Delta Tau Power Brick AC User Manual

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Page 1

Single Source Machine Control

……………………………………………..…...……………….

Power // Flexibility // Ease of Use

21314 Lassen St. Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com

^3 Programmable Servo Amplifier

^4 PBAx-xxx-xxx-xxxxxxx

^5 July 19, 2017

^1 USER MANUAL

^2 Power Brick AC

DELTA TAU

Data Systems, Inc.

NEW IDEAS IN MOTION …

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Power Brick AC User Manual

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: +1 (818) 717-5656 Fax: +1 (818) 998-7807 Email: support@deltatau.com Web: www.deltatau.com

Operating Conditions

All Delta Tau Data Systems, Inc. motion controller, accessory, and amplifier products 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 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.

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Power Brick AC User Manual

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:

IEC364resp.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.

A Warning identifies hazards that could result in personal injury or death. It precedes the discussion of interest.

Warning

Caution

A Caution identifies hazards that could result in equipment damage. It precedes the discussion of interest.

Note

A Note identifies information critical to the understanding or use of the equipment. It follows the discussion of interest.

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Power Brick AC User Manual

MANUAL REVISION HISTORY

REV

DESCRIPTION

DATE

CHANGE

APPROVED

Preliminary

05/28/2014

Released

07/20/2015

Updated I/O & Flags electrical specifications Updated power–up procedure Updated absolute power-on position and ongoing phase position Added A16 connector description Corrected serial clock/data pinouts Added factory reset, firmware reload procedures Added IP address change procedure Added AC induction motor setup Corrected Logic Power Connector Part Number Added Resolver Configuration Added Digital Tracking Filter Setup Added Serial Port RS-232 Description Modified STO Silkscreen Warning General Updates and Formatting

05/19/2016

DCDP

Corrected I2T Settings General Corrections & Formatting Added General Purpose I/Os Schematic Snippets

12/13/2016

Added Shunt Info Updated DC Brush Section & Current Loop Corrected External 5V Mating Connector PN Added Analog I/Os Schematic Snippets Added Limits & Flags Schematic Snippets Changed PwmSf to 95% of 16384 Removed /24 in AbsPhasePosSf 20-bit example Corrected GAR rating in electrical spec tables Updated X9-X12 DAC output example Added a note about scaling to user engineering units General Formatting

07/19/2017

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Power Brick AC User Manual

Table of Contents vi

Table of Contents

INTRODUCTION ................................................................................................................... 11

Documentation ..........................................................................................................................11

Downloadable Power PMAC Script ...........................................................................................12

RECEIVING AND UNPACKING ......................................................................................... 13

Use of Equipment .....................................................................................................................13

SPECIFICATIONS ................................................................................................................. 14

Part Number Designation ..........................................................................................................14

Power Brick AC Configuration ...................................................................................................16

Standard Configuration .................................................................................................................... 16

Options ............................................................................................................................................ 17

Configuration Notes ......................................................................................................................... 18

Environmental Specifications ....................................................................................................19

Protection Specifications ...........................................................................................................20

Electrical Specifications ............................................................................................................21

4-Axis Power Brick AC ..................................................................................................................... 21

6-Axis Power Brick AC ..................................................................................................................... 22

8-Axis Power Brick AC ..................................................................................................................... 23

Mounting ................................................................................................ ................................ ...24

Physical Specifications ..............................................................................................................25

4–axis Power Brick AC ..................................................................................................................... 25

6– / 8–axis Power Brick AC .............................................................................................................. 26

CONNECTIONS AND SOFTWARE SETUP ................................ ....................................... 27

A1 – A8: Motor / Brake Wiring ................................ ................................ ................................ ...27

Configuring the Brake Output ........................................................................................................... 29

Motor Cable, Noise Elimination ....................................................................................................... 30

Motor Selection ................................................................................................................................ 31

A10: Logic Power Input .............................................................................................................33

A11: Safe Torque Off STO, Dynamic Braking ...........................................................................34

Disabling the STO ............................................................................................................................ 35

Wiring and Using the STO ................................................................................................................ 35

Wiring and Using the Dynamic Braking............................................................................................ 36

A12: Brake Power (Axes 1 – 4) .................................................................................................37

A14: External Shunt Resistor ....................................................................................................38

A15: Main Bus Power Input .......................................................................................................39

Advised Power On/Off Sequence ....................................................................................................... 40

Recommended Main Bus Power Wiring / Protection ......................................................................... 41

A16: Brake Power (Axes 5 – 8) .................................................................................................45

X1 - X8: Encoder Feedback, Digital Quadrature ........................................................................46

Configuring Quadrature Encoders.................................................................................................... 48

Quadrature Counts per User Units ................................................................................................... 48

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Power Brick AC User Manual

Table of Contents vii

X1 - X8: Encoder Feedback, Sinusoidal ....................................................................................50

Configuring Sinusoidal Encoders ..................................................................................................... 51

Sinusoidal Counts per User Units ..................................................................................................... 52

X1 – X8: Encoder Feedback, Resolver......................................................................................54

Setting up Resolvers ......................................................................................................................... 55

Configuring Resolver ECT ................................................................................................................ 56

Resolver Counts per User Units ................................ ........................................................................ 56

Resolver Absolute Power-On Position .............................................................................................. 57

X1 – X8: Encoder Feedback, Serial ..........................................................................................59

Serial Encoder Control ................................................................................................ ..................... 61

Serial Encoder Command ................................................................................................................. 62

SSI Configuration Example............................................................................................................... 63

EnDat 2.1/2.2 Configuration Example .............................................................................................. 64

Hiperface Configuration Example ................................................................................................ .... 66

Yaskawa Sigma I Configuration Example ......................................................................................... 68

Yaskawa Sigma II/III/V Configuration Example ................................................................................ 70

Tamagawa FA-Coder Configuration Example .................................................................................. 72

Panasonic Configuration Example.................................................................................................... 73

Mitutoyo Configuration Example ...................................................................................................... 75

Kawasaki Configuration Example..................................................................................................... 77

Serial Encoder Ongoing Position Setup ....................................................................................78

Serial Encoder Power-On Absolute Position Setup ...................................................................83

X9 – X12: Analog Inputs / Outputs ............................................................................................89

Setting up the Analog (ADC) Inputs .................................................................................................. 90

Setting up the Analog (DAC) Outputs ............................................................................................... 94

Setting up the General Purpose Relays ............................................................................................. 98

Setting up the GP Input .................................................................................................................. 100

X13: Axis 1 – 4 Limits, Flags, EQU ......................................................................................... 101

X14: Axis 5 – 8 Limits, Flags, EQU ......................................................................................... 102

Wiring the Limits and Flags ........................................................................................................... 103

Limits and Flags Suggested Pointers .............................................................................................. 104

X15: Digital Inputs / Outputs.................................................................................................... 106

X16: Digital Inputs / Outputs (Additional) ................................................................................. 107

About the Digital Inputs and Outputs .............................................................................................. 108

Wiring the Digital Inputs and Outputs ............................................................................................ 109

X15 Digital I/O Pointers ................................................................................................................. 110

X16 Digital I/O Pointers ................................................................................................................. 110

X17: MACRO .......................................................................................................................... 111

X18: Global Abort and Watchdog ............................................................................................ 112

Abort Input ..................................................................................................................................... 112

Watchdog Relay ............................................................................................................................. 114

X19: External Encoder Supply ................................................................................................ 115

Wiring the Encoder Supply ............................................................................................................. 115

Functionality, Safety Considerations .............................................................................................. 116

X20 – X23: RTETH & Fieldbus ................................................................................................ 117

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Power Brick AC User Manual

Table of Contents viii

ETH 0/1: Ethernet Connections ............................................................................................... 117

ETH 0 Ethernet Port ....................................................................................................................... 117

ETH 1 Ethernet Port ....................................................................................................................... 117

ETH 2/3: EtherСAT Connections............................................................................................. 118

RS-232 Connection ................................................................................................................. 119

MANUAL MOTOR SETUP ................................................................ ................................. 120

Global Reset ........................................................................................................................... 121

Dominant Clock Frequencies .................................................................................................. 122

Recommended Clock Frequencies ................................................................................................... 123

Data Unpacking ...................................................................................................................... 124

Setting up the BrickAC Structure Elements ............................................................................. 125

Power-On Reset PLC.............................................................................................................. 126

Verifying Encoder Feedback ................................................................................................... 128

Configuring the Abort Input ..................................................................................................... 129

Brushless Motors .................................................................................................................... 130

Common Brushless Motor Setup Elements (e.g. Motor #1) .............................................................. 131

PWM Output Scale Factor ................................................................ .............................................. 131

Ongoing Phase Position ................................................................................................................. 132

I2T Protection ................................................................................................................................ 135

Current Loop tuning ....................................................................................................................... 137

Motor Phasing................................................................................................................................ 139

Open Loop Test .............................................................................................................................. 145

Position Loop Tuning ..................................................................................................................... 147

Absolute Power-On Phasing ........................................................................................................... 150

DC Brush Motors .................................................................................................................... 160

Common DC Brush Motor Setup Elements (e.g. Motor #1) ............................................................. 161

PWM Output Scale Factor ................................................................ .............................................. 161

I2T Protection ................................................................................................................................ 161

Current Loop Tuning ...................................................................................................................... 163

Open Loop Test .............................................................................................................................. 165

Position Loop Tuning ..................................................................................................................... 166

AC Induction Motors................................................................................................................ 167

Common AC Induction Motor Setup Elements ................................................................................ 168

PWM Output Scale Factor ................................................................ .............................................. 168

Ongoing Phase Position ................................................................................................................. 168

Magnetization Current and Slip Gain ............................................................................................. 169

I2T Protection ................................................................................................................................ 171

ADC Offsets ................................................................................................................................... 172

Current Loop Tuning ...................................................................................................................... 172

Motor Phasing................................................................................................................................ 172

Open Loop Test .............................................................................................................................. 172

Optimizing Magnetization Current.................................................................................................. 173

Position Loop Tuning ..................................................................................................................... 173

SPECIAL FUNCTIONS & TROUBLESHOOTING .......................................................... 174

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Power Brick AC User Manual

Table of Contents ix

D1: Error Codes ................................................................................................ ...................... 174

Step and Direction, PFM Output ............................................................................................. 175

Sinusoidal Encoder Bias Corrections ...................................................................................... 178

Reversing Motor Jogging Direction ......................................................................................... 184

PLC Timer Delay ..................................................................................................................... 185

Encoder Count Error ............................................................................................................... 186

Encoder Loss Detection ................................................................ .......................................... 187

Digital Quadrature ......................................................................................................................... 188

Sinusoidal | Resolver | HiperFace Encoders ................................................................................... 189

Serial Encoders .............................................................................................................................. 190

Digital Tracking Filter ................................ ................................................................ .............. 191

PTC Motor Thermal Input ........................................................................................................ 193

LED Status .............................................................................................................................. 194

Reloading Power PMAC Firmware .......................................................................................... 195

Changing Network (IP Address) Settings ................................................................................ 198

Restoring Factory Default Configuration.................................................................................. 200

Watchdog Faults ................................................................ ................................ ..................... 201

BRICKAC STRUCTURE ELEMENTS .............................................................................. 202

Global Saved Setup Elements ................................................................................................ 203

BrickAC.MonitorPeriod.................................................................................................................. 203

BrickAC.SinglePhaseIn .................................................................................................................. 204

BrickAC.UnderVoltageDisplay ....................................................................................................... 205

BrickAC.UnderVoltageWarnOnly ................................................................................................... 206

Global Non-Saved Setup Elements ......................................................................................... 207

BrickAC.Config .............................................................................................................................. 207

BrickAC.Monitor ............................................................................................................................ 209

BrickAC.Reset ................................................................................................................................ 211

Global Status Elements ........................................................................................................... 212

BrickAC.BusOverVoltage ............................................................................................................... 212

BrickAC.BusUnderVoltage ............................................................................................................. 213

BrickAC.BusVoltage ....................................................................................................................... 213

BrickAC.LineOk ............................................................................................................................. 213

BrickAC.PhaseInMissing ................................................................................................................ 214

BrickAC.PowerBoardId .................................................................................................................. 214

BrickAC.PowerFault ...................................................................................................................... 214

BrickAC.RegenFault ....................................................................................................................... 215

BrickAC.RegenOverLoad ............................................................................................................... 215

BrickAC.SoftStartFault ................................................................................................................... 216

BrickAC.STO0 ................................................................................................................................ 216

BrickAC.STO1 ................................................................................................................................ 217

BrickAC.UnderVoltageMasked ....................................................................................................... 218

BrickACVers .................................................................................................................................. 218

Channel Saved Setup Elements ............................................................................................. 219

BrickAC.Chan[j].I2tWarnOnly ................................ ....................................................................... 219

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Power Brick AC User Manual

Table of Contents x

Channel Status Elements ........................................................................................................ 220

BrickAC.Chan[j].I2tExcess............................................................................................................. 220

BrickAC.Chan[j].IgbtOverTempFault ............................................................................................. 221

BrickAC.Chan[j].IgbtTemp............................................................................................................. 221

BrickAC.Chan[j].InvalidPwmFreq ................................................................................................. 222

BrickAC.Chan[j].OverCurrent ....................................................................................................... 223

BrickAC.Chan[j].OverTemp ........................................................................................................... 223

BrickAC.Chan[j].PwmFreq ............................................................................................................ 224

APPENDIX A: DIGITAL INPUTS SCHEMATIC ................................ ............................. 225

APPENDIX B: DIGITAL OUTPUTS SCHEMATIC ......................................................... 226

APPENDIX C: ANALOG I/OS SCHEMATICS ................................................................. 227

APPENDIX D: LIMITS & FLAGS SCHEMATIC ............................................................. 229

Page 11

Power Brick AC User Manual

Introduction 11

INTRODUCTION

The Power Brick AC is a smart servo drive package. It combines the intelligence and capability of the Power PMAC motion controller with high performance IGBT-based drives resulting into a 4-, 6-, or 8-axis compact smart drive.

The Power Brick AC is designed for up to 240 VAC main input power. It supports virtually any type of feedback device and can drive directly the following types of motors:

➢ 3-phase AC/DC brushless servo (synchronous) – rotary/linear ➢ AC Induction (asynchronous) – with or without encoder ➢ 2-phase DC brush

Note

The Power Brick AC can also provide pulse and direction PFM output signals to third-party stepper drives.

The number of axes in a Power Brick AC application can be expanded through MACRO or EtherCat.

The Power Brick AC carries onboard up to 32 digital inputs and 16 digital outputs (I/Os) which can also be expanded through MACRO, ModBus, or EtherCat.

The trajectory planner, built-in software PLCs (programmable in Power PMAC script and / or C language), and safety features make the Power Brick AC a fully scalable machine automation controller-drive which can be integrated in virtually any kind of motion control application.

Documentation

In conjunction with this manual, the following manuals are essential for the proper operation and use of the Power Brick AC:

➢ Power PMAC Software Reference Manual ➢ Power PMAC User Manual

These manuals are available for download, to registered members, at Delta Tau Forums.

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Power Brick AC User Manual

Introduction 12

Downloadable Power PMAC Script

Caution

Some code snippets may require the user to input specific information pertaining to their system application. Occasionally, they are denoted in a commentary ending with – User Input.

This manual contains downloadable code snippets in Power PMAC script. These examples can be copied and pasted into the editor area of the IDE software. Care must be taken when using pre-configured Power PMAC code, some information may need to be updated to match hardware or system specific configurations. Downloadable code found in this manual is enclosed in the following format:

// POWER PMAC SCRIPT CODE EXAMPLE

GLOBAL MyCounter = 0; // Arbitrary global variable, counter GLOBAL MyCycles = 10; // Arbitrary global variable, number of cycles --User Input

OPEN PLC ExamplePLC // Open PLC buffer

WHILE (MyCounter < MyCycles) // While counter is less than number of cycles

{ // Start while loop MyCounter ++ // Increment MyCounter by 1 } // End while loop MyCounter = 0 // Reset Mycounter

DISABLE PLC ExamplePLC // Disable PLC

CLOSE // Close PLC buffer

Caution

It is the user’s responsibility to manage the application’s PLCs

properly. The code samples are typically enclosed in a PLC buffer with the user defined name ExamplePLC.

It is the user’s responsibility to use the PLC examples presented in this manual properly, and incorporate the statement code in the application project accordingly.

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Power Brick AC User Manual

Receiving and Unpacking 13

RECEIVING AND UNPACKING

Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the Power Brick AC is received, there are several things to be done immediately:

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

carrier that delivered the package.

• Remove the equipment from the shipping container and remove all packing materials. Check all

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

• Verify that the part number of the product received is the same as the part number listed on the purchase

order.

• Inspect the equipment for external physical damage that may have been sustained during shipment and

report any damage immediately to the commercial carrier.

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

proper procedures when handling the equipment.

• If the equipment is to be stored for several weeks before use, be sure that it is stored in a location that

conforms to published storage humidity and temperature specifications.

Use of Equipment

The following restrictions will ensure the proper use of the Power Brick AC:

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

of such equipment.

• The Power Brick AC must not be operated on power supply networks without a ground or with an

asymmetrical ground.

• If the Power Brick AC is used in residential areas, or in business or commercial premises, implement

additional filtering measures.

• The Power Brick AC may be operated only in a closed switchgear cabinet, taking into account the

ambient conditions defined in the environmental specifications.

