Delta Tau Power PMAC Clipper User Manual

Single Source Machine Control

……………………………………………..…...……………….

Power // Flexibility // Ease of Use

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

^1 User Manual

^3Power PMAC Clipper

^4 4-4050xx0-xx0-xxx0xx

April 15, 2016

DELTA TAU

Data Systems, Inc.

NEW IDEAS IN MOTION …

^2 Power PMAC Clipper

Power PMAC Clipper User Manual

Copyright Information

© 2016 Delta Tau Data Systems, Inc. All rights reserved.
This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses

are unauthorized without written permission of Delta Tau Data Systems, Inc.
Information contained in this manual may be updated from time-to-time due to product
improvements, etc., and may not conform in every respect to former issues.

To report errors or inconsistencies, call or email:

Delta Tau Data Systems, Inc. Technical Support

Phone: [phone]
Fax: [phone]
Email: [e-mail]
Website: http://www.deltatau.com

Operating Conditions

All Delta Tau Data Systems, Inc. motion controller products, accessories, and amplifiers
contain static sensitive components that can be damaged by incorrect handling. When
installing or handling Delta Tau Data Systems, Inc. products, avoid contact with highly
insulated materials. Only qualified personnel should be allowed to handle this
equipment.

In the case of industrial applications, we expect our products to be protected from
hazardous or conductive materials and/or environments that could cause harm to the
controller by damaging components or causing electrical shorts. When our products are
used in an industrial environment, install them into an industrial electrical cabinet or
industrial PC to protect them from excessive or corrosive moisture, abnormal ambient
temperatures, and conductive materials. If Delta Tau Data Systems, Inc. products are
directly exposed to hazardous or conductive materials and/or environments, we cannot
guarantee their operation.

Power PMAC Clipper User Manual

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.

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.

Power PMAC Clipper User Manual

REVISION HISTORY

REV.

DESCRIPTION

DATE

CHG

APPVD

0

Preliminary

10/13/14

Sgm

1

Released

07/21/15

RN

RN

2

Update motor setup

04/15/16

Sgm

Sgm

Power PMAC Clipper User Manual

Table of Contents

INTRODUCTION ....................................................................................................................................... 9

Documentation .............................................................................................................................................. 9

Downloadable Power PMAC Script ........................................................................................................... 10

SPECIFICATIONS ................................................................................................................................... 11

Part Number ................................................................................................................................................ 11

Standard Configuration ............................................................................................................................... 11

Options ........................................................................................................................................................ 12

Accessories ................................................................................................................................................. 13

Environmental Specifications ..................................................................................................................... 16

Electrical Specifications .............................................................................................................................. 17

Digital Power Supply ............................................................................................................................. 17

DAC Outputs Power Supply .................................................................................................................. 17

Flags Power Supply ............................................................................................................................... 17

RECEIVING AND UNPACKING .......................................................................................................... 18

Use of Equipment ....................................................................................................................................... 18

MOUNTING .............................................................................................................................................. 19

Physical Specifications ............................................................................................................................... 20

Board Dimensions Rev101 .................................................................................................................... 20

Board Layout Rev101 ............................................................................................................................ 20

CONNECTIONS AND SOFTWARE SETUP ....................................................................................... 21

Default Jumper Configurations ................................................................................................................... 21

TB1 (JPWR): Power Supply Input.............................................................................................................. 21

J2: Serial Port .............................................................................................................................................. 23

J3: Machine Connector (JMACH1 Port) .................................................................................................... 24

Configuring Quadrature Encoders ........................................................................................................ 27

Wiring the DAC Output ......................................................................................................................... 29

Amplifier Enable Signal (AENAn/DIRn) ............................................................................................... 31

Amplifier Fault Signal (FAULT-) .......................................................................................................... 32

Analog Inputs ......................................................................................................................................... 33

Setting up the Analog (ADC) Inputs ...................................................................................................... 33

J4: Machine Connector (JMACH2 Port) .................................................................................................... 36

Overtravel Limits and Home Switches ................................................................................................... 37

