder is used for PMAC-based brushless-motor commutation, the hardware counter, not the fully interpolated position value, will be used for the commutation position feedback. Therefore, the units of Ixx71 will be hardware counts.

Second, if the hardware position-compare circuits in the Servo IC are used, the units of the compare register are hardware counts. (The same is true of the hardware position-capture circuits, but often these scaling issues are handled automatically through the move-until-trigger constructs).

The second, parallel, processing of the sine and cosine signals is through analog-to-digital converters, which produce numbers proportional to the input voltages. These numbers are used to calculate mathematically an arctangent value that represents the location within a single line. This is calculated to

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1/4096 of a line, so there are 4096 unique states per line, or 1024 states per hardware count.

For historical reasons, PMAC expects the position it reads for its servo feedback software to have units of 1/32 of a count. That is, it considers the least significant bit (LSB) of whatever it reads for position feedback to have a magnitude of 1/32 of a count for the purposes of its software scaling calculations. We call the resulting software units software counts and any software parameter that uses counts from the servo feedback (e.g., jog speed in counts/msec, axis scale factor in counts/engineering-unit) is using these software counts. In most cases, such as digital quadrature feedback, these software counts are equivalent to hardware counts.

However, with the added resolution produced by the Geo Drive interpolator option, software counts and hardware counts are no longer the same. The LSB produced by the interpolator (through the encoder conversion table processing) is 1/1024 of a hardware count, but PMAC software considers it 1/32 of a software count. Therefore, with the Geo drive, a software count is 1/32 the size of a hardware count.

The following equations express the relationships between the different units when using the Geo Drive:

1 line = 4 hardware counts = 128 software counts = 4096 states (LSBs)

¼-line = 1 hardware count = 32 software counts = 1024 states (LSBs)

1/128-line = 1/32-hardware count = 1 software count = 32 states (LSBs)

1/4096-line = 1/1024-hardware count = 1/32-software count = 1 state (LSB)

Note that these are all just naming conventions. Even the position data that is fractional in terms of software counts is real. The servo loop can see it and react to it, and the trajectory generator can command to it.

128 whole software counts and 3 bits of fractional counts (1024) states per line)

One HW count

Four hardware counts per line

The Interpolator can accept a voltage-source (1Vp-p) signal from the encoder. The maximum sine-cycle frequency input is approximately 8 MHz (1,400,000 SIN cycles/sec), which gives a maximum speed of about 5.734 billion steps per second.

When used with a 1000 line sinusoidal rotary encoder, there will be 4,096,000 discrete states per revolution (128,000 software counts). The maximum calculated electrical speed of this encoder would be 1,400 RPS or 84,000 RPM, which exceeds the maximum physical speed of most encoders.

Example 1:

A 4-pole rotary brushless motor has a sinusoidal encoder with 2000 lines. It directly drives a screw with a 5-mm pitch. The encoder is used for both commutation and servo feedback. The user first needs to set MS<node>, MI101=6 and/or MS<node>, MI102=6 for sinusoidal encoder. If needed the direction decode can also be reversed with MS<node>, MI910 equal to 3 (CW) or 7 (CCW)

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The commutation uses the hardware counter. There are 8000 hardware counts per revolution, and two commutation cycles per revolution of the 4-pole motor. Therefore, Ixx70 will be set to 2, and Ixx71 will be set to 8000. Ixx83 will contain the address of the hardware counter’s phase capture register.

For the servo, the interpolated results of the conversion table are used. There are 128 software counts per line, or 256,000 software counts per revolution. With each revolution corresponding to 5 mm on the screw, there are 51,200 software counts per millimeter. The measurement resolution, at 4096 states per line, is 1/8,192,000 of a revolution, or 1/1,638,400 of a millimeter (~0.6 nanometers/state).

Example 2:

A linear brushless motor has a commutation cycle of 60.96 mm (2.4 inches). It has a linear scale with a 20-micron line pitch. The scale is used for both commutation and servo feedback. The user first needs to set MS<node>,MI101=6 and/or MS<node>,MI102=6 for sinusoidal encoder. If needed the direction decode can also be reversed with MS<node>,MI910 equal to 3 (CW) or 7 (CCW)

The commutation uses the hardware counter. There are 200 hardware counts per millimeter (5 microns per count), so 12,192 hardware counts per commutation cycle. Ixx70 should be set to 1, and Ixx71 should be set to 12,192.

The servo uses the interpolated results of the conversion table. With 128 software counts per line, and 50 lines per millimeter, there are 6400 software counts per millimeter (or 162,560 software counts per inch). The measurement resolution, at 4096 states per line, is 204,800 states per mm (~5 nanometers/state).

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Setting up Endat

The Geo Drive can be ordered to accept Heidenhain Corporations proprietary Endat 2.1 absolute feedback.

Requires firmware version 1.009 or higher on the Geo MACRO.

New variables:

1. MI111 and MI112 are the two new I variables that will be used on the Geo MACRO to setup the

Endat power on position and phasing. These variables read the absolute position into MI920 for the respective node. The MI920 returns a 48 bit value. The MI111 and MI112 are set as follows:

Bits 0-4: First Shift Left to move the MSB of the data being read to the 47

Bits 8-12: Second Shift Right to scale the data properly with the ongoing position.

Bit 13: 0 for 1 error bit, 1 for 2 error bits.

Bit 14: Complement the data if the direction sense is reversed. This is set to 1 or 0 based on the direction sense of the ongoing position encoder

Bit 15: Set to 0 for unsigned data. Set to 1 for Signed data.

bit.

Examples:

For a 25-bit Endat with 512 lines on the sinusoidal encoder:

Unsigned setup: MI111=$5417 (23 bits Shift Left, 20 bits Shift Right, complemented, unsigned, 1 error bit).

Signed setup: MI111=$D417 (23 bits Shift Left, 20 bits Shift Right, complemented, signed, 1 error bit).

2. Ix10 and Ix95 will be setup for MACRO absolute position parallel read. E.g. for motor 1 on node

0: I110=$100 and I195=$740000.

3. Ix81 and Ix91 will be setup for MACRO absolute parallel power on phasing. E.g. for motor 1 on

node 0: I181=$100 and I195=$740000.