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Power Brick AC User Manual

Specifications 14

SPECIFICATIONS

Part Number Designation

B C DA

P B A

- - -

E F G H I K L

0 0 0

Option

Option B

Option C

Option D Option E

4axis

800 MHz CPU

1 GB RAM

1 GB Flash

0 1 Gbs EtherNet

6axis

H 1.0 GHz CPU

2 GB RAM

4 GB Flash

1 extra Eth / EtherCAT

8axis

8 GB Flash

2 extra Eth / EtherCAT

3 extra Eth / EtherCAT Option F

Option G

Option H

No EtherCAT

No Gateway

5/10A

EtherCAT I/O Only

Profibus – DP Master

8/16A

4 EtherCAT Servo and I/O

Profibus – DP Slave

3 8 EtherCAT Servo and I/O

DeviceNet Master

4 16 EtherCAT Servo and I/O

DeviceNet Slave

32 EtherCAT Servo and I/O

CANopen Master

64 EtherCAT Servo and I/O

CANopen Slave

CC-Link Slave

EtherCAT Slave

Ethernet IP Scanner / Master

Ethernet IP Adapter / Slave

Open ModBus/TCP

ProfiNet IO RT Controller

ProfiNet IO RT Device

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Power Brick AC User Manual

Specifications 15

B C DA

P B A

- - -

E F G H I K L

0 0 0

Option I

Axis

5-6

Axis

7-8

Encoder

Inputs

Digital

I/Os

MACRO Nodes

Servo / IOs

True DAC

Analog Out

Filtered PWM

Analog Out

Analog

Inputs

Relays

- - 4

16/8 - - - -

- 1 - - 4

16/8

16/12

- 4 4

4 2 - - 8

32/16 - - - -

- 3 - - 8

32/16

32/24

- 8 8

8 4 - - 8

32/16

32/24

4 4 8

15/30A - 8

32/16 - - - -

- G 15/30A - 8

32/16

32/24

- 8 8

15/30A - 8

32/16

32/24

4 4 8

8 5 5/10A

32/16 - - - -

- 6 5/10A

32/16

32/24

- 8 8

8 8 8/16A

32/16 - - - -

- 9 8/16A

32/16

32/24

- 8 8

Option K

Option L (ACC-84B)

1 – 4

5 – 8

1 – 4

5 – 8

- 1 Sinusoidal

SSI

- 2 Resolver

EnDat

- 3 ACI

Hiperface

- 5 Sinusoidal

Sinusoidal

Yaskawa

- 6 Sinusoidal

Resolver

Tamagawa

- 7 Resolver

Sinusoidal

Panasonic

- A Resolver

Resolver

Mitutoyo

- B Resolver

ACI

BiSS B/C

ACI

Matsushita

- F ACI

Resolver

Mitsubishi

SSI

EnDat

Hiperface

Yaskawa

Tamagawa

Panasonic

Mitutoyo

BiSS B/C

Matsushita

Mitsubishi

Page 16

Power Brick AC User Manual

Specifications 16

Power Brick AC Configuration

The Power Brick AC comes standard with a powerful set of hardware and software capabilities, plus a full set of options.

Standard Configuration

CPU

800 MHz Single-Core Power PC 460EX.

Memory

2 GB DDRAM3 active, 1 GB NAND Flash non-volatile.

Communication

Ports

2 x Gbs Ethernet port for host communication. RS-232 Serial Port. USB 2.0 Host port. USB 2.0 Device port.

Digital I/O

16 x Inputs, fully protected at 12 – 24 V sourcing or sinking (user wiring). 8 x Outputs, fully protected at 12 – 24 V sourcing or sinking (user wiring).

Servo

Interface

4 channels servo interface, each including: Quadrature encoder (differential, with index) interface. UVW digital hall sensor interface. Serial encoder interface, with software selectable protocol, from the following:

o SSI o EnDat 2.1 / 2.2 (2.1-compatible features only) with delay compensation o Hiperface o Yaskawa Sigma I o Yaskawa Sigma II / III / V (no position reset or fault clear) o Tamagawa FA-Coder (no servo clock output) o Panasonic (no servo clock output) o Mitutoyo o Kawasaki

Pulse & direction output. Position compare (EQU) output (5 V TTL). Input flags (home, + limit, – limit, user) at 5 – 24 V. Motor thermal input (PTC).

Amplifier

Output

4 amplifier axes, each at 5/10A with 24V brake output.

Amplifier Safety

& Features

Internal shunt / bleeding resistor built-in. External shunt connection. Shunt resistor fault detection. Hardware I2T thermal fault detection. Short circuit detection. IGBT over-temperature detection. PWM frequency out-of-range detection. No bus voltage detection. Soft start fault detection.

Watchdog output (normally closed / open). Abort Input (category 2 stop). STO Input (category 0 stop).

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Power Brick AC User Manual

Specifications 17

Options

CPU

1 GHz Single-Core Power PC 460EX.

Memory

2 GB DDRAM3 active, 4 or 8 GB NAND Flash non-volatile.

Communication

Ports

1 or 2 x additional Gbs Ethernet ports, EtherCAT compatible.

Digital I/O

Additional 16 x Inputs, fully protected at 12 – 24 V sourcing or sinking (user wiring). Additional 8 x Outputs, fully protected at 12 – 24 V sourcing or sinking (user wiring).

Analog I/O

4 or 8 x 16-bit analog inputs. 4 or 8 x 14-bit filtered PWM analog outputs (±10 V). 4 x 16-bit true DAC analog outputs (±10 V). 4 or 8 x Amp enable outputs (to 3rd party drives). 4 or 8 x Amp fault inputs (from 3rd party drives).

Servo

Interface

4 additional channels servo interface including the same as the standard features. Sinusoidal encoder interface. Resolver encoder interface. ACC-84B serial encoder protocols:

o Matsushita (Nikon D) o Mitsubishi o EnDat 2.2 with additional information, no delay compensation o BiSS-B/C o Yaskawa II/III/V with position reset and fault clear o Tamagawa FA-Coder with servo clock output o SSI (no capabilities over Power Brick AC’s built-in interface) o Panasonic (no capabilities over Power Brick AC’s built-in interface) o Mitutoyo (no capabilities over Power Brick AC’s built-in interface)

Amplifier

Output

4 additional amplifier axes, each at 5/10 A or 8/16 A with 24 V brake output. 2 additional amplifier axes, each at 15/30 A with 24 V brake output.

MACRO Interface

16 Servo, 12 I/O nodes interface. 32 Servo, 24 I/O nodes interface.

EtherCAT

Interface

EtherCAT I/O only. 4 / 8 / 16 / 32 / 64 Servo axes plus I/O.

Fieldbus

o EtherNet / IP Scanner / Master. o EtherNet / IP Adapter / Slave. o Open Modbus / TCP. o PROFINET IO RT Controller. o PROFINET IO RT Device. o CANopen Master. o CANopen Slave.

o PROFIBUS-DP Master. o PROFIBUS-DP Slave. o DeviceNet Master. o DeviceNet Slave. o CC-Link Slave. o EtherCAT Slave. o Modbus.

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Power Brick AC User Manual

Specifications 18

Configuration Notes

o Quadrature encoders can always be wired in and processed regardless of the feedback options fitted. o The following serial encoder protocols are built into (standard) the Power Brick AC – Gate3:

HiperFace SSI Panasonic

Kawasaki EnDat 2.1 / 2.2 Yaskawa II / III / V

Tamagawa Mitutoyo

Additionally, any of the listed optional protocols can be ordered (in sets of 4 channels: 1 – 4 or 5 – 8). These are processed on what is known as the ACC–84B (piggy back inside the Power Brick AC). Some protocols may overlap between the Gate3 and ACC–84B. Users may need new, updated protocols, or additional serial data information which may not be available with the standard Gate3 protocol implementation.

o With the optional ACC-84B installed, a given channel can be configured (in software) to use either one

of the Gate3 serial encoder protocols or one of the ACC-84B protocols.

o If a serial encoder is used on a given channel, it is also possible to wire in on the same connector and

process simultaneously a quadrature/sinusoidal/resolver encoder.

Note that pins #5, 6, 13, and 14 of the encoder feedback connectors (X1 – X8) share multiple functions: only one of these functions (per channel) can be used – configured in software – at one time:

➢ Hall sensors inputs (default configuration). ➢ Pulse and direction PFM output signals (software configuration using Flag D output, OutFlagD). ➢ Serial encoder inputs (software configuration enabling serial encoder line, SerialEncEna). ➢ Quadrature encoder inputs (serial encoder enable line must be 0). ➢ Alternate Sinusoidal encoder inputs (with sinusoidal encoder option).

Note

Each channel is independent of the other channels and can have its own use for these pins.

Page 19

Power Brick AC User Manual

Specifications 19

Environmental Specifications

Specification

Description

Range

Ambient operating Temperature EN50178 Class 3K3 – IEC721-3-3

Minimum operating temperature

0°C (32 °F)

Maximum operating temperature

45°C (113 °F)

Storage Temperature Range EN 50178 Class 1K4 – IEC721-3-1/2

Minimum Storage temperature

-25°C (-13 °F)

Maximum Storage temperature

70°C (158 °F)

Humidity Characteristics with NO condensation and NO formation of ice IEC721-3-3

Minimum Relative Humidity

10% HU

Maximum Relative Humidity up to 35 °C (95 °F)

95% HU

Maximum Relative Humidity from 35 °C up to 50 °C (122 °F)

85% HU

De-rating for Altitude 0 ~ 1000m (0 ~ 3300ft)

No de-rating

1000 ~ 3000 m (3300 ~ 9840 ft)

-0.01% / m

3000 ~ 4000 m (9840 ~ 13000 ft)

-0.02% / m

Environment ISA 71-04

Degree 2 environments

Atmospheric Pressure EN50178 class 2K3

70 kPa to 106 kPa

Shock

Unspecified

Vibration

Unspecified

Air Flow Clearances

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

Cooling

Natural convection and external fan

Standard IP Protection

IP20 IP 55 can be evaluated for custom applications

Note

Above 40°C ambient, de-rate current output by 2.5% per °C.

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Specifications 20

Protection Specifications

Caution

The internal I2T applies to and protects the amplifier power blocks. The software PMAC I2T (described in a later section) must be configured properly to protect against motor / equipment damage.

Description

Specifications

Over Voltage

~ 307 VAC / 435 VDC (±2 %)

Under Voltage

~ 70 VAC / 100 VDC (±5 %)

AC Phase Loss Detection

Loss of one or more phases (single & three-phase operation)

Internal I2T protection

2 seconds at rated peak Amps per axis

Over Temperature

~ 75C

Motor Short Circuit

500 % of rated peak Amps per axis

Over Current

110 % of rated peak Amps per axis

Shunt I2T Detection

Integrated, I2T model at 2 seconds peak

Shunt Short Detection

Shunt IGBT short circuit protection

Shunt Turn On Threshold

380 VDC

Shunt Turn Off Threshold

405 VDC

Soft Start Short Detection

Soft Start short circuit protection

PWM Out Of Range

Out of [4 – 20] kHz, or on-time exceeds 1.4 msec

Safe Torque Off STO

Cut off gate driver/motor power

Note

The under voltage fault triggers when the AC Input dips below 70 VAC (100 VDC). However, if this threshold has not been reached (i.e. Low Voltage/DC operation) the under voltage logic remains unarmed.

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Specifications 21

Electrical Specifications

4-Axis Power Brick AC

PBA4-xxx-xxx-5xxxxxx

PBA4-xxx-xxx-8xxxxxx

Output Continuous Current per Axis

rms

Output Peak Current (2 sec) per Axis

rms

Rated Input Current @ 240 VAC 3-phase (All Axes)

rms

Max ADC (I2T Settings)

15.625

25.0

Output Power per Axis (Modulation depth of 60% RMS)

Watts

1247

1995

Output Power Total

Watts

4489 W

7980

Power Dissipation

Watts

498

798

PWM Frequency Operating Range

KHz

4 – 20

Main AC Input Line Voltage

VAC

rms

110

-20%

– 240

+10%

Main DC Input Line Voltage

VDC

12 – 340

Logic Power Input Voltage

VDC

±5%

Logic Power Input Current

rms

Continuous Shunt Power Rating

Watts

4000

Peak Shunt Power Rating

Watts

8000

Recommended Shunt Resistor

Ohms

GAR 15 (15 Ω)

Recommended Shunt Power Rating

Watts

300

Note

Output power ratings specified at 12 kHz PWM.

Note

All electrical specifications are rated for three-phase 240 VAC main input. De-rating applies in single-phase AC, or DC Operation.

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Specifications 22

6-Axis Power Brick AC

PBA6-xxx-xxx-5xxxxxx

PBA6-xxx-xxx-8xxxxxx

Axes

1-4

5-6

1-4

5-6

Output Continuous Current per Axis

rms

15 8 15

Output Peak Current (2 sec) per Axis

rms

Max ADC (I2T Settings)

rms

15.625

46.875

25.0

46.875

Rated Input Current @ 240 VAC 3-phase (All Axes)

Output Power per Axis (Modulation depth of 60% RMS)

Watts

1247

3741

1995

3741

Output Power Total

Watts

12470

15462

Power Dissipation

Watts

1247

1546

PWM Frequency Operating Range

KHz

4 – 20

Main AC Input Line Voltage

VAC

rms

110

-20%

– 240

+10%

Main DC Input Line Voltage

VDC

12 – 340

Logic Power Input Voltage

VDC

±10%

Logic Power Input Current

Continuous Shunt Power Rating

Watts

7500

Peak Shunt Power Rating

Watts

15000

Recommended Shunt Resistor

Ohms

GAR 10 (10 Ω)

Recommended Shunt Power Rating

Watts

300

Note

Output power ratings specified at 12 kHz PWM.

Note

All electrical specifications are rated for three-phase 240 VAC main input. De-rating applies in single-phase AC, or DC Operation.

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Specifications 23

8-Axis Power Brick AC

PBA8-xxx-xxx-55

PBA8-xxx-xxx-88

PBA8-xxx-xxx-58

PBA8-xxx-xxx-85

Axes

1 – 4

5 – 8

1 – 4

5 – 8

1 – 4

5 – 8

1 – 4

5 – 8

Output Continuous Current per Axis

rms

5 8 8

Output Peak Current (2 sec) per Axis

rms

Max ADC (I2T Settings)

rms

15.625

Rated Input Current @ 240 VAC 3-phase (All Axes)

Output Power per Axis (Modulation depth of 60% RMS)

Watts

1247

1995

1247

1995

1247

Output Power Total

Watts

9976

15960

12968

Power Dissipation

Watts

998

1596

1297

PWM Frequency Operating Range

KHz

4 – 20

Main AC Input Line Voltage

VAC

rms

110

-20%

– 240

+10%

Main DC Input Line Voltage

VDC

12 VDC to 340 VDC

Logic Power Input Voltage

VDC

±10%

Logic Power Input Current

Continuous Shunt Power Rating

Watts

8000

Peak Shunt Power Rating

Watts

8000

Recommended Shunt Resistor

Ohms

GAR 15 (15 Ω)

Recommended Shunt Power Rating

Watts

300

Note

Output power ratings specified at 12 kHz PWM.

Note

All electrical specifications are rated for three-phase 240 VAC main input. De-rating applies in single-phase AC, or DC Operation.

Page 24

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Specifications 24

Mounting

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

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

➢ For effective cooling and maintenance, the Power Brick AC should be mounted on a smooth, non-

flammable vertical surface.

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

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

➢ Temperature, humidity and Vibration specifications should also be taken into consideration.

Caution

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

The Power Brick AC can be mounted with a traditional 3-hole panel mount, two U shape/notches on the bottom and one pear shaped hole on top.

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

The Power Brick AC can be mounted to the back panel using 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).

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Specifications 25

Physical Specifications

4–axis Power Brick AC

4.00"

(101.6 mm)

14.25"

(361.95 mm)

14.75"

(374.65 mm)

7.65"

(194.31 mm)

5.934"

(150.72 mm)

4 x M4

1.88"

(47.752 mm)

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Specifications 26

6– / 8–axis Power Brick AC

7.65"

(194.31 mm)

9.53"

(242.04 mm)

14.75"

(374.65 mm)

6.50"

(165.1 mm)

14.25"

(361.95 mm)

9.50"

(241.20 mm)

4 x M4

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Connections and Software Setup 27

CONNECTIONS AND SOFTWARE SETUP

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.

A1 – A8: Motor / Brake Wiring

A1 - A8: Phoenix Contact 6-pin Female

Mating: Phoenix Contact 6-pin Male

BRK

BRK RET

CHGND

Pin #

Symbol

Function

Description

1 U Output

Phase 1

2 V Output

Phase 2

3 W Output

Phase 3

CHGND

Chassis Ground

BRK RET

Return

Brake 0 V

BRK

Output

Brake 24 V

Phoenix Contact Mating Connector P/N: 1858808 Delta Tau Mating Connector P/N:

Note

The Power Brick endorses the U, V, and W nomenclature for phases 1 through 3 respectively. Some motor manufacturers will call them A, B, and C. Others may call them L1, L2, and L3.

Caution

Brakes which require AC voltage, level other than 24V, or draw current in excess of 1 A (at 24 VDC) must be powered using a dedicated external power supply.

If the motor brake does not draw more than 1 A at 24 VDC (per channel), then the brake power supply provided on the A12 connector can be used to toggle the motor brake directly – left diagram (below).

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Connections and Software Setup 28

If the motor brake is rated to voltage level other than 24 VDC, or draws more than 1 A at 24 V, then the power supply provided through A12 can be used to toggle an external relay which routes the brake power from a dedicated power supply – right diagram (below).

CHG

B 0V

B 24V

Brake

24V

3-Phase

Motor

Shield

360° onto Ground Bar / Chassis

CHG

B 0V

B 24V

Brake

3-Phase

Motor

Shield

360° onto Ground Bar / Chassis

Brake

Power Supply

Relay

Note

The motor’s frame drain wire and the motor cable shield should be

tied together to minimize noise disturbances.

Note

For two-phase DC Brush motors, use U and W, and leave V floating.