Wiring the Limits and Flags .................................................................................................................. 37

Limits and Flags [Axis 1- 4] Structure Elements .................................................................................. 40

Step and Direction PFM Output (To External Stepper Amplifier) ........................................................ 41

Compare Equal Outputs ........................................................................................................................ 42

J7: Machine Connector (JMACH3 Port) .................................................................................................... 43

Brake Software Setup ............................................................................................................................. 44

Serial Encoder Software Setup .............................................................................................................. 44

J8: Thumbwheel Multiplexer Port (JTHW Port) ........................................................................................ 50

Table Of Contents vi

Power PMAC Clipper User Manual

Thumbwheel Port Digital Inputs and Outputs ....................................................................................... 51

Configuring Multiplexed I/O on the JTHW port .................................................................................... 51

J9: General-Purpose Digital Inputs and Outputs (JOPT Port) .................................................................... 53

General Purpose I/O (J6) Structures ..................................................................................................... 54

J10: Handwheel and Pulse/Dir Connector (JHW/PD Port) ......................................................................... 56

Handwheel Encoder Software Setup...................................................................................................... 57

Handwheel PFM Software Setup ........................................................................................................... 57

Handwheel Option-12 DAC Software Setup .......................................................................................... 57

Handwheel 5th motor using the Option -12 DAC .................................................................................. 58

P2: USB Device Port .................................................................................................................................. 59

P20: EtherCat™/Ethernet Communications Port ........................................................................................ 59

P21: Ethernet Communications Port ........................................................................................................... 59

P17: USB Communications Port ................................................................................................................ 59

LED Indicators ............................................................................................................................................ 59

DRIVE - MOTOR SETUP ....................................................................................................................... 60

Filtered PWM Output (Analog ±10V) ........................................................................................................ 61

Clock Settings, Output Mode, Command Limit ..................................................................................... 61

Typical Motor Specific Settings ............................................................................................................. 61

Open Loop Test: Encoder/Decode ......................................................................................................... 62

Position-Loop PID Gains ...................................................................................................................... 63

Typical Settings for Four Channels of Filtered PWM Setup: ................................................................ 64

Pulse Frequency Modulation Output (Step and Direction) ......................................................................... 66

Multi-Channel Setup Elements .............................................................................................................. 66

Channel-Specific Setup Elements .......................................................................................................... 66

Motor-Specific Setup Elements .............................................................................................................. 67

Typical Settings for Four Channels of Open Loop PFM Setup: ............................................................ 68

ACC-24S3 4-CHANNEL AXIS EXPANSION STACK BOARD ......................................................... 70

Hardware Assembly .................................................................................................................................... 70

Default Jumper Configurations ................................................................................................................... 72

TB1 (JPWR): Power Supply Input.............................................................................................................. 73

J3: Machine Connector (JMACH1 Port) .................................................................................................... 74

Configuring Quadrature Encoders ........................................................................................................ 74

Wiring the DAC Output ......................................................................................................................... 74

Amplifier Enable Signal (AENAn/DIRn) ............................................................................................... 75

Amplifier Fault Signal (FAULT-) .......................................................................................................... 75

Analog Inputs ......................................................................................................................................... 75

Setting up the Analog (ADC) Inputs ...................................................................................................... 75

J4: Machine Connector (JMACH2 Port) .................................................................................................... 77

Limits and Flags [Axis 1- 4] Structure Elements .................................................................................. 77

Step and Direction PFM Output (To External Stepper Amplifier) ........................................................ 78

Compare Equal Outputs ........................................................................................................................ 78

J7: Machine Connector (JMACH3 Port) .................................................................................................... 79

Brake Software Setup ............................................................................................................................. 79

Serial Encoder Software Setup .............................................................................................................. 79

Table Of Contents vii

Power PMAC Clipper User Manual

J8: Thumbwheel Multiplexer Port (JTHW Port) ........................................................................................ 80

Thumbwheel Port Digital Inputs and Outputs ....................................................................................... 80

Configuring Multiplexed I/O on the JTHW port .................................................................................... 80