4. To set the value for Ix75:

Set Ix69=0. Next do a #xO0, then set Ix79=2000 (Safe current value). Do a #x$, set Ix75=Mx71. Now set Mx71=0 and Ix79=original offset value. Set #xk and Ix69 back to the original value.

Setting up Resolvers

The Geo MACRO Drive has up to two channels of resolver inputs. The inputs may be used as feedback or master reference signals for the PMAC servo loops. The basic configuration of the drive contains one 12-bit resolution (x4096) tracking resolver-to-digital (R-to-D) converter, with an optional second resolver when a dual axis driver is ordered. The Geo drive creates the AC excitation signal (ResOut) for up to two resolvers, accepts the modulated sine and cosine signals back from these resolvers, demodulates the signals and derives the position of the resolver from the resulting information, in an absolute sense if necessary.

The Geo MACRO drive so as to read the Resolver feedback needs the device control variable MS<node>, MI101 (for the first channel #1) or MS<node>, MI102 (for the second channel #2) equal to 4 (ClockWise) or equal to 5 (CounterClockWise).

Then the user has to set three (3) MI-variables so as the Resolvers to function correctly.

The ResOut signal, Resolver excitation frequency, from the Geo MACRO Drive is derived from the

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Geo MACRO Drive User and Reference Manual

Phase Clock frequency of the PMAC set by I7m00 and I7m01. The user has the ability to select the excitation frequency to be equal with the Phase Clock frequency (default) by setting MS<node>,MI932 equal to 0. Or use lower frequencies by increasing the value of MI932.

• Excitation frequency could be set equal to a half (1/2) the Phase Clock Frequency if MI932=1

• Excitation frequency could be set equal to a quarter (1/4) the Phase Clock Frequency if MI932=2

• Excitation frequency could be set equal to a sixth (1/6) the Phase Clock Frequency if MI932=3,

this would be and the lowest available excitation frequency.

Also the user needs to set the Excitation output gain for the systems resolvers, by setting MS<node>,MI940. Default MI940 is set to 0, which means a 2.5V gain peak-to-peak. If a gain of 5V peak-to-peak is needed then the user needs to set MI940=1. With MI940=2 the output gain is 7.5V, and the maximum gain would be 10V peak-to-peak when MI940=3. Finally the resolver excitation phase time offset, MS<node>, MI941, needs to be set. The optimum setting f MI941 depends on the L/R time constant of the resolver circuit. So MI941 should be set interactively to maximize the magnitudes of the feedback ADC values. Turbo PMAC setup handles these calculations, the section below shows how someone can set it up manually.

Setting up the Phase Shift (MI941) Manually

Set up the MS<node>, MI101 or MS<node>MI102 equal to 12 ($C) or 13 ($D) depending if it was $4 or $5 respectively (basically add +8 to the value of MI101 or MI102). This decode value puts the ADC values of the Sine and Cosine into the ADC registers of the corresponding IO node register.

For example, if using a resolver for motor #1 on Node 0:

MS0,MI101

MS0,MI101=13

This would enable the ADCs of the first resolver to come back on X:$78421 and X:$78422. (Check Appendix D, ADC Registers Table.)

Now, setup two M-variables to point to these registers: M905->X:$78421,8,16,s and M906->X:$78422,8,16,s were used in the example. The values of these registers will toggle between a + and - value, sign does not matter; only the absolute

value is important. As the motor shaft is rotated, observe these values, if either of them is saturated to +/32767, the resolver gain is too high (MI940). Decrease its value.

Next, position the motor shaft so that one of the ADC values is close to the maximum value that can be monitored. The other register will be close to 0.

MI941 default value is 0, start increasing its (MI941) value by increments of 25. The value of the large ADC should slowly start increasing. If it decreases, start with MI941=255 and slowly start decreasing it in increments of 25. The ADC value should increase up to a maximum point and then start to decrease again. This point to the MI941 value that should be set to get the maximum ADC value possible.

Finally, if the maximum value of the large ADC is less than 16000, increase the gain of the resolver (MI940).

Setting up the Resolver for Power-On Absolute Position

It is possible to get absolute position directly to the Geo drive. Most commonly, this is just the absolute position within one motor revolution or even one commutation cycle to establish the commutation phase reference position without any motion. This section summarizes the variable settings for this technique; refer to the Appendix B or to the Software Reference Manual for details.

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WARNING:

An unreliable phasing reference method can lead to a runaway condition. Test the phasing reference method carefully to make sure it works properly under all conceivable conditions. Make sure the Ixx11 fatal following error limit is active and as tight as possible so the motor will be killed quickly in the event of a serious phasing search error.

Absolute Phase Power-On Position Address and Format: Ixx81, Ixx91, Ixx75

To read an R/D converter for absolute phase position, Ixx81 is set equal to the MACRO node’s position feedback register, and Ixx91 is set to $180000.

Motor phase offset variable Ixx75 contains the difference between the absolute resolver position and the resulting phase angle position (if any).

Absolute Servo Power-On Position Address and Format: Ixx10, Ixx95

Turbo PMAC will obtain the absolute servo power-on position through the MACRO ring. To read an R/D converter for absolute power on position, Ixx10 specifies the address of the register containing the position data from the Geo MACRO drive, which points to the ECT (See Appendix under Ixx95). And Ixx95 is set to $5B0000, Parallel X-register, unsigned value, 19 bits, Motor xx will do parallel data read of the Turbo PMAC memory at the address specified by Ixx10.

Motor offset variable Ixx26 contains the difference between the absolute resolver position and the resulting motor position (if any).

Scaling the Feedback Units

The Geo Drive R/D converter is a 12-bit converter. It reports 4096 separate states per electrical cycle of the resolver (per mechanical revolution for a typical 2-pole resolver, per half revolution for a 4-pole resolver.

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SETTING UP SECONDARY ENCODERS

Geo Drives have also secondary encoder inputs that can be used for dual feedback. The input signals need to be digital quadrature encoders. Single Axis drives have one secondary encoder and dual axis drives have two secondary encoders.