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Connections and Software Setup 29

Configuring the Brake Output

The brake output is high true. It is 0V when the motor is killed (or OutFlagB = 0) and 24 V when the motor is enabled (or OutFlagB = 1). The necessary settings required to synchronize the enabling and disabling of the motor with the brake output signal are as follows:

Motor[1].pBrakeOut = PowerBrick[0].Chan[0].OutFlagB.a // Motor[1].BrakeOffDelay = 1 // msec, Brake Off Delay --USER INPUT Motor[1].BrakeOnDelay = 1 // msec, Brake On Delay --USER INPUT Motor[1].BrakeOutBit = 9 // Motor[2].pBrakeOut = PowerBrick[0].Chan[1].OutFlagB.a // Motor[2].BrakeOffDelay = 1 // msec, Brake Off Delay --USER INPUT Motor[2].BrakeOnDelay = 1 // msec, Brake On Delay --USER INPUT Motor[2].BrakeOutBit = 9 // Motor[3].pBrakeOut = PowerBrick[0].Chan[2].OutFlagB.a // Motor[3].BrakeOffDelay = 1 // msec, Brake Off Delay --USER INPUT Motor[3].BrakeOnDelay = 1 // msec, Brake On Delay --USER INPUT Motor[3].BrakeOutBit = 9 // Motor[4].pBrakeOut = PowerBrick[0].Chan[3].OutFlagB.a // Motor[4].BrakeOffDelay = 1 // msec, Brake Off Delay --USER INPUT Motor[4].BrakeOnDelay = 1 // msec, Brake On Delay --USER INPUT Motor[4].BrakeOutBit = 9 // Motor[5].pBrakeOut = PowerBrick[1].Chan[0].OutFlagB.a // Motor[5].BrakeOffDelay = 1 // msec, Brake Off Delay --USER INPUT Motor[5].BrakeOnDelay = 1 // msec, Brake On Delay --USER INPUT Motor[5].BrakeOutBit = 9 // Motor[6].pBrakeOut = PowerBrick[1].Chan[1].OutFlagB.a // Motor[6].BrakeOffDelay = 1 // msec, Brake Off Delay --USER INPUT Motor[6].BrakeOnDelay = 1 // msec, Brake On Delay --USER INPUT Motor[6].BrakeOutBit = 9 // Motor[7].pBrakeOut = PowerBrick[1].Chan[2].OutFlagB.a // Motor[7].BrakeOffDelay = 1 // msec, Brake Off Delay --USER INPUT Motor[7].BrakeOnDelay = 1 // msec, Brake On Delay --USER INPUT Motor[7].BrakeOutBit = 9 // Motor[8].pBrakeOut = PowerBrick[1].Chan[3].OutFlagB.a // Motor[8].BrakeOffDelay = 1 // msec, Brake Off Delay --USER INPUT Motor[8].BrakeOnDelay = 1 // msec, Brake On Delay --USER INPUT Motor[8].BrakeOutBit = 9 //

Note

For toggling the brake output manually, set pBrakeOut = 0 and write to the PowerBrick[].Chan[].OutFlagB bit element.

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Connections and Software Setup 30

Motor Cable, Noise Elimination

The Power Brick ACs’ voltage output has a fundamental frequency and amplitude that corresponds to motor

speed, torque, and number of poles. As a Direct Digital PWM Drive, the Power Brick AC produces higher frequency voltage components corresponding to the rise, fall and repetition rate of the fast switching PWM signals. Subsequently, it could naturally couple current noise to nearby conductors. This electrical coupling can be problematic, especially in noise-sensitive applications such as using high-resolution sinusoidal encoders, or high rate of communication which could suffer from Electro-Magnetic Interference EMI. Proper grounding, shielding, and filtering can alleviate most noise issues. Some applications may require additional measures such as PWM edge filters. The following; are general guidelines for proper motor cabling:

• Use a motor cable with high quality shield. A combination braid-and-foil is best.

• The motor drain wires and cable shield should be tied together, and attached at both ends of

the motor and Power Brick AC chassis / ground bar. At the motor end, make a 360 degree connection between the shield and motor frame. If the motor has a metal shell connector, then you can tie the shield directly to the metal shell of the mating connector. The connection between the cable shield and the motor frame should be as short as possible). At the Power Brick AC end, make a 360 degree connection between the shield and the chassis ground bar (protection earth).

• The motor cable should have a separate conductor (drain wire) tying the motor frame to the

Power Brick AC drive.

• Keep the motor cable as short as possible to maintain lower capacitance (desirable). A

capacitance of up to 50 Pico Farads per foot (0.3048 m), and runs of up to 200 feet (60 m) are acceptable with 240VAC. Exceeding these lengths requires the installation of a Snubber at the motor end or an in-series inductor at the Power Brick AC end.

• If the grounding/shielding techniques are insufficient, you may install chokes in the motor phases

at the Power Brick AC end such as wrapping individual motor leads several times through a

ferrite core ring. DigiKey, Micro-Metals (T400-26D), Fair Rite (2643540002), or equivalent ferrite cores are recommended. This adds high-frequency impedance to the outgoing motor cable thereby making it harder for high-frequency noise to leave the control area.

Note

Ferrite cores are also commonly used with lower inductance motors to enhance compatibility with the Power Brick AC, which is nominally about 2 mH.

• Do not use a motor wire gauge less than 14 AWG for 5/10 A or 8/16 A axes, and 10 AWG for

15/30 A axes unless otherwise specified by the motor manufacturer. Refer to Motor manufacturer and local code recommendations.

• Avoid running sensitive signal cables (i.e. encoders, small signal transducers) in the same cable

bundle as the motor cable(s).

• Install dv/dt filter, Trans-coil V1K series (Optional).

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Connections and Software Setup 31

Motor Selection

The Power Brick AC interfaces with a wide variety of motors. It supports virtually any kind of three-phase AC/DC rotary, linear brushless, or induction motors. Using two out of the three phases, it is also possible to drive permanent magnet DC brush motors.

Motor Inductance

Digital direct PWM control requires a significant amount of motor inductance to drive the on-off voltage

signals resulting smooth current flow with minimal ripple. Typically, servomotors’ phase inductance ranges

from 2 to 15mH. The lower the inductance, the higher is the suitable PWM frequency. Low inductance motors (less than 2 mH) can see large ripple currents causing excessive energy waste and overheating. Additional in-series inductance is recommended in these cases. High inductance motors (greater than 15 mH) are slower to react and generally not considered high performance servo motors.

Motor Resistance

Motor resistance is not typically a determining factor in the drive/system performance but rather comes into play when extracting a desired torque or horsepower out of the motor is a requirement.

Motor Inertia

Motor inertia is an important parameter in motor sizing. Considering the reflected load inertia back to the motor in this process is important. In general, the higher the motor inertia, the more stable the system will inherently be. A high ratio of load to motor inertia shrinks the operating bandwidth (gain limited) of the system, especially in applications using belt or rubber based couplings. The ratio of load to motor inertia is typically around 3:1. Mechanical gearing is often used to reduce reflected inertial load going back to the shaft of the motor.

Motor Speed

In some applications, it is realistically impossible to achieve the motors’ specified maximum velocity. Fundamentally, providing sufficient voltage and proper current-loop tuning should allow attaining motor maximum speeds. Consider feedback devices being a limitation in some cases, as well as the load attached to the motor. In general, the maximum speed can be determined dividing the line-to-line input voltage by the back EMF constant Kb of the motor. Input voltage headroom of about 20% is recommended for good servo control at maximum speed.

Motor Torque

Torque requirements in an application can be viewed as both instantaneous and average Typically, the instantaneous or peak torque is the sum of machining, and frictional forces required to accelerate the inertial load. The energy required to accelerate a load follows the equation T=JA where T is the torque, J is the inertia, and A is the acceleration. The required instantaneous torque is then divided by the motor torque constant (Kt) to determine the necessary peak current of the Power Brick AC. Headroom of about 10% is always desirable to account for miscellaneous losses (aging, wear and tear, calculation roundups). The continuous torque rating of the motor is bound by thermal limitation. If the motor applies more torque than the specified threshold, it will overheat. Typically, the continuous torque ceiling is the RMS current rating of the motor, also known as torque output per ampere of input current.

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Connections and Software Setup 32

Required Bus Voltage for Speed and Torque

For a required motor Speed, and continuous Torque, the minimum DC Bus Voltage (VDC) can be estimated by looking at the equivalent single phase circuit:

BEMF

R L

Motor

The vector sum of back EMF, voltage across resistor and inductor should be less than

6/V

For a Rotary Motor:

 

Mπ2

Lπ2N

VVV

derate

RPM

BEMFR





 





 







 





 





Where:

: Voltage Across equivalent inductor

: Voltage Across equivalent resistor

BEMF

: Back electromotive force voltage

RPM

: Required Motor Speed [rpm]

: Number of pole pairs

: Phase Inductance [H]

: Phase Resistance [Ω]

: Required Continuous Torque [N.M]

: Motor Torque Constant RMS [N.M/A]

derate

: De-rate parameter (typically 0.8)

For a Linear Motor:

 

VVV

derate

pitch

motor

pitch

motor

BEMFR





 





 







 





 





Where:

: Voltage across equivalent inductor

: Voltage across equivalent resistor

BEMF

: Back electromotive Force voltage

motor

: Required Motor Speed [m/s]

derate

: De-rate parameter (typically 0.8)

: Phase Inductance [H]

: Phase Resistance [Ω]

: Required Motor Force RMS [N]

: Motor Force Constant RMS [N/A]

Pitch

: Magnetic Pitch [m]

Example:

An application requires running a motor at 500 RPM with a continuous torque of 30 N.M. The motor specs are as follow:

mH 10Lp

Ohm 2Rp

16Np

Amps / Nm 2.187Kt

Using the equation above, a minimum bus of 233 VDC (~165VAC) is necessary to achieve the speed and torque requirements.

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Connections and Software Setup 33

A10: Logic Power Input

A10 is used to bring in the 24 VDC supply powering up the logic portion of the Power Brick AC. This power can remain on regardless of the main AC bus power, allowing the signal electronics to be active while the main motor power is passive.

Caution

The 24V logic power must always be applied before applying main AC bus power.

The 24-Volt (±5%) power supply unit must be capable of providing 5 amperes per Power Brick AC. If multiple drives are sharing the same 24-Volt power supply, it is highly recommended to wire each drive back to the power supply terminals separately. This connection can be made using a 22 AWG wire directly from a protected power supply.

A10: 3-pin Female

Mating: 3-pin Male

Pin #

Symbol

Function

Description

Notes

+24 VDC

Input

Logic power input

24 VDC (±5 %)

+24 VDC RET

Return

Logic power return

0 VDC 3 CHGND

Chassis ground

Phoenix Contact Mating Connector P/N: 1777293

0 V

24 VDC (±5%)

Power Supply

24 V

Note

Chassis ground (pin #3) and + 24 VDC RET (pin #2) are tied together internally.

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Connections and Software Setup 34

A11: Safe Torque Off STO, Dynamic Braking

Connector A11 serves the following functions:

➢ Disabling the Safe Torque Off STO ➢ Arming / using the STO ➢ Using dynamic braking ➢ Wiring the STO feedback (output status)

Caution

Power Brick units shipped prior to the Q3 2016 had the Dynamic Brake (DYN BRAKE) and STO IN silkscreen etchings reversed.

A11: Phoenix 5-pin Female

Mating: Phoenix 5-pin Male

STO IN

DYN BRAKE

Pin #

Symbol

Function

Description

STO FB

Output

STO Feedback

STO IN

Input

STO 3 DYN BRAKE

Input

Dynamic Braking

DISABLE STO

Tie together to disable STO

Phoenix Contact Mating Connector P/N: 1850699 Delta Tau mating connector P/N: 016-090A03-08P

The Safe Torque Off (STO) allows the complete “hardware” disconnection of the power amplifiers from the motors by shutting down the gate-drivers power. This mechanism prevents unintentional “movement of” or torque output to the motors in accordance with IEC/EN safety standards.

Dynamic braking forces the motors to a quick uncontrolled stop preventing them from coasting freely. This is achieved by tying the motor leads together internally.

The STO FB feedback is an indicator of the STO status. Optionally, it can be brought back into the Power Brick AC as a digital input, or wired into other machine logic device(s).

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Connections and Software Setup 35

Disabling the STO

The STO can be fully disabled by tying pins #4 and #5 together.

All other pins on this connector have no practical use in this mode, and should be left floating.

STO FB

A11

STO IN

DYN BRAKE

Wiring and Using the STO

This scheme is suitable for a Category 0 safe – uncontrolled – stop in accordance with machine safety regulations. That is removing power to the actuators immediately.

In normal mode operation, the STO must be a normally closed relay (24 VDC applied).

In normal mode operation, the STO FB feedback is at 24V.

STO FB

A11

STO IN

DYN BRAKE

0 V

24 VDC

Power Supply

24 VDC

RET

CHGND

A10

24 VDC

When the STO is triggered (24 VDC disconnected):

➢ Power is removed immediately; the motors are killed, coasting freely. ➢ The STO Feedback level drops to 0 V. ➢ The 7-segment displays an E fault. ➢ The PMAC reports and latches an amplifier fault in the motor status.

Note

Power is completely removed while the 24 VDC is disconnected from the STO IN. No motor motion can be executed (amplifier fault). Once the 24 VDC is re-applied, motors are ready for motion and the display fault is cleared.

Note

If the STO is not disabled, both STO IN and DYN BRAKE must see 24 VDC to allow motor motion.

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Connections and Software Setup 36

Wiring and Using the Dynamic Braking

This scheme is used if the application mandates minimal coasting in an uncontrolled stop request.

Some applications may choose to use dynamic braking prior to triggering the STO.

In normal mode operation, the DYN BRAKE must be normally closed (24 VDC applied).

STO FB

A11

STO IN

DYN BRAKE

0 V

24 VDC

Power Supply

24 VDC

RET

CHGND

A10

When the DYN BRAKE is triggered (24 VDC disconnected):

➢ Motors are killed, leads are shorted together (internally) bringing the motors to a quick standstill. ➢ The 7-segment displays a b fault. ➢ The Power PMAC reports an amplifier fault in the motor status.

Note

No motor motion is allowed while this 24 VDC is disconnected. Once re-applied, the 7-segment display fault is cleared, and the motor is ready for motion.

Note

If the STO is not disabled, both STO IN and DYN BRAKE must see 24 VDC to allow motor motion.

Note

Dynamic braking must not be confused with controlled stop, which is performed using the Abort Input (X18).

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Connections and Software Setup 37

A12: Brake Power (Axes 1 – 4)

A12 is used to supply the +24 VDC brake power for axes 1 – 4.

Caution

Brakes which require AC voltage, other than 24 VDC, or draw current in excess of 1 A (at 24 VDC, per channel) must be powered using a dedicated external power supply and not through A12.

A12: Phoenix 2-pin Female

Mating: Phoenix 2-pin Male

Pin #

Symbol

Function

Description

+ 24 VDC

Input

+ 24 VDC RET

Input

Phoenix Contact Mating Connector P/N: 1850660 Delta Tau mating connector P/N:

Page 38

Power Brick AC User Manual

Connections and Software Setup 38

A14: External Shunt Resistor

Caution

All applications using Power Brick AC drives (all configurations) are strongly advised to install an external shunt resistor.

A14: Phoenix 2-pin Female

Mating: Phoenix 2-pin Male

Pin #

Symbol

Function

Description

SHUNT+

Input

SHUNT–

Input

Phoenix Contact Mating Connector P/N: 1777723 Delta Tau mating connector P/N: 016-PL0F02-76P

A14 is used to wire an external shunt resistor to expel the excess power during demanding deceleration profiles. The 4- and 8-axis Power Brick AC drives are designed for operation with external shunt resistors of 15 Ohms.

Caution

The external shunt resistor can reach temperatures of up to 200°C. It must be mounted away from other devices and ideally near the top of the cabinet, also ensure it is enclosed and cannot be touched during operation.

Delta Tau offers these resistors (GAR15) with pre-terminated cables that plug directly into A14. These resistors incorporate a normally closed (N.C.) thermal overload protection thermostat. The thermostat goes into an open state when the core temperature of the resistor exceeds 225°C (450° F). This thermostat is accessible through the two black leads. It is important that these two leads be wired into a safety circuit to halt operation should the resistor temperature exceed the specified threshold.

Note

The white conduits are shunt resistor leads whereas the black wires are thermostat.

SHUNT+ SHUNT–

THERMOSTAT

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Power Brick AC User Manual

Connections and Software Setup 39

A15: Main Bus Power Input

A15 is used to bring the main AC/DC bus power into the Power Brick AC.

A15: Phoenix Contact 4-pin Female

Mating: Phoenix Contact 4-pin Male

GND

Symbol

Function

Three Phase

Single Phase

Input

AC Line Phase 1

Not Connected

Input

AC Line Phase 2

Neutral

0 VDC

Input

AC Line Phase 3

Line

DC +

GND

Ground

Phoenix Contact Mating Connector P/N: 1970359 Delta Tau P/N: 016-197035-94P

Note

In single phase operation, use L2 and L3, and leave L1 floating. In DC mode operation, use L3 for DC+ and L2 for 0 V, and leave L1 floating.

Note

BrickAC.SinglePhaseIn must be set to 1 in single phase or DC operations. For this setting to take effect, BrickAC.Reset or BrickAC.Config must be set to 1 at least once.

Caution

The main AC power should NEVER be supplied to the Power Brick AC if the 24 VDC logic power is NOT applied.

Caution

Make sure that no motor commands (e.g. phasing, jogging) are being executed at the time of applying main AC power.

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Connections and Software Setup 40

Advised Power On/Off Sequence

Caution

Main AC input power should never be cycled rapidly and repeatedly within a few seconds.

Powering up the Power Brick AC must obey the following sequence:

1. Make sure main bus power is disconnected (e.g. E-Stop engaged)

2. Apply 24 VDC logic power (A10).

The STO and Dynamic Brake states are irrelevant at this point.