J9: General-Purpose Digital Inputs and Outputs (JOPT Port) .................................................................... 81

General Purpose I/O (J6) Structures ..................................................................................................... 81

J10: Handwheel and Pulse/Dir Connector (JHW/PD Port) ......................................................................... 82

Handwheel Encoder Software Setup...................................................................................................... 82

Motor Setup Code ....................................................................................................................................... 83

Typical Settings for Four Channels of Filtered PWM Setup: ................................................................ 83

Typical Settings for Four Channels of Open Loop PFM Setup: ............................................................ 85

Table Of Contents viii

Power PMAC Clipper User Manual

Note

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

INTRODUCTION

The Power Clipper is a 4 axis motion controller combining the intelligence and capability of a Power
PMAC CPU with the convenience and savings of a low cost platform that is 100% hardware compatible
with its Turbo PMAC family member the Turbo PMAC Clipper.

It supports virtually any type of feedback device (with the optional ACC-84S and ACC-51S) and can
drive directly the following types of motors with the optional Clipper Drive Stack:

 3-phase AC/DC brushless servo (synchronous) -- rotary/linear
 2-phase stepper
 DC brush

The number of axes in a Power Clipper application can be expanded to 8 with the optional ACC-24S3.

The Power Clipper comes with 32 general-purpose digital I/O points which can be expanded through the
optional ACC-34AA, ACC-24S3 or EtherCat. These can be configured as input or outputs in groups of
eight. The default factory settings are 16 inputs and 16 outputs.

The outstanding trajectory planner, built-in software PLCs (programmable in Power PMAC script and / or
C language), and other features make the Power Clipper a very scalable machine automation controller­drive which can be virtually integrated in 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 Clipper:

 Power PMAC Software Reference Manual
 Power PMAC User Manual

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

Introduction 9

Power PMAC Clipper User Manual

Caution

Some code examples require the user to input specific information
pertaining to their system hardware. When user information is
required, a commentary ending with –User Input is inserted.

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.

Downloadable Power PMAC Script

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 format 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

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.

Introduction 10

Power PMAC Clipper User Manual

SPECIFICATIONS

Part Number

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

Standard Configuration

The standard configuration of the Power Clipper provides the following features:

CPU

 1.0 GHz Dual-Core Power PC 465EX CPU

Memory

 1 GB DDRAM3 active memory, 1 GB NAND Flash non-volatile memory

Communications Ports

 100 Mbps Ethernet port for host communications
 RS-232 port
 USB 2.0 Host port
 USB 2.0 Device port

Servo Interface

4 channels servo interface, each including:

 Quadrature encoder (with index) interface
 UVW digital Hall sensor interface

Specifications 11

Power PMAC Clipper User Manual

 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 II/III/V (no position reset or fault clear)
o Tamagawa FA-Coder
o Panasonic (no servo clock output)
o Mitutoyo
o Kawasaki
o Basic quadrature (no index, no capture)

 Filtered PWM analog output (~13-bit resolution)
 Pulse & direction output
 Input flags (home, +limit, -limit, user) at 5V CMOS levels (24V tolerant)
 Position compare (EQU) output
 Amplifier-enable output and amplifier-fault input flags
 Brake control output

General-Purpose I/O

 JIO Port: 16 5V CMOS I/O points, direction selectable by byte (flat cable connection to Opto-22

or equivalent)

 JTHW Port: 16 5V CMOS I/O points, direction selectable by byte (flat cable connection to Delta

Tau ACC-34x boards)

Stacking Connector Configuration

The standard configuration of the Power Clipper comes with:

 The “short-pin” version of the expansion port connectors. These support accessories that stack on

top of the Power Clipper (e.g. ACC-24S3, 8AS, 8FS, 8TS, 51S, and 84S), but not those that stack
under it (e.g. LV Stack Amplifier).

 The “short-pin” version of the right-angle box header connectors. These support flat cable

connections to field wiring, but not connections through breakout boards that stack under it (e.g.
Delta Tau’s stack breakout board or custom breakout boards).

