Delta Tau TURBO CLIPPER DRIVE User Manual

^1 USER MANUAL

^2 Turbo Clipper Drive

^3 4-Axis Low Voltage Intelligent Amplifier

^4 TCD 4-XX-400-0X1-0XXX

^5 November 19, 2013

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

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

Turbo Clipper Drive User Manual

Copyright Information

© 2010 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-to­time due to product improvements, etc., and may not conform in every respect to
former issues.
To report errors or inconsistencies, call or email:

Delta Tau Data Systems, Inc. Technical Support

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

Operating Conditions

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

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

Turbo Clipper Drive User Manual

MANUAL REVISION HISTORY

REV.

DESCRIPTION

DATE

CHANGE

APPROVED

1

PRELIMINARY MANUAL CREATION

07/01/10

M.Y

R.N

2

FORMATTING & CORRECTIONS

09/25/10

M.Y

R.N

3

MANUAL RELEASE

01/13/10

R.N

R.N

4

ASSEMBLY DRAWING

03/29/11

M.Y

R.N

5

CORRECTED PIN-OUT, PAGE 43

04/18/11

M.Y

R.N

6

FORMAT. FIXED LABES J37

12/18/12

R.N

R.N

7

ADDED E4 JUMPER IN REV103

11/19/13

M.C

R.N

Turbo Clipper Drive User Manual

Table of Contents

INTRODUCTION .....................................................................................................................7

Documentation ........................................................................................................................7

Turbo Clipper Drive Features ..................................................................................................7

SPECIFICATIONS ...................................................................................................................8

Part Number ............................................................................................................................8

Electrical Specifications ..........................................................................................................9

Environmental Specifications ..................................................................................................9

RECEIVING AND UNPACKING ......................................................................................... 10

Use of Equipment.................................................................................................................. 10

Mounting .............................................................................................................................. 11

CAD Drawing ....................................................................................................................... 12

POWER BOARD: WIRING, SOFTWARE SETUP ............................................................. 14

TB1-TB4: Motor Wiring ....................................................................................................... 14

TB5: 24-Volt Logic Power .................................................................................................... 15

TB6: Bus Voltage.................................................................................................................. 16

J13: E-Stop, Reset ................................................................................................................. 17

D1: AMP STATUS ............................................................................................................... 20

Error Codes.......................................................................................................................... 20

BREAKOUT BOARD: WIRING, SOFTWARE SETUP ...................................................... 21

TB1: External Power Supply ................................................................................................. 21

J11-J14: Encoder Feedback, Digital A Quad B ................................................................ ...... 21

ACC-51S: Sinusoidal Feedback (Optional) ........................................................................... 24

J15: Flag(s) Power Supply ................................................................................................ ..... 25

J16-J19: Axis 1 thru 4 Limits & Home Flags ......................................................................... 25

J20: Axis 1 thru 4 EQU Outputs ............................................................................................ 26

J21: Axis 1 thru 4 User Flags ................................................................................................ 26

Wiring The Flags .................................................................................................................. 28

J23: Watchdog Output ........................................................................................................... 29

J24: DAC Output, 12-bit Filtered PWM ................................................................................ 30

J25: ADC Inputs ................................................................................................................... 31

J26: Thumbwheel Multiplexer Port Inputs ............................................................................. 32

J27: Thumbwheel Multiplexer port Outputs (sinking) ............................................................ 33

J37: Thumbwheel Multiplexer port Outputs (Sourcing) ......................................................... 34

Thumbwheel Port As Discrete I/Os, Suggested M-Variables ................................................. 34

Wiring The Thumbwheel As Discrete I/Os ............................................................................ 35

J28: General Purpose Inputs .................................................................................................. 37

Table Of Contents 4

Turbo Clipper Drive User Manual

J29: General Purpose Outputs (sinking) ................................................................................. 38

J30: General Purpose I/O Power ............................................................................................ 39

J38: General Purpose Outputs (sourcing) ............................................................................... 40

General Purpose I/Os, Suggested M-Variables ..................................................................... 43

J31-J32: Handwheel Port(s) ................................................................................................... 44

J33-J34: Pulse and Direction Output(s) (PFM) ...................................................................... 45

J35: Programmable Output ................................................................................................ .... 48

External Amp 1-4: ................................................................................................................. 49

CLIPPER BOARD: WIRING, SOFTWARE SETUP ........................................................... 51

USB 2.0 Connector ............................................................................................................... 51

RJ45, Ethernet Connector ...................................................................................................... 51

RS232: Serial Communication Port ....................................................................................... 52