3. Configure the PMAC to execute the Power On Reset PLC. That is setting BrickAC.Reset = 1

and waiting for it to return a 0 indicating a successful reset operation.

4. Apply main bus power (A15) (e.g. Releasing the E-Stop). Wait at least 1 second for the soft start

circuitry to finish its task.

5. Reset STO / Dynamic Brake (if utilized).

6. Energize motors.

Powering down the Power Brick AC must obey the following sequence:

1. Disconnect main bus power (A15).

Kill / de-energize motors simultaneously (e.g. via an E-Stop PLC). The STO and Dynamic Brake states are irrelevant at this point.

2. Allow approximately 1 second.

3. Disconnect 24 VDC logic power (A10).

Note

Killing all motors (in software logic, background PLC) upon engaging the E-Stop is highly recommended. This could be triggered by a general purpose input which is typically tied to the E-Stop button/circuit.

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Recommended Main Bus Power Wiring / Protection

Caution

Main AC power lines should run in a separate duct at least 12” (or 30 cm) away from – and should never be bundled with – the I/O, communication, or encoder cables.

Grounding, Bonding

System grounding is crucial for proper performance of the Power Brick AC. Panel wiring requires that a central earth-ground (also known as ground bus bar) location be installed at one part of the panel. The ground bus bar is usually a copper plate directly bonded to the back panel. This electrical ground connection allows for each device within the enclosure to have a separate wire brought back to the central earth-ground.

• Implement a star point ground connection scheme; so that each device wired to earth ground

has its own conductor brought directly back to the central earth ground plate (bus bar).

• Use an unpainted back panel. This allows a wide area of contact for all metallic surfaces,

reducing frequency impedances.

• Use a heavy gauge ground earth conductors made up of many strands of fine conducts.

• The Power Brick AC is brought to the earth-ground via one or two wire(s) connected to the M4

mounting stud(s) through a heavy gauge multi-strand conductor to the central earth-ground. It can alternately be tied to the motor grounding bar.

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Three-Phase Main AC Power Wiring Diagram

3-PHASE

TRANSFORMER

Up to 240 VAC

GND L1 L2 L3

PROTECTION EARTH

FUSE

GND

Shielded

And

Twisted

EMC/EMI

FILTER

Phase-Phase

Voltage

Suppressors

Magnetic Contactor

(E-Stop Circuit)

Single-Phase Main AC Power Wiring Diagram

GND

Neutral

Line

PROTECTION EARTH

FUSE

GND

Shielded

And

Twisted

EMC/EMI

FILTER

Phase-Phase

Voltage

Suppressors

Single Phase Source

Up to 240 VAC

Magnetic Contactor

(E-Stop Circuit)

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Connections and Software Setup 43

Transformers

Y-Y or Y- transformers should be used.

- Transformers are NOT advised. They try to balance phases dynamically, creating instances of

instability in the Power Brick AC’s rectifying circuitry.

Note

A line reactor should be installed if a transformer or reliable source of power is not available. Line reactors suppress harmonics bidirectionally, eliminating low frequency spikes.

Fuses

High peak currents and high inrush currents demand the use of slow blow time delayed type fuses. RK1 or RK5 (i.e. current limiting) classes are recommended. FRN-R and LPN-RK from Cooper

Bussmann or similar fuses can be used.

The following table summarizes fuse gauges for three-phase bus input (240 VAC) at full load:

Model

Fuse (amps)

Model

Fuse (amps)

PBA4-xxx-xxx-5

PBA6-xxx-xxx-55

PBA4-xxx-xxx-8

PBA6-xxx-xxx-88

PBA6-xxx-xxx-5

PBA6-xxx-xxx-58

PBA6-xxx-xxx-8

PBA6-xxx-xxx-85

Specific applications fuse sizing can be done using the following equations. Take, as an example, a 4-axis Power Brick AC (5/10 A) on 240 VAC bus, and driving 4 motors (5 A continuous current rating):

DC Bus Voltage:

DCBus

= √2 × V

ACBus

= 1.414 × 240= 339.4

[VDC]

Motor Phase voltage:

MotorPhase

DCBus

√

339

2.45

= 138.5

[VDC]

Power per axis:

Axis

= 3 × V

MotorPhase

× I

MotorPhase

× 0.6= 3×138.6×5×0.6= 1247

[Watts]

Total power:

Total

= ∑P

Axis

= 4 ×1247 = 4988.3 Watts

[Watts]

Dissipated power:

Dis

= 0.1 × P

Total

= 0.1 ×4988 = 498.8 Watts

[Watts]

Current draw per

phase

(for 3 bus input)

3Phase

Total

+ P

Dis

√

3 × V

ACBus

4988 + 499

1.732×240

= 13.2 Amps

[Amps]

Current draw per

phase

(for 1 bus input)

1Phase

Total

+ P

Dis

ACBus

4988 + 499

1.732×240

= 22.8 Amps

[Amps]

Thus, 15 and 25 amp fuses are chosen for three and single phase bus power input lines respectively.

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Connections and Software Setup 44

Magnetic Contactors

SC-E series from Fuji Electric or similar contactor can be used.

Line Filters

Line filters eliminate electromagnetic noise in a bi-directional manner (from and into the system). T type filters are NOT recommended. PI type line filters are highly advised:

➢ Filter should be mounted on the same panel as the drive and power source. ➢ Filter should be mounted as close as possible to the power source. ➢ Filter should be mounted as close as possible to incoming cabinet power.

FN-258 series from Schaffner or similar filter can be used.

Voltage Suppressors

Voltage suppressors eliminate undesirable voltage spikes typically generated by the magnetic contactor or external machinery in the plant. This 3-phase voltage arrester from Phoenix Contact or similar suppressor can be used.

Bus Power Cables

The Power Brick AC electronics create a DC bus by rectifying the incoming AC lines. The current flow into the drive is not sinusoidal but rather a series of narrow, high-peak pulses. Keeping the incoming impedance small is essential for not hindering these current pulses. Whether single- or three-phase, it is important that the AC input wires be twisted together to eliminate noise radiation as much as possible. Recommended wire gauge:

Model

Wire Gauge

(AWG)

Model

Wire Gauge

(AWG)

PBA4-xxx-xxx-5

PBA6-xxx-xxx-55

PBA4-xxx-xxx-8

PBA6-xxx-xxx-88

PBA6-xxx-xxx-5

PBA6-xxx-xxx-58

PBA6-xxx-xxx-8

PBA6-xxx-xxx-85

Note

All ground conductors should be 8AWG minimum using wires constructed of many strands of small gauge wire. This ensures the lowest impedance to high-frequency noises.

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A16: Brake Power (Axes 5 – 8)

A16 is used to supply the +24 VDC brake power for axes 5 – 8.

Caution

Brakes which require AC voltage, other than 24 VDC, or draw current in excess of 1 A (at 24 VDC, per channel) must be powered using a dedicated external power supply and not through A16.

A16: Phoenix 2-pin Female

Mating: Phoenix 2-pin Male

Pin #

Symbol

Function

Description

+ 24 VDC

Input

2 + 24 VDC RET

Input

Phoenix Contact Mating Connector P/N: 1850660 Delta Tau mating connector P/N:

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X1 - X8: Encoder Feedback, Digital Quadrature

The Power Brick AC processes digital quadrature (also known as incremental) encoder signals by default. It provides up to four counts per square cycle, and extends it using hardware-computed (ASIC) 1/T.

X1-X8: D-sub DA-15F

Mating: D-sub DA-15M

Pin#

Symbol

Function

Primary Use

Alternate Use

CHA +

Input

Encoder A +

CHB +

Input

Encoder B +

CHC +

Input

Index C +

Amp. Enable +

ENCPWR

Output

Encoder Power 5 VDC (max 250 mA per channel)

CHU / DIR +

In / Out

Halls U

Direction Out +

Serial Data –

CHW / PUL +

In / Out

Halls W

Pulse Out +

Serial Clock –

2.5V

Output

2.5 VDC Reference power

PTC

Input

Motor Thermal Input

CHA –

Input

Encoder A –

CHB –

Input

Encoder B –

CHC –

Input

Index C –

Amp. Enable –

GND

Common

Common ground

CHV / DIR –

In / Out

Halls V

Direction Out –

Serial Clock +

CHT / PUL –

In / Out

Halls T

Pulse Out –

Serial Data +

Note

Quadrature encoders can be wired in and processed regardless of the encoder feedback option(s) fitted.

Caution

The +5 VDC encoder power is limited to ~250 mA per channel. For encoders requiring more current, the +5 VDC power can be alternately brought in externally through the +5 VDC ENC connector.

Caution

Encoders requiring voltage levels other than +5 VDC (higher or lower) should be powered directly from an external power supply.

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Quadrature encoders provide two digital signals to determine the position of the motor. These signals are typically 5V TTL/CMOS level. Each nominally with 50% duty cycle, and 1/4 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.

Channel A

Channel B

Quadrature encoders can be wired either in a differential or single-ended manner. Differential signals can enhance noise immunity by providing common mode noise rejection. Modern design standards virtually mandate their use in industrial systems.

Differential

Single-Ended

A+

A-

B-

B+

C+

C-

+ 5VDC

GND

Encoder shield (solder to shell)

Hall U

Hall V

Hall W

Hall T

A+

B+

C+

+ 5VDC

GND

Encoder shield (solder to shell)

Hall U

Hall V

Hall W

Hall T

Note

In single-ended mode, leave the negative pins floating. They are terminated internally.

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Configuring Quadrature Encoders

The Power Brick AC firmware is configured to process quadrature incremental encoders by default. This type of encoders is processed as a single 32-bit word in the Encoder Conversion Table (ECT). The 1/T extension is done in the DSPGate3 hardware. Starting from factory default settings, activating the channel is sufficient to display counts in the position window when the motor / encoder shaft is moved by hand.

Default Encoder Conversion Table for quadrature incremental encoders:

EncTable[1].type = 1 EncTable[1].pEnc = PowerBrick[0].Chan[0].ServoCapt.a EncTable[1].pEnc1 = Sys.Pushm EncTable[1].index1 = 0 EncTable[1].index2 = 0 EncTable[1].index3 = 0 EncTable[1].index4 = 0 EncTable[1].index5 = 0 EncTable[1].index6 = 0 EncTable[1].ScaleFactor = 1 / 256

Default settings for quadrature incremental encoders:

Motor[1].ServoCtrl = 1 Motor[1].pEnc = EncTable[1].a Motor[1].pEnc2 = EncTable[1].a

Note

The hardware 1/T extension produces 8 bits of fractional data, thus the (1 / 256) 0.00390625 scale factor.

Ch. #

Source Address

Ch. #

Source Address

PowerBrick[0].Chan[0].ServoCapt.a

5 PowerBrick[1].Chan[0].ServoCapt.a

PowerBrick[0].Chan[1].ServoCapt.a

6 PowerBrick[1].Chan[1].ServoCapt.a

PowerBrick[0].Chan[2].ServoCapt.a

7 PowerBrick[1].Chan[2].ServoCapt.a

PowerBrick[0].Chan[3].ServoCapt.a

8 PowerBrick[1].Chan[3].ServoCapt.a

Quadrature Counts per User Units

With quadrature incremental encoders, the number of counts per user units (usually motor revolutions) is 4 times (depending on the setting of encoder/decode PowerBrick[].Chan[].EncCtrl) the specified number of lines of the encoder. For example, a 2,000–line rotary encoder should result in 8,000 motor units per revolution (before any gearing or coupling).

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Quadrature Encoder Count Error

With quadrature encoders, the Power Brick AC has the capability of trapping encoder count (loss) errors. This is described in detail in the Encoder Count Error section of this manual.

Quadrature Encoder Loss Detection

Warning

Loss of the feedback sensor signal is potentially a very dangerous condition in closed-loop control, because the servo loop no longer has any idea what the true physical position of the motor is – usually it thinks it is “stuck” – and it can react wildly, often causing a runaway condition.

With quadrature encoders, the Power Brick AC has the capability of detecting the loss of an encoder signal. This is described in detail in the Encoder Loss Detection section of this manual.

Note

Note the distinction between the encoder count error, which reports loss of counts due to bad transitions of the quadrature signals, and encoder loss, which indicates that one or more quadrature signals are missing.

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X1 - X8: Encoder Feedback, Sinusoidal

The Power Brick AC can process sinusoidal encoders (up to 1.2 V

peak-peak

), and provide high resolution (x

16384) interpolated position data.

X1-X8: D-sub DA-15F

Mating: D-sub DA-15M

Pin#

Symbol

Function

Primary

Use

Alternate Use

SIN +

Input

Sine +

COS +

Input

Cosine +

CHC +

Input

Index C +

Amp. Enable +

ENCPWR

Output

Encoder Power 5 VDC (max 250 mA per channel)

CHU / DIR +

In / Out

Halls U

Direction Out +

Serial Data –

AltSin +

CHW / PUL +

In / Out

Halls W

Step Out +

Serial Clock –

AltCos + 7 2.5V

Output

2.5 VDC Reference power

PTC

Input

Motor Thermal Input

SIN –

Input

Sine –

COS –

Input

Cosine –

CHC –

Input

Index C –

Amp. Enable –

GND

Common

Common ground

CHV / DIR –

In / Out

Halls V

Direction Out –

Serial Clock +

AltSin –

CHT / PUL –

In / Out

Halls T

Step Out –

Serial Data +

AltCos –

Caution

The +5 VDC encoder power is limited to ~250 mA per channel. For encoders requiring more current, the +5 VDC power can be alternately brought in externally through the +5 V ENC connector.

Caution

Encoders requiring a voltage level other than +5 VDC (higher or lower) should be powered directly from an external power supply.

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The Power Brick AC can accept “sine” and “cosine” signals (90° out of phase with each other), of up to 1.2 V (peak-topeak) magnitude.

Due to their inherit susceptibility to electrical noise, these signals are most commonly differential pairs, wired into the SIN+, SIN-, COS+, and COS- inputs for the channel. Differential signals can enhance immunity by providing common mode noise rejection. Single-ended inputs can also be used, wired into the SIN+ and COS+ inputs for the channel, with the SIN- and COS- inputs connected directly to the 2.5V reference (pin #7).

A good quality shielded cable with twisted-pair shielded conduits is highly recommended for sinusoidal encoder applications.

Sine + Sine -

Cosine -

Cosine +

Index + Index -

5VDC

GND

Encoder shield (solder to shell)

Hall U Hall V Hall W Hall T

Configuring Sinusoidal Encoders

The sinusoidal encoder signals are interpolated in the ASIC (hardware); the resulting data is brought into the encoder conversion table (ECT) as a single 32-bit word without any scaling:

The Arctangent calculation must be enabled for this channel. The encoder type for this motor must be set for a DSPGate3 arctangent extension. Activating the channel, should then be sufficient to display counts in the position window when the motor/encoder shaft is moved by hand.

PowerBrick[0].Chan[0].AtanEna = 1 Motor[1].EncType = 6

Motor[1].ServoCtrl = 1 Motor[1].pEnc = EncTable[1].a Motor[1].pEnc2 = EncTable[1].a

Ch. #

Source Address

Ch. #

Source Address

PowerBrick[0].Chan[0].ServoCapt.a

5 PowerBrick[1].Chan[0].ServoCapt.a

PowerBrick[0].Chan[1].ServoCapt.a

6 PowerBrick[1].Chan[1].ServoCapt.a

PowerBrick[0].Chan[2].ServoCapt.a

7 PowerBrick[1].Chan[2].ServoCapt.a

PowerBrick[0].Chan[3].ServoCapt.a

8 PowerBrick[1].Chan[3].ServoCapt.a

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The sine and cosine signals can be accessed through the following elements. This may be helpful in diagnostics, or plotting the Lissajous.

Ch. #

Signal

Element

Ch. #

Signal

Element

Sine

PowerBrick[0].Chan[0].AdcEnc[0]

Sine

PowerBrick[1].Chan[0].AdcEnc[0]

Cosine

PowerBrick[0].Chan[0].AdcEnc[1]

Cosine

PowerBrick[1].Chan[0].AdcEnc[1]

Sine

PowerBrick[0].Chan[1].AdcEnc[0]

Sine

PowerBrick[1].Chan[1].AdcEnc[0]

Cosine

PowerBrick[0].Chan[1].AdcEnc[1]

Cosine

PowerBrick[1].Chan[1].AdcEnc[1]

Sine

PowerBrick[0].Chan[2].AdcEnc[0]

Sine

PowerBrick[1].Chan[2].AdcEnc[0]

Cosine

PowerBrick[0].Chan[2].AdcEnc[1]

Cosine

PowerBrick[1].Chan[2].AdcEnc[1]

Sine

PowerBrick[0].Chan[3].AdcEnc[0]

Sine

PowerBrick[1].Chan[3].AdcEnc[0]

Cosine

PowerBrick[0].Chan[3].AdcEnc[1]

Cosine

PowerBrick[1].Chan[3].AdcEnc[1]

Note

The Sine and Cosine data is in the upper 16 bits of these 32-bit structure elements. Scaling them properly requires shifting right by 16 bits or dividing by 65,536.

Sinusoidal Counts per User Units

The (Gate 3) ASIC in the Power Brick AC has the capability of computing the sub-count interpolated position in hardware. The sub-count data is then combined with the whole-count data from the quadrature counter and latched into PowerBrick[].Chan[].PhaseCapt each phase cycle, and into PowerBrick[].Chan[].ServoCapt each servo cycle. The low 12 bits of these values represent sub-count data, so there are 4,096 states per quadrature count, or 16,384 states per encoder line, in the resulting values.