Options

The following options can be ordered for the Power Clipper board:

CPU Options

 1.2 GHz Dual-Core Power PC 465EX CPU

Memory Options

The following optional memory configurations can be ordered:

 1 GB DDRAM3 active memory, 4 GB NAND Flash non-volatile memory
 2 GB DDRAM3 active memory, 1 GB NAND Flash non-volatile memory
 2 GB DDRAM3 active memory, 4 GB NAND Flash non-volatile memory

Specifications 12

Power PMAC Clipper User Manual

Communications Port Options

Added Ethernet Port ,1 Gbps, EtherCAT compatible

EtherCAT Software License Options (require 2nd Ethernet port option)

When the second Ethernet port option is ordered, software license options can also be ordered to support
EtherCAT data transfers. The following software license options can be ordered:

 EtherCAT I/O only (no servo axes)
 EtherCAT I/O with 4 servo axes
 EtherCAT I/O with 8 servo axes
 EtherCAT I/O with 16 servo axes
 EtherCAT I/O with 32 servo axes
 EtherCAT I/O with 64 servo axes

Analog I/O Option

4-channels 12-bit ADC plus 1 additional channel filtered-PWM analog output (~13 bits)

Digital Laser Control Output Option

Programmable PWM laser-control IC with output drivers

Stacking Connector Options

 “Long-pin” version of expansion-port connectors to support communications interface to boards

that stack under Power Clipper (e.g. LV Stack Amplifier). “Short-pin” version of right-angle box

header connectors that only support flat cable connections for field wiring.

 “Long-pin” version of expansion-port connectors to support communications interface to boards

that stack under Power Clipper (e.g. LV Stack Amplifier). “Long-pin” version of right-angle box

header connectors to support connections through breakout boards that stack under it (e.g. Delta
Tau’s stack breakout board or custom breakout boards).

Accessories

The following accessory boards can be used with the Power Clipper board:

ACC-24S3 4-Channel Axis Expansion Stack Board

The ACC-24S3 can be stacked on top of the Power Clipper to provide an additional 4 channels of servo
interface circuitry and 32 additional digital I/O points equivalent to what is on the Power Clipper itself.
Optionally, it can provide 4 additional 12-bit ADCs and 1 additional filtered-PWM analog output (~13
bits).

Only one ACC-24S3 board can be used with the Power Clipper. If it is installed on top of the Power
Clipper, only one small stack board (ACC-8AS, 8FS, 8TS, 51S, 84S) can be installed directly on the
Power Clipper between it and the ACC-24S3. Two of these small stack boards can be installed on top of
the ACC-24S3.

ACC-8AS 4-Channel 2-Phase 16-Bit True-DAC Stack Board

The ACC-8AS can be stacked on top of either the Power Clipper or the ACC-24S3 to provide 4 channels
of 16-bit “true DAC” output with two DACs per channel. This board is mainly used for very high-
precision servo applications that require more resolution than the filtered-PWM analog outputs on the

Specifications 13

Power PMAC Clipper User Manual

Power Clipper and the ACC-24S3. The dual-phase DAC outputs support the “sine-wave output” control
mode where brushless motor commutation is performed by the Power PMAC.

The true-DAC outputs of the ACC-8AS can be used simultaneously with the filtered-PWM analog output
on the same channel of the Power Clipper or ACC-24S3 without interference.

ACC-8FS 4-Channel Direct-PWM Interface Stack Board

The ACC-8FS can be stacked on top of either the Power Clipper or the ACC-24S3 to provide 4 channels
of 3-phase direct-PWM output through Mini-D 36-pin connectors to “power block” amplifiers. This board
is mainly used for applications where the Power Clipper is performing both the commutation and digital
current loop closure for brushless motors.

The 3-phase PWM outputs of the ACC-8FS cannot be used simultaneously with the filtered-PWM analog
output on the same channel of the Power Clipper or ACC-24S3. However, they can be used
simultaneously with the PFM (pulse-and-direction) outputs of the same channel of the Power Clipper or
ACC-24S3 without interference.