Secondary encoders so as to be enabled require a motor node. So the user needs to “burn” a motor channel/node so he can read the encoder feedback. The motors need to be activated Ixx00 equal to one, and activate the MACRO motor nodes I6841/I6891/I6941/I6991, and set MS<node>, I996 enabled.

Note:

The Secondary Encoders of a Geo MACRO drive can not be assigned to nodes before the

primary nodes of that drive. For example if you have for your primary encoders node 4

(channel#1) and node 5 (channel#2), then the secondary encoders can be in any free motor

node after that 8/9/12/13 ( MACRO IC0) , 16/17/20/21/24/25/28/29 (MACRO IC1),

32/33/36/3/40/41/44/45 (MACRO IC2), 48/49/52/53/56/57/60/61 (MACRO IC3), and

cannot be assigned as node 1 or 2 or any occupied by another motor node.

For the Secondary encoders at the Geo MACRO drives the MI variables are a little different than the primary encoder channels. By setting MI910 equal to 0 (default) the encoder decode is x4 (cts.) or it can be set equal to 1 for an encoder decode x1 (cts.)

The user can only reverse the direction by setting the MS<node>,MI911 equal to 0 for Clockwise(CW) or equal to 1 for CounterClockWise (CCW). Make sure when you change the direction decode that the output sense direction also follows, else runaway can occur.

For capturing the user needs first to select which input to use, Home Flag or Index channel. MS<node>, MI915 . If the user wants to capture on the Index channel (only) then MI915 has to be set equal to $C0. If the user wants to capture on the Home Flag then MI915 needs to be set equal to $6000. For capturing to both inputs, Home Flag and Index Input, MI915 needs to be set equal to $40C0. Depending on the input that the user chose, MI912 or MI913 need to be set respectively. For Capturing at the Index input (C channel) MS<node>,MI912 can be set equal to 0 for capturing at the rising edge, or equal to 1 for capturing at the falling edge (edge trigger not level trigger). Default the value is equal to 0. The trigger would be armed as soon as the position capture register is read.

If the user wants to capture at the Home Flag (HMFL) then MS<node>, MI913 has to be set equal to 0 for capturing on the rising edge, or equal to 1 for capturing on the falling edge (edge trigger not level trigger).

Using the secondary encoder requires enabling an additional motor (not I/O) node, in both the Geo MACRO drive and the Turbo PMAC to transfer the data back to the Turbo PMAC.

If the user wants to use only one primary encoder and one secondary encoder without “burning” extra motor nodes, it is possible to disable the second primary encoder of the drive (check “MS<node>,MI100” variable), and enable the appropriate motor nodes. For example, if the user wants to setup a single axis Geo MACRO (Station=1) with one quadrature primary encoder and one secondary encoder, he would have to enable two motor nodes. (no I/O nodes are being set for this example)

MS0,MI996=$FC003 ; Enable motor nodes 0 and 1

MS0,MI100=1 ; Disable second primary channel

MS0,MI101=0 or 1 ; Set up the primary encoder channel for quadrature feedback

MSSAVE0 ; All changes to take effect

MS$$$0 or power cycle

I100=1 ; Activates axis #1 position

I200=1 ; Activates axis #2 position

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76 Setting Up Secondary Encoders

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SETTING UP THE TURBO PMAC CONVERSION TABLE

The position feedback from the Geo MACRO drive must be processed in the Turbo PMAC’s encoder conversion table (ECT) before it can be used for servo purposes, such as position or velocity loop feedback. The position feedback, whether primary or secondary, appears in the 24-bit Register 0 for the servo node used. This is mapped as a Y-register in the Turbo PMAC, and the servo tasks can only access X-registers for their source data.

So the primary purpose of the Turbo PMAC ECT entries for processing feedback from the Geo MACRO drive is to move the data from the Y-registers in the MACRO ICs to X-registers in RAM, where they can quickly be accessed by servo tasks, without requiring other processing.

This task is accomplished by conversion method “$2”: parallel read of a Y-register, no filtering. Typically, the data from the Geo MACRO drive has already been shifted the standard 5 bits, so the standard shifting in the ECT can be disabled by setting bit 19 of the first setup word (first I-variable of the entry) to 1. This makes the method word $280000 + {Node Register 0 address}.

The second and last line (I-variable) of the entry should be set to $018000. The “018” (hexadecimal) specifies that all 24 bits of the source register be used; the “000” specifies that the bits used start at bit 0.

The following table shows an ECT in which the first eight entries are conversions of the first eight MACRO servo nodes. Note have the combination of the bit 19 “shift disable bit and the “7” in the second digit of the register address (e.g. $078420 for Node 0 Register 0) make the second hex digit of setup word of each entry equal to “F”.

I-Var. Setting Meaning Turbo PMAC Address I8000 $2F8420 MACRO Node 0 Reg. 0 Read $003501 I8001 $018000 24 bits, bit 0 LSB $003502 I8002 $2F8424 MACRO Node 1 Reg. 0 Read $003503 I8003 $018000 24 bits, bit 0 LSB $003504 I8004 $2F8428 MACRO Node 4 Reg. 0 Read $003505 I8005 $018000 24 bits, bit 0 LSB $003506 I8006 $2F842C MACRO Node 5 Reg. 0 Read $003507 I8007 $018000 24 bits, bit 0 LSB $003508 I8008 $2F8430 MACRO Node 8 Reg. 0 Read $003509 I8009 $018000 24 bits, bit 0 LSB $00350A I8010 $2F8434 MACRO Node 9 Reg. 0 Read $00350B I8011 $018000 24 bits, bit 0 LSB $00350C I8012 $2F8438 MACRO Node 12 Reg. 0 Read $00350D I8013 $018000 24 bits, bit 0 LSB $00350E I8014 $2F843C MACRO Node 13 Reg. 0 Read $00350F I8015 $018000 24 bits, bit 0 LSB $003510

The I-variables that use the results of the conversions (e.g. Ixx03 and Ixx04 for position and velocity-loop feedback) will be set to the address of the last line of the entry. For example, if Motor 1 used the processed data for Node 0 Register 0 from the above table for position-loop feedback, I103 would be set to $3502. It is also possible to set these variables by specifying that you want to use the address of the last I-variable in the entry. The command I103=@I8001 performs the same action as I103=$3502.