➢ A rotary encoder with 1,024 sine/cosine periods per revolution produces:

1,024 x 16,384 = 16,777,216 motor units / revolution

➢ A 20 μm linear encoder produces:

16,384 / 0.020 = 819,200 motor units / mm

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Bias Correction

The Power Brick AC has the capability of correcting for biases of the cosine / sine signals. These corrections are suitable when interpolating in the DSPGate3 without the ACI (Auto Correcting Interpolator) option. This procedure is described in the Sinusoidal Encoder Bias Corrections section of this manual.

Note

Automatic correction for signal magnitude mismatch and phase offset at the cost of additional processor time can be obtained through use of a Type 4 Encoder Conversion Table Entry. Refer to Conversion Method DetailsType 4 under the Setting up the Encoder Conversion Table section of the Power PMAC User Manual for more details.

Sinusoidal Encoder Count Error

With Sinusoidal encoders, the Power Brick AC has the capability of trapping encoder count (loss) errors. This is described in detail in the Encoder Count Error section of this manual.

Sinusoidal Encoder Loss Detection

Warning

With Sinusoidal encoders, the Power Brick AC has the capability of detecting the loss of an encoder signal. This is described in detail in the Encoder Loss Detection section of this manual.

Note

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X1 – X8: Encoder Feedback, Resolver

The Power Brick can "optionally" accept resolver encoder input (up to 5 V

peak-peak

) and provide interpolated

position data.

X1-X8: D-sub DA-15F

Mating: D-sub DA-15M

Pin#

Symbol

Function

Primary

Use

Alternate Use

SIN +

Input

Sine +

COS +

Input

Cosine +

CHC +

Input

Index C +

Amp. Enable +

ENCPWR

Output

Encoder Power 5 VDC (max 250 mA per channel)

CHU / DIR +

In / Out

Halls U

Direction Out +

Serial Data –

AltSin +

CHW / PUL +

In / Out

Halls W

Step Out +

Serial Clock –

AltCos +

2.5V

Output

2.5 VDC Reference power

PTC

Input

Motor Thermal Input

SIN –

Input

Sine –

COS –

Input

Cosine –

CHC –

Input

Index C –

Amp. Enable –

GND

Common

Common ground

CHV / DIR –

In / Out

Halls V

Direction Out –

Serial Clock +

AltSin –

CHT / PUL –

In / Out

Halls T

Step Out –

Serial Data +

AltCos –

RES EXC.

Out

Resolver Excitation Output

Caution

The +5 VDC encoder power is limited to ~250 mA per channel. For encoders requiring more current, the +5 VDC power can be alternately brought in externally through the +5 VDC ENC connector.

Caution

Encoders requiring a voltage level other than +5 VDC (higher or lower) should be powered up using an external power supply directly into the encoder.

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Setting up Resolvers

Configuring a resolver requires setting up the excitation signal control. The excitation signal control element, PowerBrick[].ResolverCtrl, is a 4-channel saved component:

Excitation Signal Control

Channels 1 – 4

PowerBrick[0].ResolverCtrl

Channels 5 – 8

PowerBrick[1].ResolverCtrl

The excitation signal control element is a 32-bit element wherein the upper 12 bits carry meaningful information is broken down as follows:

Bit #:

Binary:

Reserved

Hex ($):

123

0000

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0011

24252627

0000

28293031

0001

Freq.

Mag.

Phase Shift (Delay)

00000C08

Bits [31 – 24] specify the phase shift or delay of the excitation sine wave with respect to the phase clock.

The unit of this field is 1 / 512 of an excitation cycle. This component is usually set experimentally to maximize the magnitude of the feedback signal.

Bits [23 – 22] specify the magnitude of the excitation output. The highest magnitude that does not cause

saturation of the feedback ADCs (which occurs when values in the lower 16 bits of

PowerBrick[].Chan[].AtanSumOfSqr exceed 32767) should be used.

Peak-Peak [Volts]

Value

Binary

3.2

6.2

8.8

12.2 (Max.)

Bits [21 – 20] specify the frequency of the excitation output. The frequency that comes closest, but slightly

higher, to that recommended by the resolver manufacturer should be used.

Excitation Frequency

Value

Binary

Phase Clock / 1

Phase Clock / 2

Phase Clock / 4

Phase Clock / 6

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Connections and Software Setup 56

Utilizing the following expression, for channels 1 – 4 as an example:

GLOBAL ResExcitDelay; GLOBAL ResExcitMag; GLOBAL ResExcitFreqDiv;

ResExcitMag = 3 // [0 - 3] ResExcitFreqDiv = 0 // [0 - 3] ResExcitDelay = 65 // [0 - 255] PowerBrick[0].ResolverCtrl = ResExcitDelay*EXP2(24) + ResExcitMag*EXP2(22) + ResExcitFreqDiv*EXP2(20)

And monitoring the magnitude of the signals in the lower 16 bits of PowerBrick[].Chan[].AtanSumOfSqr (e.g. in the watch window):

➢ First, set up the excitation output magnitude, ResExcitMag. Start with highest (value of 3). We

want the value of AtanSumOfSqr (lower 16 bits) to be the greatest possible.

➢ Set up the excitation frequency divider, ResExcitFreqDiv. Resolver manufacturers generally

specify a minimum operating frequency. Set this typically to a value of 0, same as the phase clock.

➢ Set up the excitation delay (from the phase clock), ResExcitDelay. This value is also configured

experimentally to produce the greatest possible value of the signal’s magnitude, which is in the lower 16 bits of AtanSumOfSqr.

Configuring Resolver ECT

Once, the resolver excitation signal is set up, the encoder conversion table can be configured as follows (e.g. channel 1, motor #1):

Motor[1].ServoCtrl = 1

EncTable[1].Type = 1 EncTable[1].pEnc = PowerBrick[0].Chan[0].AtanSumofSqr.a EncTable[1].pEnc1 = Sys.pushm EncTable[1].index1 = 0 EncTable[1].index2 = 0 EncTable[1].index3 = 0 EncTable[1].index4 = 0 EncTable[1].index5 = 0 EncTable[1].index6 = 0 EncTable[1].ScaleFactor = 1 / 65536

Resolver Counts per User Units

With resolvers, the feedback resolution is set by the ASIC interface hardware, and produces 65,536 counts per revolution.

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Resolver Absolute Power-On Position

With resolvers, the absolute position is computed directly from the upper 16 bits of the AtanSumOfSqr register. It is set up using the following key structure elements:

➢ Motor[].pAbsPos = PowerBrick[0].Chan[2].AtanSumOfSqr.a ➢ Motor[].AbsPosSf = Motor[].PosSf ➢ Motor[].ApsPosFormat = $00001010 (Upper 16 bits) ➢ Motor[].HomeOffset = user desired home offset value

Note

With resolvers, it is not recommended to use PowerOnMode (value of 2) for power-on absolute position read. Instead, it is recommended to issue a HOMEZ command from an initialization PLC.

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Bias Correction

The resolver sine and cosine signals may be corrected for biases similarly to sinusoidal encoders. This is described in the Sinusoidal Encoder Bias Corrections section of this manual.

Note

Automatic correction for signal magnitude mismatch and phase offset at the cost of additional processor time can be obtained through use of a type 4 encoder conversion table entry. Refer to Conversion Method Details, type 4 under the setting up the encoder conversion table section of the Power PMAC User Manual for more details.

Resolver Encoder Count Error

The Power Brick AC has the capability of trapping encoder count (loss) errors for resolvers. This is described in detail in the Encoder Count Error section of this manual.

Resolver Encoder Loss Detection

Warning

With Resolvers, the Power Brick AC has the capability of detecting the loss of an encoder signal. This is described in detail in the Encoder Loss Detection section of this manual.

Note

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Power Brick AC User Manual

Connections and Software Setup 59

X1 – X8: Encoder Feedback, Serial

The Power Brick AC, in its standard configuration, accepts a variety of serial encoder protocols. These protocols are built into the DSPGate3. This section discusses the configuration of these serial encoders.

X1-X8: D-sub DA-15F

Mating: D-sub DA-15M

Symbol

Function

Hiperfac

SSI

EnDat

Panasoni

Mitutoy

Sigma

II/II/V/VI

BiSS

Tamagaw

ENA –

Output

–

SENA

ENCPW

Output

Encoder Power 5 VDC (max 250 mA per channel)

DATA –

In / Out

DAT–

MRR

SDI

blu/blk

SLO–

CLOCK –

Output

–

CLK– – –

–

MA–

–

2.5V

Output

2.5 VDC – Reference

PTC

Input

Motor Thermal Input

10 11

ENA +

Output

–

SENA

GND

Commo

Common Ground

CLOCK +

Output

–

CLK+ – –

–

MA+

–

DATA +

In / Out

DAT+

DAT

SDO

blu

SLO

Caution

The +5 VDC encoder power is limited to ~250 mA per channel. For encoders requiring more current, the +5 VDC power can be alternately brought in externally through the +5 VDC ENC connector.

Caution

Encoders requiring a voltage level other than +5 VDC (higher or lower) should be powered directly from an external power supply.

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Note

Quadrature / sinusoidal encoders can be wired and processed simultaneously with serial encoders on the same channel.

Pins #5, 6, 13, and 14 of the encoder feedback connectors (X1 – X8) share multiple functions: only one of these functions (per channel) can be used – configured in software – at one time:

➢ Hall sensor inputs (default configuration). ➢ Pulse and direction PFM output signals (software configuration using Flag D output, OutFlagD). ➢ Serial encoder inputs (software configuration enabling serial encoder line, SerialEncEna). ➢ Quadrature encoder inputs (serial encoder enable line must be 0). ➢ Alternate Sinusoidal encoder inputs (with sinusoidal encoder option).

Note

Each channel is independent of the other channels and can have its own use for these pins.

Configuring a serial encoder requires the programming of two essential structure elements, and the enabling of the serial encoder line:

➢ The Serial Encoder Control word, PowerBrick[].SerialEncCtrl ➢ The Serial Encoder Command word, PowerBrick[].Chan[].SerialEncCmd ➢ PowerBrick[].Chan[].SerialEncEna = 1

These structure elements must be initialized and can be placed in the startup file of the IDE application project under Configuration.

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Serial Encoder Control

The Serial Encoder Control is a 32-bit, 4-channel (1 – 4, or 5 – 8), structure element. It specifies the protocol type, delay compensation time, trigger edge, trigger clock, and transmission frequency of the 4 serial encoder channels.

Serial Encoder Control Elements

Channels 1 – 4

PowerBrick[0].SerialEncCtrl

Channels 5 – 8

PowerBrick[1].SerialEncCtrl

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

0000

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

0000

28293031

0000

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Encoder Protocol

Typically 0

(Units of Serial Clock Cycles)

00000000

Serial Encoder Transmission Frequency

Bits [31 – 20] specify the serial interface transmission frequency. This frequency (or range) is usually

specified by the encoder manufacturer and programmed by the user or pre-defined by the protocol.

Bit 17 specifies the trigger source; Phase clock is recommended (value 0). Bit 16 specifies the active edge; rising edge is recommended (value 0).

Bits [15 – 8] specify the trigger delay (in units of serial clock cycles) used to compensate for transmission

over long encoder lines.

Bits [3 – 0] specify the encoder protocol of the serial encoder:

Protocol

Value Protocol

Value

Protocol

Value

Protocol

Value

–

0 Hiperface

4 Panasonic

8 –

12 ($C)

–

1 Sigma I

5 Mitutoyo

9 –

13 ($D)

SSI

2 Sigma II/III/V

6 Kawasaki

10 ($A)

– 14 ($E)

EnDat

3 Tamagawa

7 –

11 ($B)

SW Ctrl

15 ($F)

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Serial Encoder Command

The Serial Encoder Command is a 32-bit, channel specific, structure element. It specifies the bit length (resolution), status bits, data type, conversion method, trigger enable, trigger mode, parity, and command code of the serial encoder channel.

Ch.#

Serial Encoder Command

Ch. #

Serial Encoder Command

PowerBrick[0].Chan[0].SerialEncCmd

PowerBrick[1].Chan[0].SerialEncCmd

PowerBrick[0].Chan[1].SerialEncCmd

PowerBrick[1].Chan[1].SerialEncCmd

PowerBrick[0].Chan[2].SerialEncCmd

PowerBrick[1].Chan[2].SerialEncCmd

PowerBrick[0].Chan[3].SerialEncCmd

PowerBrick[1].Chan[3].SerialEncCmd

Bit #:

Binary:

Bit Length

(Resolution)

Hex ($):

123

0000

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

0000

28293031

0000

00000000

Status

Bits

DataRdy

G to B

Trig Ena

Mode

ParityCommand Code

Protocol Specific

00: None 01: Odd 10: Even

0: Continuous 1: One Shot

0: Disable 1: Enable

0: No Conversion 1: Gray to Binary

Read Only

Single Turn +

Multi Turn

Bits [31 – 16] specify the command code. This field is protocol specific.

Bits [15 – 14] specify the parity. This field is protocol specific.

Bit 13 specifies the trigger mode.

Bit 12 is the trigger enable toggle.

Bit 11 specifies the conversion type. This field is protocol specific.

Bit 10 is the data ready bit, read only.

Bits [9 – 6] specify the encoder status field. This field is protocol specific.

Bits [5 – 0] specify the serial encoder bit length (single-turn + multi-turn).

Following, are examples for setting up the control and command words for each of the supported protocols. Also, the resulting data registers and their format.

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SSI Configuration Example

Serial Encoder Control – SSI

No trigger delay, rising edge of phase, and 2.5 MHz transmission

M = 39 ($27) N = 0

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

0100

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

1110

28293031

0100

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =2 SSI

20000072

Serial

= 2.5 MHz

= Delay

µsec

x f

SerialMHz

Serial Encoder Command – SSI

A 25-bit SSI encoder in Gray code, with odd parity

Bit #:

Binary:

Bit Length

(Resolution)

Hex ($):

123

1001

4567

1000

891011

0001

12131415

1010

16171819

0000

20212223

0000

24252627

0000

28293031

0000

91850000

G to B

Trig Ena

Mode

Parity

0: Disable 1: Enable

0: Continuous 1: One Shot

Single Turn +

Multi Turn = 25 ($19)

00: none 01: Odd 10: Even

0: No Conversion 1: Gray to Binary

PowerBrick[0].SerialEncCtrl = $27000002 PowerBrick[0].Chan[0].SerialEncCmd = $5819 PowerBrick[0].Chan[0].SerialEncEna = 1

Serial Data Registers – SSI

The resulting position data, status, and error bits for SSI are found in the following Serial Data Registers:

PowerBrick[].Chan[].SerialEncDataA

Possible Single/Multi-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Parity Error

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EnDat 2.1/2.2 Configuration Example

Serial Encoder Control – EnDat 2.1/2.2

No trigger delay, rising edge of phase, and 2.0 MHz transmission

M = 1 N = 0

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

1100

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

1000

28293031

0000

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =3 EnDat

30000010

Serial

= 2 MHz

= Delay

µsec

x f

SerialMHz

Serial Encoder Command – EnDat 2.1/2.2

The DSPGate3 interface to EnDat supports four 6-bit command codes:

o 000111 ($7) for reporting position (EnDat2.1/2.2). o 101010 ($2A) for resetting the encoder (EnDat2.1/2.2). o 111000 ($38) for reporting position with possible additional information (EnDat 2.2 only) o 101101 ($2D) for resetting the encoder (EnDat 2.2 only)

Note

By the EnDat standard, EnDat 2.2 encoders should be able to accept and process EnDat 2.1 command codes. However, not all encoders sold as meeting the EnDat 2.2 standard can do this.

Note

With the Power Brick AC, EnDat additional information is supported via the (optional) ACC-84B serial interface.

A 37-bit EnDat 2.2 encoder for continuous position reporting:

Bit #:

Binary:

Bit Length

(Resolution)

Hex ($):

123

1001

4567

0100

891011

0000

12131415

1000

16171819

1110

20212223

0000

24252627

0000

28293031

0000

52017000

Trig Ena

Mode

Command Code

0: Disable 1: Enable

0: Continuous 1: One Shot

Single Turn +

Multi Turn = 37 ($25)

Delay

Compensation

000111 ($07): Report Position 101010 ($2A): Reset Encoder 111000 ($38): Report Position w/ possible add’l info (EnDat 2.2 only) 101101 ($2D): Reset Encoder (EnDat 2.2 only)

PowerBrick[0].SerialEncCtrl = $1000003 PowerBrick[0].Chan[0].SerialEncCmd = $71025 PowerBrick[0].Chan[0].SerialEncEna = 1

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With EnDat 2.2, bit 31 is the StartDelayComp control bit. Setting this bit to 1 starts a delay identification and compensation cycle which measures the propagation delay between the encoder and the controller. The delay is measured three times and the average is used in the compensation. When these calculations are done, the StartDelayComp bit 31 is automatically cleared. This delay identification operation must be performed after every power-up cycle. Delay compensation permits high bit transmission rates over very long cables.

To perform the delay identification and compensation cycle on this encoder, set PowerBrick[].Chan[].SerialEncCmd = $80071025, then wait for bit #31 to clear.

This same encoder can be reset with a command code of $2A sent in one-shot mode, so by setting

PowerBrick[].Chan[].SerialEncCmd = $2A3025.

Serial Data Registers – EnDat 2.1/2.2

The resulting position data, status, and error bits for EnDat are found in the following Serial Data Registers:

PowerBrick[].Chan[].SerialEncDataA

Possible Single/Multi-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Encoder Err

Possible Single/Multi-Turn Position (cont.)

CRC Error

Timeout Err

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Hiperface Configuration Example

Serial Encoder Control – Hiperface

Because there is no explicit clock signal with Hiperface, the serial clock frequency is set 20 times higher

than the bit transmission frequency to “oversample” the input data stream. For the default 9600 baud

transmission of the Hiperface encoder, this clock frequency should be 9.6 x 20 = 192 kHz.