The ADC inputs passed through the ACC-8FS can be used simultaneously with the Option 12 ADCs on
the Power Clipper or ACC-24S3 without interference.

ACC-8TS Bridge Stack Board to ACC-28B ADCs

The ACC-8TS can be stacked on top of either the Power Clipper or the ACC-24S3 to provide a flat-cable
interface to one or two ACC-28B 4-channel 16-bit ADC boards.

The ADC inputs passed through the ACC-8TS can be used simultaneously with the Option 12 ADCs on
the Power Clipper or ACC-24S3 without interference.

ACC-51S 4-Channel Sinusoidal Encoder Interpolator Stack Board

The ACC-51S can be stacked on top of either the Power Clipper or the ACC-24S3 to provide 4 channels
of sinusoidal encoder interpolation with 16,384 states per line.

The sinusoidal encoder inputs passed through the ACC-51S cannot be used simultaneously with the main
quadrature encoder inputs of the same channel of the Power Clipper or ACC-24S3 without interference.
However, it is possible to pass digital quadrature signals through the ACC-51S.

ACC-84S 4-Channel Serial Encoder Interface Stack Board

The ACC-84S can be stacked on top of either the Power Clipper or the ACC-24S3 to provide 4 channels
of serial-encoder interface. The ACC-84S can be ordered from the factory with a single encoder protocol
installed from the following list:

 EnDat2.2 with additional information, no delay compensation
 BiSS-B/C
 Yaskawa II/III/V with position reset and fault clear
 Tamagawa FA-Coder with servo clock output
 Matsushita (Nikon D)
 Mitsubishi
 SSI (no capabilities over Power Clipper’s built-in interface)
 Panasonic (no capabilities over Power Clipper’s built-in interface)
 Mitutoyo (no capabilities over Power Clipper’s built-in interface)

Specifications 14

Power PMAC Clipper User Manual

The serial-encoder inputs on the ACC-84S can be used simultaneously with the serial-encoder input on
the same channel of the Power Clipper or ACC-24S3 without interference.

Clipper 4-Channel Breakout Board

The Clipper 4-Channel Breakout Board can be stacked under the Power Clipper board to provide discrete
connectors for each channel and each I/O functionality. It also provides optical isolation and driver
circuitry for axis flags and general-purpose I/O.

The Clipper 4-Channel Breakout Board cannot be used to provide connections for the ACC-24S3 Axis
Expansion Board.

Clipper 4-Channel LV Stack Amplifier

The Clipper 4-Channel LV (Low-Voltage) Stack Amplifier can be stacked under the Power Clipper board
or its 4-Channel Breakout board to provide the power amplifier circuitry for 4 motors with up to 60VDC
supply and a rating of up to 5A(rms) continuous, 15A(rms) peak. Each motor can be 1-phase (e.g. DC
brush motor), 2-phase (e.g. stepper motor), or 3-phase (e.g. brushless servo motor).

The Clipper 4-Channel LV Stack Amplifier cannot be used to provide the power stage for the ACC-24S3
Axis Expansion Board.

ACC-28B 4-Channel 16-Bit ADC Board

The ACC-28B provides 2 or 4 channels of 16-bit A/D converters on a DIN-rail mountable board. It can
be connected to the Power Clipper or ACC-24S3 by flat cable through an ACC-8TS bridge stack board.

ACC-34 Family Multiplexed I/O Boards

The ACC-34 family of multiplexed I/O boards each provide 32 general-purpose digital inputs and 32
general-purpose digital outputs. Up to 32 of these DIN-rail mountable boards can be connected to the
JTHW multiplexer port on the Power Clipper through standard flat cables. Due to the multiplexed access
and serial data transfers, these I/O points cannot react as quickly as the I/O points on the Power Clipper
itself.

Specifications 15

Power PMAC Clipper User Manual

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

5% 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 ~ 3000m (3300 ~ 9840ft)

-0.01%/m

3000 ~ 4000m (9840 ~ 13000ft)

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

Cooling

Natural convection and built-in CPU fan

Standard IP Protection

IP20
IP 55 can be evaluated for custom applications

Environmental Specifications

Specifications 16

Power PMAC Clipper User Manual

Note

Clipper base board requires 2.75A with no other connections. Size
your application accordingly to your encoder load. The above assumes
typical encoder loads at ~100mA per encoder.