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78 Setting Up Turbo PMAC Conversion Table

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SETTING UP TURBO MOTOR OPERATION

Turbo PMAC Basic Setup for Brushless Servo or Induction Motor

1) Basic I-variable settings:

• Ixx00 = 1

• Ixx01=3 ;setting for commutation across MACRO

• Ixx02 = node address – base +0 – output address

I102 $078420 MACRO IC 0 Node 0 Reg. 0 I1702 $07A420 MACRO IC 2 Node 0 Reg. 0

I202 $078424 MACRO IC 0 Node 1 Reg. 0 I1802 $07A424 MACRO IC 2 Node 1 Reg. 0

I302 $078428 MACRO IC 0 Node 4 Reg. 0 I1902 $07A428 MACRO IC 2 Node 4 Reg. 0

I402 $07842C MACRO IC 0 Node 5 Reg. 0 I2002 $07A42C MACRO IC 2 Node 5 Reg. 0

I502 $078430 MACRO IC 0 Node 8 Reg. 0 I2102 $07A430 MACRO IC 2 Node 8 Reg. 0

I602 $078434 MACRO IC 0 Node 9 Reg. 0 I2202 $07A434 MACRO IC 2 Node 9 Reg. 0

I702 $078438 MACRO IC 0 Node 12 Reg. 0 I2302 $07A438 MACRO IC 2 Node 12 Reg. 0

I802 $07843C MACRO IC 0 Node 13 Reg. 0 I2402 $07A43C MACRO IC 2 Node 13 Reg. 0

I902 $079420 MACRO IC 1 Node 0 Reg. 0 I2502 $07B420 MACRO IC 3 Node 0 Reg. 0

I1002 $079424 MACRO IC 1 Node 1 Reg. 0 I2602 $07B424 MACRO IC 3 Node 1 Reg. 0

I1102 $079428 MACRO IC 1 Node 4 Reg. 0 I2702 $07B428 MACRO IC 3 Node 4 Reg. 0

I1202 $07942C MACRO IC 1 Node 5 Reg. 0 I2802 $07B42C MACRO IC 3 Node 5 Reg. 0

I1302 $079430 MACRO IC 1 Node 8 Reg. 0 I2902 $07B430 MACRO IC 3 Node 8 Reg. 0

I1402 $079434 MACRO IC 1 Node 9 Reg. 0 I3002 $07B434 MACRO IC 3 Node 9 Reg. 0

I1502 $079438 MACRO IC 1 Node 12 Reg. 0 I3102 $07B438 MACRO IC 3 Node 12 Reg. 0

I1602 $07943C MACRO IC 1 Node 13 Reg. 0 I3202 $07B43C MACRO IC 3 Node 13 Reg. 0

• Ixx03 = ECT address for position encoder - $35xy

• Ixx04 = ECT address for velocity encoder - $35xy

• Ixx24 = flag mode (limit switches)

• Ixx25 = node space for flags - $34xy

I125 $003440 MACRO Flag Register Set 0 I1725 $003460 MACRO Flag Register Set 32

I225 $003441 MACRO Flag Register Set 1 I1825 $003461 MACRO Flag Register Set 33

I325 $003444 MACRO Flag Register Set 4 I1925 $003464 MACRO Flag Register Set 36

I425 $003445 MACRO Flag Register Set 5 I2025 $003465 MACRO Flag Register Set 37

I525 $003448 MACRO Flag Register Set 8 I2125 $003468 MACRO Flag Register Set 40

I625 $003449 MACRO Flag Register Set 9 I2225 $003469 MACRO Flag Register Set 41

I725 $00344C MACRO Flag Register Set 12 I2325 $00346C MACRO Flag Register Set 44

I825 $00344D MACRO Flag Register Set 13 I2425 $00346D MACRO Flag Register Set 45

I925 $003450 MACRO Flag Register Set 16 I2525 $003470 MACRO Flag Register Set 48

I1025 $003451 MACRO Flag Register Set 17 I2625 $003471 MACRO Flag Register Set 49

I1125 $003454 MACRO Flag Register Set 20 I2725 $003474 MACRO Flag Register Set 52

I1225 $003455 MACRO Flag Register Set 21 I2825 $003475 MACRO Flag Register Set 53

I1325 $003458 MACRO Flag Register Set 24 I2925 $003478 MACRO Flag Register Set 56

I1425 $003459 MACRO Flag Register Set 25 I3025 $003479 MACRO Flag Register Set 57

I1525 $00345C MACRO Flag Register Set 28 I3125 $00347C MACRO Flag Register Set 60

I1625 $00345D MACRO Flag Register Set 29 I3225 $00347D MACRO Flag Register Set 61

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• Ixx66 = 16384 ; Geo MACRO PWM scale factor

• Ixx82 = node address = base node address + 2 (ADC B) – commutation current feedback