Divide the 100 MHz clock by M=130 ($83) and by 4 (N = 2) to get 192 kHz triggering on the falling edge of servo clock without delay. Since this is a “one-shot” read, the selection of the triggering clock edge does not matter much.

Virtually always For Hiperface

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

0010

4567

0000

891011

0000

12131415

0000

16171819

1100

20212223

0100

24252627

0100

28293031

0001

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =4 Hiperface

40003228

M = 130 ($82) N = 2

= Delay

µsec

x 0.192

Serial Encoder Command – Hiperface

The DSPGate3 interface to Hiperface supports three 8-bit command codes:

o $42 for reporting position. o $50 for reporting status o $53 for resetting the encoder

These command codes reside in the lower 8 bits of the Serial Encoder Command word. The upper 8 bits contain the address of the encoder in the interface. The Hiperface protocol permits up to 8 separate encoders to be “daisy-chained” on a single multi-drop interface. While this can be done, it is expected that each channel of the Power Brick AC will be connected to a separate individual encoder, simplifying the wiring.

In this configuration, this address field can either match the encoder’s address value (+ $40), or it can be

set to $FF (broadcast mode).

A Hiperface encoder at user address 0 with odd parity would be set up for one-shot position reporting as follows:

Bit #:

Binary:

Hex ($):

123

1001

4567

0100

891011

0000

12131415

1110

16171819

0100

20212223

0010

24252627

0000

28293031

0010

00072404

Trig Ena

Mode

ParityCommand Code

0: Disable 1: Enable

0: Continuous 1: One Shot

Encoder ID

00: None 01: Odd 10: Even

$42: Report Position $50: Report Status $53: Reset Encoder

$4n: where n is encoder ID $FF: Broadcast mode

PowerBrick[].Chan[].SerialEncCmd = $40427000 or $FF427000

PowerBrick[0].SerialEncCtrl = $82230004 PowerBrick[0].Chan[0].SerialEncCmd = $40427000 PowerBrick[0].Chan[0].SerialEncEna = 1

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Serial Data Registers – Hiperface

The resulting position data, status, and error bits for Hiperface are found in the following Serial Data Registers:

PowerBrick[].Chan[].SerialEncDataA

Possible Single/Multi-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Encoder Err.

Encoder Error Code

Parity Err.

Chksum Err.

Timeout Err.

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Yaskawa Sigma I Configuration Example

Serial Encoder Control – Sigma I

Because there is no explicit clock signal with Sigma I, the serial clock frequency is set 20 times higher than the bit transmission frequency to “oversample” the input data stream. For the default 9600 baud transmission of the Sigma I encoder, this clock frequency should be 9.6 x 20 = 192 kHz.

Divide the 100 MHz clock by M=130 ($83) and by 4 (N = 2) to get 192 kHz. triggering on the falling edge of servo clock without delay. Since this is a “one-shot” read, the selection of the triggering clock edge does not matter much. Example settings:

Virtually always For Hiperface

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

1010

4567

0000

891011

0000

12131415

0000

16171819

1100

20212223

0100

24252627

0100

28293031

0001

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =5 Sigma I

50003228

M = 130 ($82) N = 2

= Delay

µsec

x 0.192

Serial Encoder Command – Sigma I

Yaskawa no longer produces Sigma I absolute encoders. However, newer generations of Yaskawa Sigma servo drives synthesize the Yaskawa Sigma I protocol for return to the controller even when using newer Sigma II, III, and V encoders. Bit 16 is set to strobe the encoder and Sigma I should use one-shot trigger, set as follows:

Bit #:

Binary:

Hex ($):

123

0000

4567

0000

891011

0000

12131415

1100

16171819

1000

20212223

0000

24252627

0000

28293031

0000

00031000

Trig Ena

Mode

0: Disable 1: Enable

0: Continuous 1: One Shot

PowerBrick[0].SerialEncCtrl = $82230005 PowerBrick[0].Chan[0].SerialEncCmd = $13000 PowerBrick[0].Chan[0].SerialEncEna = 1

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Serial Data Registers – Sigma I

The resulting position data, status, and error bits for Sigma I are found in the following Serial Data Registers:

PowerBrick[].Chan[].SerialEncDataA

Multi-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Parity Err.

Multi-Turn PositionSign (±)

Timeout Err.

"P"

In the Data A register, bits [7 – 0] represent the bits of the ASCII code for the “ones digit” of the turns count, bits [15 – 8] represent bits of the “tens digit”, bits [23 – 16] represent bits of the “hundreds digit”, bits [31 – 24] represent bits of the “thousands digit”.

In the Data B register, Bits [7 – 0] represent bits of the “ten-thousands digit”, bits [15 – 8] represent bits of the ASCII code for the plus or minus sign, bits [23 – 16] represent bits of the ASCII code for the letter “P”, bits [31 – 30] represent bits of the error field (bit 30 is a parity error; bit 31 is a timeout error).

For each of the five numeric ASCII digits, the numeric value of the digit can be obtained by subtracting 48 ($30) from the value of the ASCII code.

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Yaskawa Sigma II/III/V Configuration Example

Serial Encoder Control – Sigma II/III/V

No trigger delay, rising edge of phase, and 4.0 MHz transmission:

M = 0 N = 0

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

0110

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

1110

28293031

0100

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =6 Sigma II/III/V

60000000

Serial

= 4 MHz

= Delay

µsec

x f

SerialMHz

Serial Encoder Command – Sigma II/III/V

For continuous position reporting:

Bit #:

Binary:

Hex ($):

123

0000

4567

0000

891011

0000

12131415

1000

16171819

0000

20212223

0000

24252627

0000

28293031

0000

00010000

Trig Ena

Mode

0: Disable 1: Enable

0: Continuous 1: One Shot

PowerBrick[0].SerialEncCtrl = $6 PowerBrick[0].Chan[0].SerialEncCmd = $1000 PowerBrick[0].Chan[0].SerialEncEna = 1

Serial Data Registers – Sigma II/III/V

The resulting position data, status, and error bits for Sigma II/III/V are found in the following Serial Data Registers:

Yaskawa Sigma II (absolute 17-bit)

PowerBrick[].Chan[].SerialEncDataA

Single-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Alarm Code

Multi-Turn Position

Multi-Turn PositionTemperature

Coding Err.

CRC Err.

Timeout Err.

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Yaskawa Sigma II (incremental 17-bit)

PowerBrick[].Chan[].SerialEncDataA

Single-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Alarm Code

Compensation Position

Temperature

Coding Err.

CRC Err.

Timeout Err.

Hall U

Hall V

Hall W

Index Z

Yaskawa Sigma III/V (absolute 20-bit)

PowerBrick[].Chan[].SerialEncDataA

Single-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Alarm Code

Multi-Turn Position

Multi-Turn PositionTemperature

Coding Err.

CRC Err.

Timeout Err.

Yaskawa Sigma II/II/V Encoders Alarm Code (Serial Encoder Data B Register)

Bit #

Alarm Code

20 – 21

Power-on error self-detected

–

Revolution count (index to index) incorrect

–

Position reference (index) not found yet

–

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Tamagawa FA-Coder Configuration Example

Serial Encoder Control – Tamagawa FA-Coder

No trigger delay, rising edge of phase, and 2.5 MHz transmission:

M = 1 N = 0

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

1110

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

1000

28293031

0000

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =7 Tamagawa

70000010

Serial

= 2.5 MHz

= Delay

µsec

x f

SerialMHz

Serial Encoder Command – Tamagawa FA-Coder

For continuous position reporting:

Bit #:

Binary:

Hex ($):

123

0000

4567

0000

891011

0000

12131415

1000

16171819

0101

20212223

1000

24252627

0000

28293031

0000

0001A100

Trig Ena

Mode

0: Disable 1: Enable

0: Continuous 1: One Shot

Command code

$1A: Report Position $BA: Reset Multi-Turn $C2: Reset Multi-Turn $62: Reset Multi-Turn

If the command code is set to $BA, $C2, or $62, the multi-turn position value in the encoder is reset to 0. This should be done in “one-shot” mode, making the element equal to $00BA3000, $00C23000, or $00623000, respectively. When the reset operation is done, the component should report as $00BA2000, $00C22000, or $00622000, respectively.

PowerBrick[0].SerialEncCtrl = $1000007 PowerBrick[0].Chan[0].SerialEncCmd = $1A1000 PowerBrick[0].Chan[0].SerialEncEna = 1

Serial Data Registers – Tamagawa FA-Coder

The resulting position data, status, and error bits for Tamagawa FA-Coder are found in the following Serial Data Registers:

PowerBrick[].Chan[].SerialEncDataA

Single-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Alarm CodeStatus Field Multi-Turn Position

CRC Err.

Timeout Err.

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Panasonic Configuration Example

Serial Encoder Control – Panasonic

No trigger delay, rising edge of phase, and 2.5 MHz transmission:

M = 1 N = 0

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

0001

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

1000

28293031

0000

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =8 Panasonic

80000010

Serial

= 2.5 MHz

= Delay

µsec

x f

SerialMHz

Serial Encoder Command – Panasonic

For continuous position reporting:

Bit #:

Binary:

Hex ($):

123

0001

4567

0000

891011

0000

12131415

1000

16171819

0101

20212223

0100

24252627

0000

28293031

0000

0001A200

Trig Ena

Mode

0: Disable 1: Enable

0: Continuous 1: One Shot

Command code

$2A: Report Absolute Position $52: Single-Turn Position with Encoder ID code $4A: Reset Multi-Turn $7A: Reset Multi-Turn $DA: Reset Multi-Turn $F2: Reset Multi-Turn

If the command code is set to $52 for single-turn position reporting with alarm code, the encoder ID value is reported where multi-turn position is normally reported.

If the command code is set to $4A, $7A, $DA, or $F2, the multi-turn position value in the encoder is reset to 0. This should be done in “one-shot” mode, making the element equal to $004A3000, $007A3000, $00DA3000, or $00F23000, respectively. When the reset operation is done, the component should report as $004A2000, $007A2000, $00DA2000, or $00F22000, respectively.

PowerBrick[0].SerialEncCtrl = $1000008 PowerBrick[0].Chan[0].SerialEncCmd = $2A1000 PowerBrick[0].Chan[0].SerialEncEna = 1

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Serial Data Registers – Panasonic

The resulting position data, status, and error bits for Panasonic are found in the following Serial Data Registers:

PowerBrick[].Chan[].SerialEncDataA

Single-Turn Position

PowerBrick[].Chan[].SerialEncDataB

31 2627282930 012345678910111213141516171819202122232425

Status Field

CRC Err.

Timeout Err.

Multi-Turn Position Or

Encoder ID Code

Multi-Turn Position Or

Encoder ID Code

Alarm code

when commanded

Bits 24 – 31 (SerialEncDataA) of the encoder ID code are fixed at a value of $11.

Bit #

Alarm Code

Overspeed error

Full resolution status; = 1 when over 100 rpm and reporting reduced resolution

Count Error

Counter Overflow

–

Multi-revolution error

System undervoltage error (< 2.5 V)

Battery low (< 3.1 V)

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Mitutoyo Configuration Example

Serial Encoder Control – Mitutoyo

No trigger delay, rising edge of phase, and 2.5 MHz transmission:

M = 1 N = 0

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

1001

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

1000

28293031

0000

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =9 Mitutoyo

90000010

Serial

= 2.5 MHz

= Delay

µsec

x f

SerialMHz

Serial Encoder Command – Mitutoyo

For continuous position reporting:

Bit #:

Binary:

Hex ($):

123

0000

4567

0000

891011

0000

12131415

1000

16171819

1000

20212223

0000

24252627

0000

28293031

0000

00011000

Trig Ena

Mode

0: Disable 1: Enable

0: Continuous 1: One Shot

Command code

$01: Report Position $85: Same as $01 $89: Reset Multi-Turn $9D: Report Encoder ID

If the command code is set to $89, the multi-turn position value in the encoder is reset to 0 (after 8 cycles). If the command code is set to $9D, the encoder ID value is reported in bits 8 – 15 of SerialEncDataB. If the command code is set to $85, absolute position is reported, similarly to $01.

PowerBrick[0].SerialEncCtrl = $1000009 PowerBrick[0].Chan[0].SerialEncCmd = $11000 PowerBrick[0].Chan[0].SerialEncEna = 1

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Serial Data Registers – Mitutoyo

The resulting position data, status, and error bits for Mitutoyo are found in the following Serial Data Registers:

PowerBrick[].Chan[].SerialEncDataA

Possible Single-Turn/Multi-turn Position

PowerBrick[].Chan[].SerialEncDataB

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Status Field

CRC Err.

Timeout Err.

Encoder IDAlarm code

Bit #

Alarm Code

Initialization error

Mismatch of optical and capacitive sensors

Optical sensor error

Capacitive sensor error

CPU error (AT303); CPU/ROM/RAM error (AT503)

EEPROM error

ROM/RAM error (AT303); communication error (AT503)

Overspeed error

Bit #

Status Field

Fatal (unrecoverable) encoder error

–

Illegal command code from controller

–

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Kawasaki Configuration Example

Serial Encoder Control – Kawasaki

No trigger delay, rising edge of phase, and 2.5 MHz transmission:

M = 1 N = 0

Bit #:

Binary:

Protocol

0: Rising 1: Falling

0: Phase 1: Servo

Hex ($):

123

0101

4567

0000

891011

0000

12131415

0000

16171819

0000

20212223

0000

24252627

1000

28293031

0000

Trigger Delay

Edge

Clock

Reserved

N DivisorM Divisor

Protocol: =A Kawasaki

A0000010

Serial

= 2.5 MHz

= Delay

µsec

x f

SerialMHz

Serial Encoder Command – Kawasaki

Bit #:

Binary:

Hex ($):

123

0000

4567

0000

891011

0000

12131415

1000

16171819

0000

20212223

0000

24252627

0000

28293031

0000

00010000

Trig Ena

Mode

0: Disable 1: Enable

0: Continuous 1: One Shot

PowerBrick[0].SerialEncCtrl = $100000A PowerBrick[0].Chan[0].SerialEncCmd = $1000 PowerBrick[0].Chan[0].SerialEncEna = 1

Serial Data Registers – Kawasaki

The resulting position data, status, and error bits for Kawasaki are found in the following Serial Data Registers:

PowerBrick[].Chan[].SerialEncDataA

Single-Turn Position

PowerBrick[].Chan[].SerialEncDataB

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Alarm Code

CRC Err.

Timeout Err.

Interpolated

Position

Multi-Turn Position

Correction

Multi-Turn Position

Coding Err.

Bit #

Alarm code

Interpolator error

Absolute track error

Busy flag

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Serial Encoder Ongoing Position Setup

For the ongoing "incremental" position data, it is sufficient to process whatever position data (single-turn and/or multi-turn) is available in the serial data A register. The PMAC firmware does not require processing the entire bit length because the difference change in between servo cycles is used to compute the ongoing position. This will not limit the resolution or hinder the performance. Some people may choose to use strictly the single-turn data in the Encoder Conversion Table for simplicity.

A key step, however, is to make sure that the Most Significant Bit MSB of the data chosen is most leftshifted to bit #31 in order to handle the rollover gracefully.

Following, are examples for setting up the Encoder Conversion Table ECT for ongoing position of various serial encoders. These settings depend primarily on the location of the position data in the serial encoder data A register.

Example: A serial encoder with 17 bits of single-turn (or an equivalent 1 µm linear scale) position data

located in the lower 17 bits of serial data A register.

PowerBrick[].Chan[].SerialEncDataA

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The position data should be shifted 15 bits left (using index1) so that the Most Significant Bit MSB is at bit #31 to handle the rollover gracefully. Also, the scale factor should reflect the new location of the Least Significant Bit LSB.

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EncTable[1].type = 1 EncTable[1].pEnc = PowerBrick[0].Chan[0].SerialEncDataA.a EncTable[1].pEnc1 = Sys.Pushm EncTable[1].index1 = 15 EncTable[1].index2 = 0 EncTable[1].index3 = 0 EncTable[1].index4 = 0 EncTable[1].index5 = 0 EncTable[1].index6 = 0 EncTable[1].ScaleFactor = 1 / EXP2(15)

Activating the corresponding motor channel, and setting up the position and velocity pointers is sufficient to display motor/encoder units in the position window:

Motor[1].ServoCtrl = 1 Motor[1].pEnc = EncTable[1].a Motor[1].pEnc2 = EncTable[1].a

In this case, the user will see 217 = 131,072 motor units per revolution for a rotary encoder. And 1/0.001 = 1,000 motor units per mm for a linear encoder.

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Example: A serial encoder with 20 bits of single-turn (or an equivalent 50 nm linear scale) position data

located in serial data A register and starting at bit #4. The low nibble may contain other information, irrelevant to position data.

PowerBrick[].Chan[].SerialEncDataA

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The position data should be first shifted 4 bits to the right (using index2) to eliminate the unwanted bits. Then shifted 12 bits to the left (using index1), so that the MSB is at bit #31 to handle the rollover gracefully. Also, the scale factor should reflect the new location of the LSB.

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EncTable[1].type = 1 EncTable[1].pEnc = PowerBrick[0].Chan[0].SerialEncDataA.a EncTable[1].pEnc1 = Sys.Pushm EncTable[1].index1 = 12 EncTable[1].index2 = 4 EncTable[1].index3 = 0 EncTable[1].index4 = 0 EncTable[1].index5 = 0 EncTable[1].index6 = 0 EncTable[1].ScaleFactor = 1 / EXP2(12)

Activating the corresponding motor channel, and setting up the position and velocity pointers is sufficient to display motor/encoder units in the position window:

Motor[1].ServoCtrl = 1 Motor[1].pEnc = EncTable[1].a Motor[1].pEnc2 = EncTable[1].a

In this case, the user will see 220 = 1,048,576 motor units per revolution for a rotary encoder. And 1 /

0.000050 = 20,000 motor units per mm for a linear encoder.