Electrical Specifications

Digital Power Supply

The +5V and ground reference lines from the power supply should be connected to TB1 terminal block of
the Power PMAC Clipper board using 18 AWG stranded wire. The power requirement (± 5%) is:

+5 V (20W) @ 3.5 A (Four-channel configuration with a typical load of encoders)
+5 V (20W) @ 5.5 A (Eight-channel ACC-24S3 configuration with a typical load of encoders)

DAC Outputs Power Supply

The ±12V lines from the supply, including the ground reference, can be brought in from the TB1 terminal
block.

+12 to +15 V (4.5W) @ 0.30 A (Four-channel configuration with a typical DAC load)

-12 to -15 V (3.8W) @ 0.25 A

+12 to +15 V (4.5W) @ 0.50 A (Eight-channel configuration with a typical DAC load)

-12 to -15 V (3.8W) @ 0.45 A

Flags Power Supply

Each channel of PMAC has five dedicated digital inputs on the machine connector: PLIMn, MLIMn
(overtravel limits), HOMEn (home flag), FAULTn (amplifier fault), and USERn. A power supply from 5
to 24V must be used to power the circuits related to these inputs. This power supply can be the same
used to Power PMAC Clipper and can be connected from the TB1 terminal block.

Specifications 17

Power PMAC Clipper User Manual

RECEIVING AND UNPACKING

Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the
Power PMAC Clipper 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 board.

 Remove the Power PMAC Clipper 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 board received is the same as the part number listed on the

purchase order.

 Inspect for external physical damage that may have been sustained during shipment and report

any damage immediately to the commercial carrier that delivered the board.

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

use proper procedures when handling the equipment.

 If the Power PMAC Clipper 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 PMAC Clipper:

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

components of such equipment.

 The Power PMAC Clipper must not be operated on power supply networks without a ground or

with an asymmetrical ground.

 If the Power PMAC Clipper is used in residential areas, or in business or commercial premises,

implement additional filtering measures.

 The Power PMAC Clipper may be operated only in a closed switchgear cabinet, taking into

account the ambient conditions defined in the environmental specifications.

Delta Tau guarantees the conformance of the Power PMAC Clippers with the standards for industrial
areas stated in this manual, only if Delta Tau components (cables, controllers, etc.) are used.

Receiving and Unpacking 18

Power PMAC Clipper User Manual

Caution

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

MOUNTING

The location of the Power PMAC Clipper 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 board.

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

 For effective cooling and maintenance, the Power PMAC Clipper should be mounted on a

smooth, non- flammable vertical or horizontal surface.

 At least 10 mm (0.4 inches) top and bottom clearance must be provided for air flow.
 Temperature, humidity and Vibration specifications should also be taken in account.

The Power PMAC Clipper can be mounted as a stand-alone controller using standoffs. At each of the
four corners of the board and at the center edges, there are mounting holes that can be used for this.

If the Power PMAC Clipper 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 standoffs pattern of the board.

The board can be mounted to the back panel using four standoffs and internal-tooth lock washers. It is

important that the teeth break through any anodization on the board’s mounting gears to provide a good

electrically conductive path in as many places as possible. Mount the board on the back panel so there is
airflow at both the top and bottom areas of the board (at least 0.4 inches).

Mounting 19

Power PMAC Clipper User Manual

Physical Specifications

Board Dimensions Rev101

Top View

Board Layout Rev101

Top View

Mounting are holes shown with screw heads.

Mounting 20

Power PMAC Clipper User Manual

WARNING

Installation of electrical equipment is subject to many regulations
including national, state, local, and industry guidelines and rules.
The following are general recommendations but it is important
that the integration be carried out in accordance with all
regulations pertaining to the installation.

Jumper

Position Description

Note

E0

CPU RESET

Do Not Install

E1

Install E1 to bypass watchdog timer for bootstrap
software load.