I182 $078422 MACRO IC 0 Node 0 Reg. 2 I1782 $07A422 MACRO IC 2 Node 0 Reg. 2

I282 $078426 MACRO IC 0 Node 1 Reg. 2 I1882 $07A426 MACRO IC 2 Node 1 Reg. 2

I382 $07842A MACRO IC 0 Node 4 Reg. 2 I1982 $07A42A MACRO IC 2 Node 4 Reg. 2

I482 $07842E MACRO IC 0 Node 5 Reg. 2 I2082 $07A42E MACRO IC 2 Node 5 Reg. 2

I582 $078432 MACRO IC 0 Node 8 Reg. 2 I2182 $07A432 MACRO IC 2 Node 8 Reg. 2

I682 $078436 MACRO IC 0 Node 9 Reg. 2 I2282 $07A436 MACRO IC 2 Node 9 Reg. 2

I782 $07843A MACRO IC 0 Node 12 Reg. 2 I2382 $07A43A MACRO IC 2 Node 12 Reg. 2

I882 $07843E MACRO IC 0 Node 13 Reg. 2 I2482 $07A43E MACRO IC 2 Node 13 Reg. 2

I982 $079422 MACRO IC 1 Node 0 Reg. 2 I2582 $07B422 MACRO IC 3 Node 0 Reg. 2

I1082 $079426 MACRO IC 1 Node 1 Reg. 2 I2682 $07B426 MACRO IC 3 Node 1 Reg. 2

I1182 $07942A MACRO IC 1 Node 4 Reg. 2 I2782 $07B42A MACRO IC 3 Node 4 Reg. 2

I1282 $07942E MACRO IC 1 Node 5 Reg. 2 I2882 $07B42E MACRO IC 3 Node 5 Reg. 2

I1382 $079432 MACRO IC 1 Node 8 Reg. 2 I2982 $07B432 MACRO IC 3 Node 8 Reg. 2

I1482 $079436 MACRO IC 1 Node 9 Reg. 2 I3082 $07B436 MACRO IC 3 Node 9 Reg. 2

I1582 $07943A MACRO IC 1 Node 12 Reg. 2 I3182 $07B43A MACRO IC 3 Node 12 Reg. 2

I1682 $07943E MACRO IC 1 Node 13 Reg. 2 I3282 $07B43E MACRO IC 3 Node 13 Reg. 2

• Ixx83 = node address = base node address +0 – commutation position feedback address

I183 $078420 MACRO IC 0 Node 0 Reg. 0 I1783 $07A420 MACRO IC 2 Node 0 Reg. 0

I283 $078424 MACRO IC 0 Node 1 Reg. 0 I1883 $07A424 MACRO IC 2 Node 1 Reg. 0

I383 $078428 MACRO IC 0 Node 4 Reg. 0 I1983 $07A428 MACRO IC 2 Node 4 Reg. 0

I483 $07842C MACRO IC 0 Node 5 Reg. 0 I2083 $07A42C MACRO IC 2 Node 5 Reg. 0

I583 $078430 MACRO IC 0 Node 8 Reg. 0 I2183 $07A430 MACRO IC 2 Node 8 Reg. 0

I683 $078434 MACRO IC 0 Node 9 Reg. 0 I2283 $07A434 MACRO IC 2 Node 9 Reg. 0

I783 $078438 MACRO IC 0 Node 12 Reg. 0 I2383 $07A438 MACRO IC 2 Node 12 Reg. 0

I883 $07843C MACRO IC 0 Node 13 Reg. 0 I2483 $07A43C MACRO IC 2 Node 13 Reg. 0

I983 $079420 MACRO IC 1 Node 0 Reg. 0 I2583 $07B420 MACRO IC 3 Node 0 Reg. 0

I1083 $079424 MACRO IC 1 Node 1 Reg. 0 I2683 $07B424 MACRO IC 3 Node 1 Reg. 0

I1183 $079428 MACRO IC 1 Node 4 Reg. 0 I2783 $07B428 MACRO IC 3 Node 4 Reg. 0

I1283 $07942C MACRO IC 1 Node 5 Reg. 0 I2883 $07B42C MACRO IC 3 Node 5 Reg. 0

I1383 $079430 MACRO IC 1 Node 8 Reg. 0 I2983 $07B430 MACRO IC 3 Node 8 Reg. 0

I1483 $079434 MACRO IC 1 Node 9 Reg. 0 I3083 $07B434 MACRO IC 3 Node 9 Reg. 0

I1583 $079438 MACRO IC 1 Node 12 Reg. 0 I3183 $07B438 MACRO IC 3 Node 12 Reg. 0

I1683 $07943C MACRO IC 1 Node 13 Reg. 0 I3283 $07B43C MACRO IC 3 Node 13 Reg. 0

• Ixx84 = $fff000 - mask word

Turbo PMAC Basic Setup for DC Brush Motors

Special settings are needed to use the direct-PWM algorithms for DC brush motors. The basic idea is to trick the commutation algorithm into thinking that the commutation angle is always stuck at 0 degrees, so current into the A phase is always quadrature (torque-producing) current. These instructions assume:

• The brush motor’s rotor field comes from permanent magnets or a wound field excited by a separate

means; the field is not controlled by one of the phases of this channel.

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• The two leads of the brush motor’s armature are connected to amplifier phases (half-bridges) that are

driven by the A and C-phase PWM commands from Turbo PMAC. The amplifier may have an unused B-phase half-bridge, but this does not need to be present.

The following settings are the same as for permanent-magnet brushless servo motors with an absolute phase reference:

• Ixx01=3 (commutation over the MACRO ring)

• Ixx02 should contain the address of the PWM A register for the output channel used or the MACRO

Node register 0 (these are the defaults), just as for brushless motors.

• Ixx29 and Ixx79 phase offset parameters should be set to minimize measurement offsets from the A

and B-phase current feedback circuits, respectively.

• Ixx61, Ixx62, and Ixx76 current loop gains are set just as for brushless motors.

• Ixx73 = 0, Ixx74 = 0: These default settings ensure that Turbo PMAC will not try to do a phasing

search move for the motor. A failed search could keep Turbo PMAC from enabling this motor.

• Ixx77 = 0 to command zero direct (field) current.

• Ixx78 = 0 for zero slip in the commutation calculations.

• Ixx82 should contain the address of ADC B register for the feedback channel used (just as for

brushless motors) when the ADC A register is used for the rotor (armature) current feedback. The B register itself should always contain a zero or near-zero value.

• Ixx81 > 0: Any non-zero setting here makes Turbo PMAC do a phasing read instead of a search

move for the motor. This is a dummy read, because whatever is read is forced to zero degrees by the settings of Ixx70 and Ixx71, but Turbo PMAC demands that some sort of phase reference be done. (Ixx81=1 is fine.)

• Ixx84 is set just as for brushless motors, specifying which bits the current ADC feedback uses.

Usually, this is $FFF000 to specify the high 12 bits.

Special settings for brush motor direct PWM control:

• Ixx70 = 0: This causes all values for the commutation cycle to be multiplied by 0 to defeat the

rotation of the commutation vector.

• Ixx72 = 512 (90

the same. If the amplifier would use 683 (120 1365 (240

e) if voltage and current numerical polarities are opposite, 1536 (270oe) if they are

e) for a 3-phase motor, use 1536 here.

e) for a 3-phase motor, use 512 here; if it would use

• Ixx96 = 1: This causes Turbo PMAC to periodically clear the integrator for the (non-existent) direct

current loop, which could slowly charge up due to noise or numerical errors and eventually interfere with the real quadrature current loop.