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Example: A serial encoder with 36 bits of single-turn (or an equivalent 1 nm linear scale) position data

located in serial data A and B registers consecutively.

PowerBrick[].Chan[].SerialEncDataA

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PowerBrick[].Chan[].SerialEncDataB

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Reading and processing the 32 bits of position data in serial data register A is sufficient for producing the proper ongoing position.

EncTable[1].type = 1 EncTable[1].pEnc = PowerBrick[0].Chan[0].SerialEncDataA.a EncTable[1].pEnc1 = Sys.Pushm EncTable[1].index1 = 0 EncTable[1].index2 = 0 EncTable[1].index3 = 0 EncTable[1].index4 = 0 EncTable[1].index5 = 0 EncTable[1].index6 = 0 EncTable[1].ScaleFactor = 1

Activating the corresponding motor channel, and setting up the position and velocity pointers is sufficient to display motor/encoder units in the position window:

Motor[1].ServoCtrl = 1 Motor[1].pEnc = EncTable[1].a Motor[1].pEnc2 = EncTable[1].a

In this case, the user will see 2

SingleTurn

= 236 = 68,719,476,736 motor units per revolution for a rotary motor.

And 1 / 0.000001 = 1,000,000 motor units per mm for a linear motor.

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Example: A 29-bit serial encoder with 17 bits of single-turn and 12 bits of multi-turn position data starting

at bit #0 of serial data A register and continuously extending to bit #28.

PowerBrick[].Chan[].SerialEncDataA

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Single-Turn Position DataMulti-Turn Position Data

Both single-turn and multi-turn data can be used for ongoing position. The entire bit length is shifted left (using index1) 3 bits to place the MSB at bit #31.

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Single-Turn Position DataMulti-Turn Position Data

Ongoing Position

EncTable[1].type = 1 EncTable[1].pEnc = PowerBrick[0].Chan[0].SerialEncDataA.a EncTable[1].pEnc1 = Sys.Pushm EncTable[1].index1 = 3 EncTable[1].index2 = 0 EncTable[1].index3 = 0 EncTable[1].index4 = 0 EncTable[1].index5 = 0 EncTable[1].index6 = 0 EncTable[1].ScaleFactor = 1 / EXP2(3)

Activating the corresponding motor channel, and setting up the position and velocity pointers is sufficient to display motor/encoder units in the position window:

Motor[1].ServoCtrl = 1 Motor[1].pEnc = EncTable[1].a Motor[1].pEnc2 = EncTable[1].a

In this case, the user will see 2

SingleTurn

= 217 = 131,072 motor units per revolution.

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Example: A 36-bit serial encoder with 24 bits of single-turn and 12 bits of multi-turn position data starting

at bit #0 of serial data A register and continuously extending to bit #3 of serial data register B.

PowerBrick[].Chan[].SerialEncDataA

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Single-Turn Position DataMulti-Turn Position Data

PowerBrick[].Chan[].SerialEncDataB

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Multi-Turn Position Data

For ongoing position, we are only interested in the position data residing in serial data register A. Some people may elect to use only the single-turn data for ongoing position processing. This would require shifting to the left 8 bits (index1 = 8), and setting EncTable[].ScaleFactor = 1 / 256.

But, also it is possible to just simply process the whole 32-bit word comprised of single-turn, and multiturn position data.

Activating the corresponding motor channel, and setting up the position and velocity pointers is sufficient to display motor/encoder units in the position window:

Motor[1].ServoCtrl = 1 Motor[1].pEnc = EncTable[1].a Motor[1].pEnc2 = EncTable[1].a

In this case, the user will see 2

SingleTurn

= 224 = 16,777,216 motor units per revolution.

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Serial Encoder Power-On Absolute Position Setup

The absolute position is computed directly from the serial data registers, and set up using the following key structure elements:

➢ Motor[].pAbsPos, typically = PowerBrick[].Chan[].SerialEncDataA.a ➢ Motor[].AbsPosSf = Motor[].PosSf ➢ Motor[].ApsPosFormat:

a a b b c c d d

Motor[].AbsPosFormat = $

Number of the starting bit of the data from register A

Number of the starting bit of the data from register B

Total Number of bits

0 0 0 0 0 0 0 0

= 000 Unsigned binary = 001 Signed binary = 010 ($2) Gray Code, convert to unsigned binary = 011 ($3) Gray code, convert to signed binary

Shift Register A data left by this much first

= 0 No additional shift = 1 Shift the data in Register A 16 more bits

Note

Motor[].PowerOnMode (value of 2) specifies an absolute position read on power up. Alternately, #1HMZ from the online terminal or a HOMEZ 1 from a PLC can be issued to retrieve the absolute position.

Following, are examples for setting up the absolute position read with various serial encoders. These settings depend primarily on the location of the position data in the serial encoder data A and B registers.

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Example: A serial encoder with 17 bits of binary single-turn (or linear scale), and no multi-turn, position

data located in the lower fields of serial data A register.

PowerBrick[].Chan[].SerialEncDataA

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0 0 0 0 1 1 0 0

Motor[].AbsPosFormat = $

Serial data A start at bit 00

Serial data B: none 00

17 bits

00: unsigned binary

Motor[1].pAbsPos = PowerBrick[0].Chan[0].SerialEncDataA.a Motor[1].AbsPosSf = Motor[1].PosSf Motor[1].ApsPosFormat = $00001100 Motor[1].HomeOffset = 0

Example: A serial encoder with 20 bits of binary single-turn (or linear scale), and no multi-turn, position

data starting at bit #4 of serial data A register.

PowerBrick[].Chan[].SerialEncDataA

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0 0 0 0 1 4 0 4

Motor[].AbsPosFormat = $

Serial data A start at bit 4

Serial data B: none 00

20 bits

00: unsigned binary

Motor[1].pAbsPos = PowerBrick[0].Chan[0].SerialEncDataA.a Motor[1].AbsPosSf = Motor[1].PosSf Motor[1].AbsPosFormat = $00001404 Motor[1].HomeOffset = 0

Example: A serial encoder with 36 bits of single-turn (or linear scale) position data located in serial data

A and B registers consecutively.

PowerBrick[].Chan[].SerialEncDataA

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PowerBrick[].Chan[].SerialEncDataB

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0 0 0 0 2 4 0 0

Motor[].AbsPosFormat = $

Serial data A start at bit 0

Serial data B start at bit 0

36 bits

00: unsigned binary

Motor[1].pAbsPos = PowerBrick[0].Chan[0].SerialEncDataA.a Motor[1].AbsPosSf = Motor[1].PosSf Motor[1].AbsPosFormat = $00002400 Motor[1].HomeOffset = 0

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Note

Encoders with no multi-turn position data are set up as unsigned.

Example: A 29-bit binary serial encoder with 17 bits of single-turn and 12 bits of multi-turn position data

starting at bit #0 of serial data A register and continuously extending to bit #28.

PowerBrick[].Chan[].SerialEncDataA

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Single-Turn Position DataMulti-Turn Position Data

0 1 0 0 1 D 0 0

Motor[].AbsPosFormat = $

Serial data A start at bit 0

Serial data B, none

29 bits

01: signed binary

Motor[1].pAbsPos = PowerBrick[0].Chan[0].SerialEncDataA.a Motor[1].AbsPosSf = Motor[1].PosSf Motor[1].AbsPosFormat = $01001D00 Motor[1].HomeOffset = 0

Example: A 36-bit binary serial encoder with 24 bits of single-turn and 12 bits of multi-turn position data

starting at bit #0 of serial data A register and continuously extending to bit #3 of serial data register B.

PowerBrick[].Chan[].SerialEncDataA

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Single-Turn Position DataMulti-Turn Position Data

PowerBrick[].Chan[].SerialEncDataB

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Multi-Turn Position Data

0 1 0 0 2 4 0 0

Motor[].AbsPosFormat = $

Serial data A start at bit 0

Serial data B start at bit 0

36 bits

01: signed binary

Motor[1].pAbsPos = PowerBrick[0].Chan[0].SerialEncDataA.a Motor[1].AbsPosSf = Motor[1].PosSf Motor[1].AbsPosFormat = $01002400 Motor[1].HomeOffset = 0

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Example: A 36-bit binary serial encoder with 24 bits of single-turn in the lower fields of serial data register

A, and 12 bits of multi-turn position data in the lower fields of serial data register B.

PowerBrick[].Chan[].SerialEncDataA

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Single-Turn Position Data

PowerBrick[].Chan[].SerialEncDataB

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Multi-Turn Position Data

The single turn data must be shifted 8 bits left first, to make it contiguous with the multi-turn data. This shift is done using the upper 5 bits of the $aa byte of Motor[].AbsPosFormat. The data would then look like:

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8 1 0 0 2 4 0 8

Motor[].AbsPosFormat = $

Serial data A start at bit 8

Serial data B start at bit 0

36 bits

01: signed binary

Shift data A left 8 bits

Motor[1].pAbsPos = PowerBrick[0].Chan[0].SerialEncDataA.a Motor[1].AbsPosSf = Motor[1].PosSf Motor[1].AbsPosFormat = $81002408 Motor[1].HomeOffset = 0

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Example: A 32-bit Gray code serial encoder with 20 bits of single-turn in serial data register A starting at

bit #4, and 12 bits of multi-turn position data in serial data register B starting at bit #8.

PowerBrick[].Chan[].SerialEncDataA

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Single-Turn Position Data

PowerBrick[].Chan[].SerialEncDataB

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Multi-Turn Position Data

The single turn data must be shifted 8 bits left first. This shift is done using the upper 5 bits of the $aa byte of Motor[].AbsPosFormat. The data would then look like:

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8 3 0 8 2 0 0 C

Motor[].AbsPosFormat = $

Serial data A start at bit 12

Serial data B start at bit 8

32 bits

011 ($3) Gray Code

Shift data A left 8 bits

Motor[1].pAbsPos = PowerBrick[0].Chan[0].SerialEncDataA.a Motor[1].AbsPosSf = Motor[1].PosSf Motor[1].AbsPosFormat = $8308200C Motor[1].HomeOffset = 0

Note

Encoders with multi-turn position data are typically set up as signed.

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Example: A 33-bit binary serial encoder (for example, Panasonic) with 17 bits of single-turn and 16 bits

of multi-turn position data in the following fields:

PowerBrick[].Chan[].SerialEncDataA

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Single-Turn Position DataMulti-Turn Position Data

PowerBrick[].Chan[].SerialEncDataB

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Multi-Turn Position Data

The automatic settings are not suitable for the discontinuity between the single-turn and multi-turn data. We will assemble the absolute position word manually (in a background or initialization PLC), and hold the data in two consecutive open memory registers to feed the automatic settings. Below is the example PLC for performing this operation:

GLOBAL Enc1StData; GLOBAL Enc1MtData; GLOBAL Enc1Data;

#define Enc1AbsPos1 Sys.Udata[10] #define Enc1AbsPos2 Sys.Udata[11]

OPEN PLC PanasonicAbsPosPLC

LOCAL Enc1MtDataA, Enc1MtDataB;

Enc1StData = PowerBrick[0].Chan[0].SerialEncDataA & $1FFFF; Enc1MtDataA = (PowerBrick[0].Chan[0].SerialEncDataA & $FF000000) >> 24; Enc1MtDataB = PowerBrick[0].Chan[0].SerialEncDataB & $000000FF; Enc1MtData = Enc1MtDataA + Enc1MtDataB * EXP2(8);

IF (Enc1MtData > 32768) // NEGATIVE?

{ Enc1Data = (Enc1StData - 131072) + (Enc1MtData - 65535) * EXP2(17); }

ELSE // POSITIVE?

{ Enc1Data = Enc1StData + Enc1MtData * EXP2(17); } Enc1AbsPos1 = Enc1Data & $FFFFFFFF; Enc1AbsPos2 = (Enc1Data >> 31) & $1;

DISABLE PLC PanasonicAbsPosPLC;

The automatic settings can now be set up to read the absolute position at the first corresponding user defined register:

0 1 0 0 2 1 0 0

Motor[].AbsPosFormat = $

Sys.Udata[10] start at bit 0

Sys.Udata[11] start at bit 0

33 bits

01: signed binary

Motor[1].pAbsPos = Sys.Udata[10].a Motor[1].AbsPosSf = Motor[1].PosSf Motor[1].AbsPosFormat = $01002100 Motor[1].HomeOffset = 0

Once the example code in the sample PLC is executed, an HMZ command can be issued for an absolute position read.

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X9 – X12: Analog Inputs / Outputs

Each of the analog I/O connectors (X9, X10, X11, and X12) provides:

➢ 2 x 16-bit Analog Inputs ➢ 2 x ~14-bit Analog Outputs ➢ 2 x General Purpose Relays ➢ 2 x General Purpose Inputs / External Amp Faults

X9-X10: D-Sub DE-15 F

Mating: D-Sub DE-15 M

245 3

7 6910 8

12 111415 13

Pin #

Symbol

Function

Description

AGND

Ground

Common Analog Ground

DAC1-

Output

Analog Output 1-

AE-NO1

Relay

Normally Open GP Relay / Brake 1

ADC2+

Input

Analog Input 2+

AE-COM2

Common

GP Relay / Brake Common 2

ADC1-

Input

Analog Input 1-

DAC1+

Output

Analog Output 1+

AMPFLT1

Input

GP Input / Ext Amp Fault 1

DAC2-

Output

Analog Output 2-

AE-NO2

Relay

Normally Open GP Relay / Brake 2

ADC1+

Input

Analog Input 1+

AE-COM1

Common

GP Relay / Brake Common 1

ADC2-

Input

Analog Input 2-

DAC2+

Output

Analog Output 2+

AMPFLT2

Input

GP / Amp Fault Input 2

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Setting up the Analog (ADC) Inputs

The analog inputs accept ±5 V differential signals, or ±10 V single-ended signals.

Differential Analog Input Signal

Single Ended Analog Input Signal

7 6910 8

ADC1+

ADC1-

AGND

7 6910 8

ADC1+

ADC1-

AGND

Note

For single-ended connections, tie the negative ADC pin to ground.

The ADC software data resides in the upper 16 bits of the 32-bit structure element PowerBrick[].Chan[].AdcAmp[2]. The structure elements do not allow bit masking (of the upper 16 bits), hence scaling (shifting) is required to obtain the raw ADC data. Using the explicit address registers makes bit masking easier:

Channel /

Connector

Address

Structure Element

ADC 1, X9

$900028

PowerBrick[0].Chan[0].AdcAmp[2]

ADC 2, X9

$9000A8

PowerBrick[0].Chan[1].AdcAmp[2]

ADC 1, X10

$900128

PowerBrick[0].Chan[2].AdcAmp[2]

ADC 2, X10

$9001A8

PowerBrick[0].Chan[3].AdcAmp[2]

Channel /

Connector

Address

Structure Element

ADC 1, X11

$904028

PowerBrick[1].Chan[0].AdcAmp[2]

ADC 2, X11

$9040A8

PowerBrick[1].Chan[1].AdcAmp[2]

ADC 1, X12

$904128

PowerBrick[1].Chan[2].AdcAmp[2]

ADC 2, X12

$9041A8

PowerBrick[1].Chan[3].AdcAmp[2]

Note

The explicit address register(s) can be found by subtracting Sys.piom from PowerBrick[].Chan[].AdcAmp[2].a

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Note

The ADC input data must be in the “unpacked” format to be read

properly; use PowerBrick[].Chan[].PackInData = 0.

Raw ADC Data (bits)

PowerBrick[0].Chan[0].PackInData = 0 // Unpack Input Data PowerBrick[0].Chan[1].PackInData = 0 // Unpack Input Data PowerBrick[0].Chan[2].PackInData = 0 // Unpack Input Data PowerBrick[0].Chan[3].PackInData = 0 // Unpack Input Data PowerBrick[1].Chan[0].PackInData = 0 // Unpack Input Data PowerBrick[1].Chan[1].PackInData = 0 // Unpack Input Data PowerBrick[1].Chan[2].PackInData = 0 // Unpack Input Data PowerBrick[1].Chan[3].PackInData = 0 // Unpack Input Data

PTR ADC1X9 ->S.IO:$900028.16.16; // ADC1 X9 [Counts] PTR ADC2X9 ->S.IO:$9000A8.16.16; // ADC2 X9 [Counts] PTR ADC1X10->S.IO:$900128.16.16; // ADC1 X10 [Counts] PTR ADC2X10->S.IO:$9001A8.16.16; // ADC2 X10 [Counts] PTR ADC1X11->S.IO:$904028.16.16; // ADC1 X11 [Counts] PTR ADC2X11->S.IO:$9040A8.16.16; // ADC2 X11 [Counts] PTR ADC1X12->S.IO:$904128.16.16; // ADC1 X12 [Counts] PTR ADC2X12->S.IO:$9041A8.16.16; // ADC2 X12 [Counts]

The analog inputs have 16 bits of resolution (65,536 software counts) spanning over the full range of the input voltage. Wiring ±10 V voltage in single-ended, or ±5 V in differential mode produces the following counts in software:

Single-Ended

[VDC]

Differential

[VDC]

Software

Counts

-10

-5

-32768 0 0

+32768

Scaling the analog input Data

For general purpose usage, the ADC data (reported in bits) can be easily scaled and converted into “user” voltage or units (e.g. force, height). In the example PLC below:

➢ The global parameter ADCnXxxZeroOffset represents the voltage offset with a zero volt input.

This is user adjustable.

➢ The pointer ADCnXxx reports the raw ADC data in software counts, units of 16-bit (±32768). ➢ The global parameter ADCnXxxVolts reports the ADC data in “user” volts.

Where n is the ADC channel number (1 or 2) of the corresponding xx connector (X9, X10, X11, or X12).