Do Not Install
E4

Factory use only, should always be 1-2.

Do Not change

E5

Not currently used

Not Installed

E6

Selection between handwheel input or serial encoder
input on Gate3[i].Chan[0].SerialEncDataA
1-2 FOR SENC1
2-3 ENC-HW-1

Default 1-2

E7

Selection between handwheel input or serial encoder
input on Gate3[i].Chan[1].SerialEncDataA
1-2 FOR SENC2
2-3 ENC-HW-2

Default 1-2

E14

Install to make GPIO 0-7 lines inputs
Remove jumper to make GPIO 0-7 lines outputs

Installed (Required for MuxIO)

E15

Install to make GPIO 8-15 lines inputs
Remove jumper to make GPIO 8-15lines outputs

Not Installed (Required for
MuxIO)

E16

Install to make GPIO 16-23 lines inputs
Remove jumper to make GPIO 16-23 lines outputs

Not Installed

E17

Install to make GPIO 24-31 lines inputs
Remove jumper to make GPIO 24-31 lines outputs

Installed

TB1 (JPWR): Power Supply

4-Pin Terminal Block

Pin#

Symbol

Function

Description

Notes

1

GND

Common

Digital Common

CONNECTIONS AND SOFTWARE SETUP

Default Jumper Configurations

The following table shows the default jumper configurations:

TB1 (JPWR): Power Supply Input

This 4-pin terminal block is used to bring the 5VDC logic power and +/-12VDC DAC supply into the
Power PMAC Clipper.

Connections and Software Setup 21

Power PMAC Clipper User Manual

2

+5V

Input

Logic Voltage

Supplies all PMAC digital circuits

3

+12V

Input

DAC Supply Voltage

Ref to Digital GND

4

-12V

Input

DAC Supply Voltage

Ref to Digital GND

Note

For +5V and GND, 18 gauge (AWG) stranded wire is recommended.
For +12V and -12V, a minimum of 22 gauge (AWG) stranded wire is
recommended.

Connections and Software Setup 22

Power PMAC Clipper User Manual

J2 (JRS232) Serial Port Connector

10-Pin Header

56341

2

9107

8

Pin#

Symbol

Function

Description

Notes

1

No Connection

2

DTR

Bidirect

Data Terminal Ready

Tied to "DSR"

3

TXD/

Output

Send Data

Host receive data

4

CTS

Input

Clear to Send

Host ready bit

5

RXD/

Input

Receive Data

Host transmit data

6

RTS

Output

Request to Send

PMAC ready bit

7

DSR

Bidirect

Data Set Ready

Tied to "DTR"

8

No Connection

9

GND

Common

Digital Common

10

RESET_SW#

Input

Hardware CPU Reset

Ground is Reset

J2: Serial Port

This connector allows communicating with Power PMAC Clipper from a host computer through a RS­232 port. Delta Tau provides the Accessory 3L cable that connects the PMAC to a DB-9 connector.

10-pin female flat cable connector T&B Ansley P/N 609-1041
Standard flat cable stranded 10-wire T&B Ansley P/N 171-10

Connections and Software Setup 23

Power PMAC Clipper User Manual

J3 (JMACH1): Machine Port Connector

50-Pin Header

495047484546434441423940373835363334313229302728252623242122192017181516131411129107856341