Settings that do not matter:

• Ixx71 (commutation cycle size) does not matter because Ixx70 setting of 0 defeats the commutation

cycle.

• Ixx75 (Offset in the power-on phase reference) does not matter because commutation cycle has been

defeated. Leaving this at the default of 0 is fine.

• Ixx83 (ongoing commutation position feedback address) doesn’t matter, since the commutation has

been defeated. Leaving this at the default value is fine.

Ixx91 (power-on phase position format) does not matter, because whatever is read for the poweron phase position is reduced to zero.

2) Set up all M-Var definitions. If using PEWIN32Pro and using a node space setup which equates each motor number with the sequential node number (i.e. motor 1 is node 0, motor 2 is node 1, motor

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3 is node 4, motor 4 is node 5, motor 6 is node 8, etc) then you can simply use the Configure M Variables utility in PEWIN32Pro. Tell it to “Download Suggested M Variable Definitions” and click on the “Use Suggested M Variable Definitions” checkbox. This is highly recommended. You may wish to replace M-Var definitions for flag variables with those of the MACRO Flag address definitions.

3) Set MACRO Ivariables:

• I70-I77 ;all motor node bits go high if used – i.e. $33 for nodes 0,1,4,5

• I80 = 5 ;ring check period

• I81=2 ;max ring errors in ring check period

• I82=2 ;minimum sync packets in ring check period

• I6840=$30 ;set MACRO IC 0 as synchronizing ring master

• I6890,I6940,I6990 = $90 ;set MACRO ICs 1,2,3 as ring masters if present

• I6841=$f8000 + $xyza where xyza are the high bits for each node used

• I6891=$1f8000 +$xyza if used

• I6941=$2f8000 +$xyza if used

• I6991=$3f8000 + $xyza if used

4) Issue a “SAVE” command and a “$$$” command from the terminal window in PEWIN32Pro

5) Set up Geo MACRO address, MI996, either by MACSTA command (recommended) or by USB. This will be equal to bF0000 + xyza where xyza are high bits for each node used and b is the MACRO IC Master number. At the same time set the station number (MI11) on each drive.

6) Issue a “mssav15mssav31mssav47mssav63” command from the terminal window in PEWIN32Pro, or a “SAVE” command from Hyperterminal if using USB communications. Now issue a “ms$$$15ms$$$31ms$$$47ms$$$63” to reset

You should be able to now query the drives from PEWINPro. To confirm that simply issue a “MSn,MI996” command from the terminal window where n is an active node on the drive you want to talk to. You should get the value of that MI variable back in the terminal window.

This assumes that you are using the default 2.2kHz servo and 4.5 kHz PWM rate. Note that the max PWM rate for the Geo MACRO drive is 9 KHz. If you are using another PWM rate you will need to set the I68xx variables which deal with that.

Issue a “SAVE” and then a Reset “$$$”. It is recommended to then create a backup file with the PEWIN32PRO.

Now to set up PWM.

1) Check encoder direction – move the motor by hand in the positive direction and make sure that it is counting up. If it is counting in a negative direction then reverse the value of MI910 – change a 7 to a 3 or a 3 to a 7. Now check again and it should have changed direction.

2) Write a PLC like so:

Open plc10 clear

Mx02=P2

Mx04 = P4

Mx07=P7

Set I5=3 and issue a “SAVE” command from the terminal window. Be sure that there are no other PLCs in memory as we want this to execute at a very high rate.

3) Check ADC connection. Set Ixx00 = 0 for the motor in question. Add Mx05, Mx06, Mx54 to the watch window. Set Mx54=1 for that motor. You should now see the enable LED come on for that

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motor on the drive, and Mx54 in the watch window should be 1. If not, be sure that Ix00=0 for that motor and that there are no amp faults on the drive. If there is an amp fault then issue a “MS$$$n” for that drive where n is an active node on that drive. Enable PLC10. Set P2=500 P4=-500 P7=0 from the terminal window. You should now see some rather noisy values in Mx05 and Mx06 of the watch window. If the sign of Mx05 is positive and the sign of Mx06 is negative then the phases match the ADC inputs and Ixx72 will be greater than 1024. For a three phase motor it will be 1365. If not, then Ixx72 will be less than 1024. For a three phase motor it will be 683. Set p2=0p4=0p7=0 and Mx54=0.

4) Now it is time to check the PWM phasing.

• Set Ixx70= ½ the number of poles of your motor for a rotary motor, or 1 for a linear motor.

• Set Ixx71 = 32*counts in one revolution of a rotary motor or 32 * counts in one commutation

cycle for a linear motor.

• Set Ixx80 for your phasing method – it should always be disabled on startup or reset with a

MACRO drive – the MACRO station will always lose communications with the PMAC on reset or startup and you will need to explicitly reset the MACRO drives after each PMAC reset BEFORE attempting to phase. Usually Ixx80=0.

• Set Ixx73 for the amount of effort used in finding phase. Around 3000 is probably ok, but this

needs to be checked against the maximums for your system and the phasing type. If phasing to Halls or an absolute encoder this number can be very small as there will be no actual motion. If there is a large load, friction or other, this number may need to be fairly high. For very small loads this number may be fairly small (~1500).

• Set Ixx74 for the phase finding time – probably around 10. For Halls or absolute encoder this can

be 1. For large load it may need to be higher to allow time to settle.

• Issue a “save” command, then a “$$$”, then “ms$$$15ms$$$31ms$$$47ms$$$63”

• Run the Tuning Pro package and tune the current loop for the motor. You should end up with a

good step move with minimal dithering, at least 200 Hz natural frequency, and around 2 ms settling time. As a rule of thumb your integral should be about one tenth of your forward path proportional.

• Check that your motor is free to move. Probably you will want to point an unused motor at the

encoder space for this motor and set Ix00 = 1 for that motor so that you can monitor movement during this test. Set Ix00=0 for the motor being tested. Set Ixx29=0 and Ixx79=0 (no phase offsets active). Set Mx54 = 1 (check enable LED on drive) and enable PLC 10. Now set P2, P4, and P7 according to the chart below. Record the position of the motor at each step. You may need to lower or raise the magnitude of the command value for your system. Your motor should move through 1/6 of a commutation cycle for each step, and through an entire cycle for the test.