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GLOBAL ADC1X9Volts = 0; // Voltage input, ADC1 X9 [volt] GLOBAL ADC2X9Volts = 0; // Voltage input, ADC2 X9 [volt] GLOBAL ADC1X10Volts = 0; // Voltage input, ADC1 X10 [volt] GLOBAL ADC2X10Volts = 0; // Voltage input, ADC2 X10 [volt] GLOBAL ADC1X11Volts = 0; // Voltage input, ADC1 X11 [volt] GLOBAL ADC2X11Volts = 0; // Voltage input, ADC2 X11 [volt] GLOBAL ADC1X12Volts = 0; // Voltage input, ADC1 X12 [volt] GLOBAL ADC2X12Volts = 0; // Voltage input, ADC2 X12 [volt]

GLOBAL ADC1X9ZeroOffset = 0.038; // Zero Volt Offset, ADC1 X9 [volt] --USER ADJUSTABLE GLOBAL ADC2X9ZeroOffset = 0.038; // Zero Volt Offset, ADC2 X9 [volt] --USER ADJUSTABLE GLOBAL ADC1X10ZeroOffset = 0.038; // Zero Volt Offset, ADC1 X10 [volt] --USER ADJUSTABLE GLOBAL ADC2X10ZeroOffset = 0.038; // Zero Volt Offset, ADC2 X10 [volt] --USER ADJUSTABLE GLOBAL ADC1X11ZeroOffset = 0.038; // Zero Volt Offset, ADC1 X11 [volt] --USER ADJUSTABLE GLOBAL ADC2X11ZeroOffset = 0.038; // Zero Volt Offset, ADC2 X11 [volt] --USER ADJUSTABLE GLOBAL ADC1X12ZeroOffset = 0.038; // Zero Volt Offset, ADC1 X12 [volt] --USER ADJUSTABLE GLOBAL ADC2X12ZeroOffset = 0.038; // Zero Volt Offset, ADC2 X12 [volt] --USER ADJUSTABLE

OPEN PLC ExamplePLC

ADC1X9Volts = (ADC1X9 * 10 / 32768) - ADC1X9ZeroOffset // ADC1, X9 [volts] ADC2X9Volts = (ADC2X9 * 10 / 32768) - ADC2X9ZeroOffset // ADC2, X9 [volts] ADC1X10Volts = (ADC1X10 * 10 / 32768) - ADC1X10ZeroOffset // ADC1, X10 [volts] ADC2X10Volts = (ADC2X10 * 10 / 32768) - ADC2X10ZeroOffset // ADC2, X10 [volts] ADC1X11Volts = (ADC1X11 * 10 / 32768) - ADC1X11ZeroOffset // ADC1, X11 [volts] ADC2X11Volts = (ADC2X11 * 10 / 32768) - ADC2X11ZeroOffset // ADC2, X11 [volts] ADC1X12Volts = (ADC1X12 * 10 / 32768) - ADC1X12ZeroOffset // ADC1, X12 [volts] ADC2X12Volts = (ADC2X12 * 10 / 32768) - ADC2X12ZeroOffset // ADC2, X12 [volts]

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Using the ADC for Servo Feedback

Using the ADC data for servo feedback requires bringing it into the Encoder Conversion Table (ECT) into which the motor’s position and velocity elements are assigned to.

Example:

EncTable[9].Type = 1 EncTable[9].pEnc = PowerBrick[0].Chan[0].AdcAmp[2].a EncTable[9].pEnc1 = Sys.pushm EncTable[9].index1 = 16 EncTable[9].index2 = 16 EncTable[9].index3 = 0 EncTable[9].index4 = 0 EncTable[9].index5 = 0 EncTable[9].index6 = 0 EncTable[9].ScaleFactor = 1 / EXP2(16)

Motor[9].PosSf = 1 Motor[9].pEnc = EncTable[9].a Motor[9].pEnc2 = EncTable[9].a

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Setting up the Analog (DAC) Outputs

The analog outputs provide ±10 V signals interfacing to either differential or single-ended devices.

Differential DAC Output Signal

Single Ended DAC Output Signal

245 3

7 6910 8

12 111415 13

DAC1+

DAC1-

AGND

Analog

Device

245 3

7 6910 8

12 111415 13

DAC1+

AGND

Analog

Device

The analog output circuitry is filtered PWM optimized (in hardware) for a PWM cut off frequency of about 15 kHz. The recommended PWM frequency of 10 kHz in the Power Brick AC should be good enough for general purpose usage.

Note

These analog outputs are synthesized filtered PWM. They are designed for general purpose use; they are not industrially graded for servo use. True DAC outputs are typically used in servo applications.

The analog output command data resides in the upper 16 bits of the 32-bit structure element PowerBrick[].Chan[].Pwm[3]. The structure elements do not allow bit masking (of the upper 16 bits), hence scaling (shifting) is required to write to the outputs properly. Using the explicit address registers makes it easier for bit masking:

Channel /

Connector

Address

Channel /

Connector

Address

Channel 1, X9

$90004C

Channel 1, X11

$90404C

Channel 2, X9

$9000CC

Channel 2, X11

$9040CC

Channel 1, X10

$90014C

Channel 1, X12

$90414C

Channel 2, X10

$9001CC

Channel 2, X12

$9041CC

Note

The explicit address register(s) can be found by subtracting Sys.piom from PowerBrick[].Chan[].Pwm[3].a

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Note

Writing directly into PowerBrick[].Chan[].Pwm[3] register to produce voltage output requires shifting left by 16 bits (or multiplying by 65536).

Note

The command output data must be in the “unpacked” format;

PowerBrick[].Chan[].PackOutData = 0.

Note

The analog outputs are generated from the fourth output channel, phase D. Therefore, it must be set for PWM mode.

Command Register Pointers

PowerBrick[0].Chan[0].PackOutData = 0 // DAC1, X9, Unpack Output Data PowerBrick[0].Chan[1].PackOutData = 0 // DAC2, X9, Unpack Output Data PowerBrick[0].Chan[2].PackOutData = 0 // DAC1, X10, Unpack Output Data PowerBrick[0].Chan[3].PackOutData = 0 // DAC2, X10, Unpack Output Data PowerBrick[1].Chan[0].PackOutData = 0 // DAC1, X11, Unpack Output Data PowerBrick[1].Chan[1].PackOutData = 0 // DAC2, X11, Unpack Output Data PowerBrick[1].Chan[2].PackOutData = 0 // DAC1, X12, Unpack Output Data PowerBrick[1].Chan[3].PackOutData = 0 // DAC2, X12, Unpack Output Data

PowerBrick[0].Chan[0].OutputMode = PowerBrick[0].Chan[0].OutputMode & $7 // D phase PWM PowerBrick[0].Chan[1].OutputMode = PowerBrick[0].Chan[1].OutputMode & $7 // D phase PWM PowerBrick[0].Chan[2].OutputMode = PowerBrick[0].Chan[2].OutputMode & $7 // D phase PWM PowerBrick[0].Chan[3].OutputMode = PowerBrick[0].Chan[3].OutputMode & $7 // D phase PWM PowerBrick[1].Chan[0].OutputMode = PowerBrick[1].Chan[0].OutputMode & $7 // D phase PWM PowerBrick[1].Chan[1].OutputMode = PowerBrick[1].Chan[1].OutputMode & $7 // D phase PWM PowerBrick[1].Chan[2].OutputMode = PowerBrick[1].Chan[2].OutputMode & $7 // D phase PWM PowerBrick[1].Chan[3].OutputMode = PowerBrick[1].Chan[3].OutputMode & $7 // D phase PWM

PTR DAC1X9-> S.IO:$90004C.16.16; // DAC Channel 1, X9 [Counts] PTR DAC2X9-> S.IO:$9000CC.16.16; // DAC Channel 2, X9 [Counts] PTR DAC1X10->S.IO:$90014C.16.16; // DAC Channel 1, X10 [Counts] PTR DAC2X10->S.IO:$9001CC.16.16; // DAC Channel 2, X10 [Counts] PTR DAC1X11->S.IO:$90404C.16.16; // DAC Channel 1, X11 [Counts] PTR DAC2X11->S.IO:$9040CC.16.16; // DAC Channel 2, X11 [Counts] PTR DAC1X12->S.IO:$90414C.16.16; // DAC Channel 1, X12 [Counts] PTR DAC2X12->S.IO:$9041CC.16.16; // DAC Channel 2, X12 [Counts]

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The effective resolution of the analog output circuitry is about ~13.5 bits (±13380 software counts) spanning over the full output range of ±10 V (saturates at about ~10.5 Volts). Writing to the user defined

DACnXxxInBits pointer produces the following voltage output:

DACnXxxInBits

Single Ended [VDC]

Differential [VDC]

-13380

-10

-20

0 0 0

13380

+10

+20

Note

The output voltage is measured between AGND and DAC+ in singleended mode. And between DAC- and DAC+ in differential mode.

Scaled DAC Output (In Volts)

The outputs can be scaled and converted into “user” voltage units. The following example PLC scales the

data as needed to allow the user to command the output in units of volts:

➢ The global parameter(s) DACnXxxZeroOffset represents the voltage offset (as seen on a digital

multi-meter or scope) when an output of zero is commanded. This is user adjustable.

➢ The global parameter DACnXxxCtPerVolt acts a software adjustment pot which the user can

calibrate for at the rails (±10 V) of the output.

➢ The global parameter DACnXxxVolts is the output command in volts

Where n is the DAC channel number (1 or 2) of the corresponding xx connector (X9, X10, X11, or X12).

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Example Code:

GLOBAL DAC1X9Volts = 0; // DAC Channel 1, X9 [volts] GLOBAL DAC2X9Volts = 0; // DAC Channel 2, X9 [volts] GLOBAL DAC1X10Volts = 0; // DAC Channel 1, X10 [volts] GLOBAL DAC2X10Volts = 0; // DAC Channel 2, X10 [volts] GLOBAL DAC1X11Volts = 0; // DAC Channel 1, X11 [volts] GLOBAL DAC2X11Volts = 0; // DAC Channel 2, X11 [volts] GLOBAL DAC1X12Volts = 0; // DAC Channel 1, X12 [volts] GLOBAL DAC2X12Volts = 0; // DAC Channel 2, X12 [volts]

GLOBAL DAC1X9ZeroOffset = 0.05; // DAC1 X9, Zero Volt offset [volts] --USER ADJUSTABLE GLOBAL DAC2X9ZeroOffset = 0.05; // DAC2 X9, Zero Volt offset [volts] --USER ADJUSTABLE GLOBAL DAC1X10ZeroOffset = 0.05; // DAC1 X10, Zero Volt offset [volts] --USER ADJUSTABLE GLOBAL DAC2X10ZeroOffset = 0.05; // DAC2 X10, Zero Volt offset [volts] --USER ADJUSTABLE GLOBAL DAC1X11ZeroOffset = 0.05; // DAC1 X11, Zero Volt offset [volts] --USER ADJUSTABLE GLOBAL DAC2X11ZeroOffset = 0.05; // DAC2 X11, Zero Volt offset [volts] --USER ADJUSTABLE GLOBAL DAC1X12ZeroOffset = 0.05; // DAC1 X12, Zero Volt offset [volts] --USER ADJUSTABLE GLOBAL DAC2X12ZeroOffset = 0.05; // DAC2 X12, Zero Volt offset [volts] --USER ADJUSTABLE

GLOBAL DAC1X9CtPerVolt = 1338; // DAC1 X9, Scale Factor Counts/Volt --USER ADJUSTABLE GLOBAL DAC2X9CtPerVolt = 1338; // DAC2 X9, Scale Factor Counts/Volt --USER ADJUSTABLE GLOBAL DAC1X10CtPerVolt = 1338; // DAC1 X10, Scale Factor Counts/Volt --USER ADJUSTABLE GLOBAL DAC2X10CtPerVolt = 1338; // DAC2 X10, Scale Factor Counts/Volt --USER ADJUSTABLE GLOBAL DAC1X11CtPerVolt = 1338; // DAC1 X11, Scale Factor Counts/Volt --USER ADJUSTABLE GLOBAL DAC2X11CtPerVolt = 1338; // DAC2 X11, Scale Factor Counts/Volt --USER ADJUSTABLE GLOBAL DAC1X12CtPerVolt = 1338; // DAC1 X12, Scale Factor Counts/Volt --USER ADJUSTABLE GLOBAL DAC2X12CtPerVolt = 1338; // DAC2 X12, Scale Factor Counts/Volt --USER ADJUSTABLE

OPEN PLC ExamplePLC

DAC1X9 = (DAC1X9Volts - DAC1X9ZeroOffset) * ABS(DAC1X9CtPerVolt) DAC2X9 = (DAC2X9Volts - DAC2X9ZeroOffset) * ABS(DAC2X9CtPerVolt) DAC1X10 = (DAC1X100Volts - DAC1X10ZeroOffset) * ABS(DAC1X10CtPerVolt) DAC2X10 = (DAC2X100Volts - DAC2X10ZeroOffset) * ABS(DAC2X10CtPerVolt) DAC1X11 = (DAC1X111Volts - DAC1X11ZeroOffset) * ABS(DAC1X11CtPerVolt) DAC2X11 = (DAC2X111Volts - DAC2X11ZeroOffset) * ABS(DAC2X11CtPerVolt) DAC1X12 = (DAC1X122Volts - DAC1X12ZeroOffset) * ABS(DAC1X12CtPerVolt) DAC2X12 = (DAC2X122Volts - DAC2X12ZeroOffset) * ABS(DAC2X12CtPerVolt)

Note

Using this example code, the user can command the output by writing to DACnXxxVolts in units of volts.

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Setting up the General Purpose Relays

This normally open general purpose relay is operated by the structure element bit

PowerBrick[].Chan[].OutFlagC.

Channel /

Connector

Structure element bit

Channel /

Connector

Structure element bit

Relay 1, X9

PowerBrick[0].Chan[0].OutFlagC

Relay 1, X9

PowerBrick[1].Chan[0].OutFlagC

Relay 2, X9

PowerBrick[0].Chan[1].OutFlagC

Relay 2, X9

PowerBrick[1].Chan[1].OutFlagC

Relay 1, X10

PowerBrick[0].Chan[2].OutFlagC

Relay 1, X10

PowerBrick[1].Chan[2].OutFlagC

Relay 2, X10

PowerBrick[0].Chan[3].OutFlagC

Relay 2, X10

PowerBrick[1].Chan[3].OutFlagC

If PowerBrick[].Chan[].OutFlagC = 0, the circuit between the common pin and the Relay pin is open. If PowerBrick[].Chan[].OutFlagC = 1, the circuit between the common pin and the Relay pin is closed.

Structure Element Bit

Connection between

Pin #3 and Pin #12

Connection between

Pin #10 and Pin #5

PowerBrick[].Chan[].OutFlagC = 0

Open

PowerBrick[].Chan[].OutFlagC = 1

Closed

The relay can be wired so that the current is either sourcing from or sinking into the Power Brick AC.

Sourcing

Sinking

245 3

7 6910 8

12 111415 13

Controlled

Device

+24 V

RET

Power Supply

+24 V COM

Rly COM1

NO Rly1

245 3

7 6910 8

12 111415 13

Controlled

Device

RET

+24 V

Power Supply

COM +24 V

Rly COM1

NO Rly1

Caution

In sourcing mode, do NOT pass through voltage higher than 24 VDC.

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Note

The commons of the general purpose inputs / amp faults (pins #8, and #15) are tied internally to relay commons 1 and 2 respectively. If the relay is wired in sourcing mode, that general purpose input cannot be used.

The structure element bits can be assigned to user defined pointers:

PTR GPRelay1X9->PowerBrick[0].Chan[0].OutFlagC; // GP Relay 1, X9 PTR GPRelay2X9->PowerBrick[0].Chan[1].OutFlagC; // GP Relay 2, X9 PTR GPRelay1X10->PowerBrick[0].Chan[2].OutFlagC; // GP Relay 1, X10 PTR GPRelay2X10->PowerBrick[0].Chan[3].OutFlagC; // GP Relay 2, X10

PTR GPRelay1X11->PowerBrick[1].Chan[0].OutFlagC; // GP Relay 1, X11 PTR GPRelay2X11->PowerBrick[1].Chan[1].OutFlagC; // GP Relay 2, X11 PTR GPRelay1X12->PowerBrick[1].Chan[2].OutFlagC; // GP Relay 1, X12 PTR GPRelay2X12->PowerBrick[1].Chan[3].OutFlagC; // GP Relay 2, X12

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Setting up the GP Input

This input provides a general purpose input coming from an external device (e.g. amplifier fault). It is a single-ended 5 V TTL level input.

Note

The commons of the general purpose inputs / amp faults (pins #8 and #15) are tied internally to relay commons 1 and 2 respectively (pins #5 and #12). If the relay is wired in sourcing mode, creating voltage potential at the common, this GP input cannot be used.

245 3

7 6910 8

12 111415 13

Power Supply

COM

Input

Switch 1

Input

Switch 2

+5 V

The structure element bit reflecting the status of this input is PowerBrick[].Chan[].T. It is a low true input, meaning it is =1 when 0 V is connected and =0 when +5 V is connected.

PTR GpIn1X9->PowerBrick[0].Chan[0].T; // Channel 1, X9 Input PTR GpIn2X9->PowerBrick[0].Chan[1].T; // Channel 2, X9 Input PTR GpIn1X10->PowerBrick[0].Chan[2].T; // Channel 1, X10 Input PTR GpIn2X10->PowerBrick[0].Chan[3].T; // Channel 2, X10 Input

PTR GpIn1X11->PowerBrick[1].Chan[0].T; // Channel 1, X11 Input PTR GpIn2X11->PowerBrick[1].Chan[1].T; // Channel 2, X11 Input PTR GpIn1X12->PowerBrick[1].Chan[2].T; // Channel 1, X12 Input PTR GpIn2X12->PowerBrick[1].Chan[3].T; // Channel 2, X12 Input