2

Pin#

Symbol

Function

Description

Notes

1

+5V

Output

+5V Power

For encoders, 1

2

+5V

Output

+5V Power

For encoders, 1

3

GND

Common

Digital Common

For encoders, 1

4

GND

Common

Digital Common

For encoders, 1

5

CHA1

Input

Encoder A Channel Positive

2

6

CHA2

Input

Encoder A Channel Positive

2

7

CHA1/

Input

Encoder A Channel Negative

2,3

8

CHA2/

Input

Encoder A Channel Negative

2,3

9

CHB1

Input

Encoder B Channel Positive

2

10

CHB2

Input

Encoder B Channel Positive

2

11

CHB1/

Input

Encoder B Channel Negative

2,3

12

CHB2/

Input

Encoder B Channel Negative

2,3

13

CHC1

Input

Encoder C Channel Positive

2

14

CHC2

Input

Encoder C Channel Positive

2

15

CHC1/

Input

Encoder C Channel Negative

2,3

16

CHC2/

Input

Encoder C Channel Negative

2,3

17

CHA3

Input

Encoder A Channel Positive

2

18

CHA4

Input

Encoder A Channel Positive

2

19

CHA3/

Input

Encoder A Channel Negative

2,3

20

CHA4/

Input

Encoder A Channel Negative

2,3

21

CHB3

Input

Encoder B Channel Positive

2

22

CHB4

Input

Encoder B Channel Positive

2

23

CHB3/

Input

Encoder B Channel Negative

2,3

24

CHB4/

Input

Encoder B Channel Negative

2,3

25

CHC3

Input

Encoder C Channel Positive

2

26

CHC4

Input

Encoder C Channel Positive

2

27

CHC3/

Input

Encoder C Channel Negative

2,3

J3: Machine Connector (JMACH1 Port)

The primary machine interface connector is JMACH1, labeled J3 on the Power PMAC Clipper. It
contains the pins for four channels of machine I/O: analog outputs, incremental encoder inputs, amplifier
fault and enable signals and power-supply connections.

Connections and Software Setup 24

Power PMAC Clipper User Manual

28

CHC4/

Input

Encoder C Channel Negative

2,3

29

DAC1

Output

Analog Output Positive 1

4

30

DAC2

Output

Analog Output Positive 2

4

31

DAC1/

Output

Analog Output Negative 1

4,5

32

DAC2/

Output

Analog Output Negative 2

4,5

33

AENA1/

Output

Amplifier-Enable 1

34

AENA2/

Output

Amplifier -Enable 2

35

FAULT1/

Input

Amplifier -Fault 1

36

FAULT2/

Input

Amplifier -Fault 2

37

DAC3

Output

Analog Output Positive 3

4

38

DAC4

Output

Analog Output Positive 4

4

39

DAC3/

Output

Analog Output Negative 3

4,5

40

DAC4/

Output

Analog Output Negative 4

4,5

41

AENA3/

Output

Amplifier -Enable 3

42

AENA4/

Output

Amplifier -Enable 4

43

FAULT3/

Input

Amplifier -Fault 3

44

FAULT4/

Input

Amplifier -Fault 4

45

ADCIN_1

Input

Analog Input 1

46

ADCIN_2

Input

Analog Input 2

47

FLT_FLG_V

Input

Amplifier Fault pull-up V+

48

GND

Common

Digital Common

49

+12V

Input

DAC Supply Voltage

7

50

-12V

Input

DAC Supply Voltage

7

Note

 Note 1: These lines can be used as +5V power supply inputs to power

PMAC’s digital circuitry.

 Note 2: Referenced to digital common (GND). Maximum of ±12V

permitted between this signal and its complement.

 Note 3: Leave this input floating if not used (i.e. digital single-ended

encoders).

 Note 4: ±10V, 10 mA max, referenced to common ground (GND).
 Note 5: Leave floating if not used. Do not tie to GND.

 Note 7: Can be used to provide input power when the TB1 connector is

not being used.

50-pin female flat cable connector T&B Ansley P/N 609-5041. Standard flat cable stranded 50-wire T&B
Ansley P/N 171-50. Phoenix varioface module type FLKM 50 (male pins) P/N 22 81 08 9

Connections and Software Setup 25

Power PMAC Clipper User Manual

Note

Use an encoder cable with high quality shield.

Channel A

Channel B

The standard encoder inputs on the Power PMAC Clipper are designed for differential quadrature type
signals.

Quadrature encoders provide two digital signals to determine the position of the motor. Each nominally
with 50% duty cycle, and nominally 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.

Typically, these signals are 5V TTL/CMOS level whether they are single-ended or differential.
Differential signals can enhance noise immunity by providing common mode noise rejection. Modern
design standards virtually mandate their use in industrial systems.

Connections and Software Setup 26