P2 P4 P7

0 2000 -2000 0

2000 0 -2000 60

2000 -2000 0 120

0 -2000 2000 180

-2000 0 2000 -120

-2000 2000 0 -60

0 2000 -2000 0

Electrical

Position

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5. The motor is now at electrical 0, so set Mx71=0 in order to force the phase position to zero. If you moved negative through the positions during this test them Ixx72 should be greater than 1024; otherwise it will be less than 1024. If Ixx72 and the direction of motion do not match then you need to switch either the direction of the encoder or the direction of motion of the motor. You can switch the encoder direction by changing MI910. You can change the motor direction by swapping any two motor leads.

6. Now you should be able to run your motor open loop. Issue “Oxx” commands (open loop commands, xx: stands for any value from 00 up to 100 (maximum output)) from the terminal window, gradually stepping up from “O0” ( O zero) until you either get motion or fault. If you do not get motion then you have an issue with your phasing. Check the values of all of the IVariables listed above. Check them again. Try again.

7. Finally tune the position loop using the Tuning Pro package, and you are ready to start programming.

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Instructions for Direct-PWM Control of Brush Motors

WARNING:

Make sure before applying any PWM commands to the drive and motor in this fashion that the resulting current levels are within the continuous current rating of both drive and motor.

First, enable the amp, then apply a very small positive command value to Phase A and a very small negative command value to Phase B with the on-line commands:

M114=1 ; Enable amplifier M102=I6800/50 M104=-I6800/50 M107=0 ; A pos, B neg, C zero

This provides a command at 2% of full voltage into the motor; this should be well within the continuous current rating of both drive and motor. It is a good idea to make the sum of these commands equal to zero so as not to put a net DC voltage on the motor; putting all three commands on one line causes the changes to happen virtually instantaneously.

With power applied to the drive and the amplifier enabled (M114=1), current readings should be received in the ADC registers as shown by the M-Variables M105 and M106 in the Watch window.

Since the M-Variables are defined as +/-32,768 for full current range, which should correspond approximately to the instantaneous current limit. Make sure that the value read does not exceed the continuous current limit, usually which is about 1/3 of the instantaneous limit. If well below the continuous current limit, increase the voltage command to 5% to 10% of maximum. For example:

M102=I7000/10 M104=-I7000/10 M107=0 ; 10% of maximum

PWM/ADC Phase Match

Command values from Turbo PMAC’s Phase A PWM outputs should cause a roughly proportionate response of one sign or the other on Turbo PMAC’s Phase A ADC input (whatever the phase is named in the motor and drive). The same is true for Phase B.

If no response is received on either phase, re-check the entire setup, including:

• Is the drive properly wired to Turbo PMAC, either directly or through an interface board?

• Is the motor properly connected to the drive?

• Is the drive properly powered, both the power stage, and the input stage?

• Is the interface board properly powered?

• Is the amplifier enabled (M114=1 on Turbo PMAC and indicator ON at the drive)?

• Is the amplifier in fault condition? If so, why?

If only an ADC response is received on one phase, the phase outputs and inputs may not be matched properly. For example, the Phase B ADC may be reading current from the phase commanded by the Phase C PWM output. Confirm this by trying other combinations of commands and checking which ADC responds to which phase command. If there is not a proper match, change the wiring between Turbo PMAC and the drive. Changing the wiring between drive and motor will not help here.

Synchronous Motor Stepper Action

With a synchronous motor, this command should cause the motor to lock into a position, at least weakly, like a stepper motor. This action may be received temporarily on an induction motor, due to temporary eddy currents created in the rotor. However, an induction motor will not keep a holding torque indefinitely at the new location.

Current Loop Polarity Check

Observe the signs of the ADC register values in M105 and M106. These two values should be of approximately the same magnitude, and must be of the opposite sign from each other. (Again, remember

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that these readings may appear noisy. Observe the base value underneath the noise.) If M105 is positive and M106 is negative, the sign of the PWM commands matches the sign of the ADC feedback values. In this case, the Turbo PMAC phase angle parameter I172 must be set to a value greater than 1024 (1365 for a 3-phase motor).

If M105 is negative and M106 is positive, the sign of the PWM commands is opposite that of the ADC feedback values. In this case, I172 must be set to a value less than 1024 (683 for a 3-phase motor).

Make sure your I172 value is set properly before attempting to close the digital current loops on Turbo PMAC. Otherwise positive feedback will occur, creating unstable current loops which could damage the amplifier and/or motor.

If M105 and M106 have the same sign, the polarities of the current sense circuitry for the two phases is not properly matched. In this case, something has been mis-wired in the drive or between Turbo PMAC and the drive to give the two phase-current readings opposite polarity. One of the phases will have to be fixed.

Do not attempt to close the digital current loops on Turbo PMAC until the polarities of the current sense circuitry for the two phases have been properly matched. This will involve a hardware change in the current sense wiring, the ADC circuitry, or the connection between them. As an extra protection against error, make sure that Ixx57 and Ixx58 are set properly for I quickly if there is saturation due to improper feedback polarity.

T protection that will shut down the axis

Troubleshooting

If not getting the current readings that are expected, probe the motor phase currents on the motor cables with a snap-on hall-effect current sensor. If the current is not seen when commanding voltages, check for phase-to-phase continuity and proper resistance when the motor is disconnected.

Testing PWM and Current Feedback Operation

WARNING:

On many motor and drive systems, potentially deadly voltage and current levels are present. Do not attempt to work directly with these high voltage and current levels unless fully trained on all necessary safety procedures. Low-level signals on Turbo PMAC and interface boards can be accessed much more safely.

Usually, in setting up a direct PWM interface there is no need to execute all of the steps listed in these sections (or the Turbo Setup program will do them automatically). However, the first time this type of interface is setup or there are problems, these steps will be of assistance.

For safety reasons, all of these tests should be done with the motor disconnected from any loads. All settings made as a result of these tests are independent of load properties, so will still be valid when the load is connected.

Before testing any of Turbo PMAC’s software features for digital current loop and direct PWM interface, it is important to know whether the hardware interface is working properly. PMAC’s M-Variables are used to access the input and output registers directly. The examples shown here use the suggested MVariable definitions for Motor 1.

Purpose

The purpose of these tests is to confirm the basic operation of the hardware circuits on PMAC, in the drive, and in the motor, and to check the proper interrelationships. Specifically:

• Confirm operation of encoder inputs and decode

• Confirm operation of PWM outputs

• Confirm operation of ADC inputs

• Confirm correlation between PWM outputs and ADC inputs

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Geo MACRO Drive User and Reference Manual

• Determine proper current loop polarity

• Confirm commutation cycle size

• Determine proper commutation polarity

Preparation

First, define the M-Variables for the encoder counter; the three PWM output registers, the amplifierenable output bit, and the two ADC input registers. Using the MACRO suggested definitions for Motor 1, utilizing MACRO IC 0, Node 0:

M101->Y:$078420,0,24,S ; Channel 1 Encoder position register (read only)

M102->Y:$078420,8,16,S ; Channel 1 PWM Phase A command value (write only)

M104->Y:$078421,8,16,S ; Channel 1 PWM Phase B command value (write only)

M107->Y:$078422,8,16,S ; Channel 1 PWM Phase C command value (write only)

M105->Y:$078421,8,16,S ; Channel 1 Phase A ADC input value (read only)

M106->Y:$078422,8,16,S ; Channel 1 Phase B ADC input value (read only)

M114->X:$003440,14 ; Channel 1 Amp Enable command bit

Note:

The ADC values are declared as 16-bit variables even though typically, 12-bit ADCs are used; this puts the scaling of the variable in the same units as Ixx69, Ixx57, Ixx29, and Ixx79.

It is useful to monitor these values in the Watch window of the Executive program. Therefore, add the variable names to the Watch window which causes the program to repeatedly query Turbo PMAC for the values and display them. Then the hardware can be exercised with on-line commands issued through the Terminal window.

To prepare Turbo PMAC for these tests:

1. Set I100 to 0 to deactivate the motor.

2. Set I101 to 0 to disable commutation. (This allows for manual use of these registers.)

3. Make sure that I6800, I6804, I6816, and I6817 are set up properly to provide the PWM signals desired.

4. If the Amplifier Enable bit is 1, set it to zero with the command M114=0.

5. Set Ixx00 and Ixx01 for all other motors to zero.

Position Feedback and Polarity Test

If the PWM command values observed in the Watch window are not zero, set them to zero with the command:

M102=0 M104=0 M107=0

The motor can be turned (or pushed) freely by hand now. As the motor is turned, monitor the M101 value in the Watch window. Look for the following:

• It should change as the motor is moved.

• It should count up in one direction, and count down in the other direction.

• It should provide the expected number of counts in one revolution or linear distance increment.

• As the motor is returned repeatedly to a reference position, it should report (approximately) the same

position value each time.

If these things do not happen, check the encoder/resolver operation, its connection to Turbo PMAC and the Turbo PMAC decode variable I7mn0. Double-check that the sensor is powered. In addition, look at the encoder waveforms with an oscilloscope.

If the direction of motion to be the positive direction is known, check this here. If the direction is incorrect, invert it by changing I7mn0, usually from 7 to 3, or from 3 to 7. If the direction is not known, change it later, but make another change at that time to maintain the proper commutation polarity match;

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Geo MACRO Drive User Manual

usually by exchanging two of the motor phase leads at the drive.

Note:

Because I100 has been set to 0, and I103 may not yet have been set properly, any change of position will not be reflected in the motor position window.

Setting Up Hall Commutation Sensors

Three-phase digital hall-effect position sensors (or their equivalent) are popular for commutation feedback. They can also be used with Turbo PMAC as low-resolution position/velocity sensors. As commutation position sensors, typically, they are just used by Turbo PMAC for approximate power-up phase position; ongoing phase position is derived from the same high-resolution encoder that is used for servo feedback. (Many controllers and amplifiers use these hall sensors as their only commutation position feedback, starting and ongoing, but that is a lower-performance technique.)

Many optical encoders have hall tracks. These commutation tracks provide signal outputs equivalent to those of magnetic hall commutation sensors, but use optical means to create the signals.

Note:

These digital hall-effect position sensors should not be confused with analog halleffect current sensors used in many amplifiers to provide current feedback data for the current loop.

Signal Format

Digital hall sensors provide three digital signals that are a function of the position of the motor, each nominally with 50% duty cycle, and nominally one-third cycle apart. (This format is often called 120 spacing. Turbo PMAC has no automatic hardware or software features to work with 60

spacing.) This format provides six distinct states per cycle of the signal. Typically, one cycle of the signal set corresponds to one electrical cycle, or pole pair, of the motor. These sensors, then, can provide absolute (if low resolution) information about where the motor is in its commutation cycle, and eliminate the need to do a power-on phasing search operation.

Note:

In the case of magnetic hall sensors, the feedback signals often come back to the controller in the same cable as the motor power leads. In this case, the possibility

88 Setting Up Turbo Motor Operation

Delta Tau GEO MACRO DRIVE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Peak Torque

Continuous Torque

Wire Sizes

Fuse and Circuit Breaker Selection

Use of GFI Breakers

Transformer and Filter Sizing

Noise Problems

Operating Temperature

Single Phase Operation

J1: AC Input Connector Pinout

Earth Grounding Paths

J4: 24VDC Input Logic Supply Connector

Kinetic Energy

Energy Lost in Transformation

Capacitive Stored Energy in the Drive

Evaluating the Need for a Regen Resistor

Regen Resistor Power Capacity

Hardware Setup

Hardware Setup

Hardware Setup

Hardware Setup

Hardware Setup

Hardware Setup

Hardware Setup

Hardware Setup

MACRO ASCII Communication global commands

Absolute Phase Power-On Position Address and Format: Ixx81, Ixx91, Ixx75

Absolute Servo Power-On Position Address and Format: Ixx10, Ixx95