MOTOR TYPE & PROTECTION POWER-ON PLCs ........................................................ 53

Stepper Motor Power-On PLC .............................................................................................. 53

Brushless/Brush Motor Power-On PLC ................................................................................. 54

Hybrid Motor Power-On PLC Example ................................................................................. 54

MOTOR SETUP GUIDELINES ............................................................................................ 55

Motor Setup Flow Chart ........................................................................................................ 55

Dominant Clock Settings ................................ ....................................................................... 56

Setting Up Stepper Motor, Direct Micro-Stepping ................................................................. 57

Before you start .................................................................................................................... 57

Encoder Conversion Table Setup ................................ .......................................................... 57

Position, Velocity Pointers: Ixx03, Ixx04 .............................................................................. 58

Motor Activation, Commutation Enable: Ixx00, Ixx01........................................................... 58

Command Output Address: Ixx02 ......................................................................................... 58

Current Feedback, ADC Mask, Commutation angle: Ixx82, Ixx84, Ixx72 .............................. 58

Flag Address, Mode Control: Ixx25, Ixx24 ........................................................................... 59

Commutation Address, Cycle size: Ixx83, Ixx70, Ixx71 ......................................................... 59

Maximum Achievable Motor Speed, Output Command Limit: Ixx69 ..................................... 60

PWM Scale Factor: Ixx66 ..................................................................................................... 61

I2T Protection, Magnetization Current: Ixx57, Ixx58, Ixx69, Ixx77 ....................................... 62

Phasing, Power-On Mode: Ixx80, Ixx73, Ixx74, Ixx81, Ixx91 ................................................ 63

Position-Loop PID Gains: Ixx30…Ixx39 ............................................................................... 63

Current-Loop Gains: Ixx61, Ixx62, Ixx76 .............................................................................. 64

Number Of Counts Per Revolution (Stepper Motors) ............................................................ 64

Setting Up DC Brushless Motor ............................................................................................ 65

Before you start .................................................................................................................... 65

Flag Control, Commutation Angle, Current Mask: Ixx24, Ixx72, Ixx84 ................................. 65

PWM Scale Factor: Ixx66 ..................................................................................................... 65

Table Of Contents 5

Turbo Clipper Drive User Manual

Current Feedback Address: Ixx82 ......................................................................................... 65

Commutation Position Address, Commutation Enable: Ixx83, Ixx01 ..................................... 66

I2T Protection: Ixx57, Ixx58, Ixx69 ....................................................................................... 66

Commutation Cycle Size: Ixx70, Ixx71 .................................................................................. 67

ADC Offsets: Ixx29, Ixx79 .................................................................................................... 67

Current-Loop Gains: Ixx61, Ixx62, Ixx76 .............................................................................. 67

Open-Loop Test, Encoder Decode: I7mn0 ............................................................................ 68

Motor Phasing, Power-On Mode: Ixx73, Ixx74, Ixx80, Ixx91 ................................................ 70

Position-Loop PID Gains: Ixx30…Ixx39 ............................................................................... 75

Setting Up DC Brush Motor .................................................................................................. 77

Before you start .................................................................................................................... 77

Phasing Search Error Bit, Current-Loop Integrator Output .................................................. 77

Flag Control, Commutation Enable, Phase Angle, Current Mask: Ixx24, Ixx01, Ixx72, Ixx84

............................................................................................................................................. 77

PWM Scale Factor: Ixx66 ..................................................................................................... 78

Current Feedback Address: Ixx82 ......................................................................................... 78

Commutation Cycle Size: Ixx70, Ixx71 .................................................................................. 78

I2T Protection, Magnetization Current: Ixx57, Ixx58, Ixx69, Ixx77 ....................................... 79

ADC Offsets: Ixx29, Ixx79 .................................................................................................... 79

Current-Loop Gains, Open-Loop/Enc. Decode: Ixx61, Ixx62, Ixx76, I7mn0 .......................... 79

Position-Loop PID Gains: Ixx30…Ixx39 ............................................................................... 80

APPENDIX A .......................................................................................................................... 82

D-Sub Connector Spacing Specifications .............................................................................. 82

APPENDIX B: CLIPPER BOARD E-POINT JUMPERS .................................................... 83

E0: Forced Reset Control ..................................................................................................... 83

E3: Re-Initialization On Reset Control ................................................................................. 83

E4: Watchdog Disable Jumper ............................................................................................. 83

E5: Reserved for factory use only ......................................................................................... 83

E6: ADC Inputs Enable ........................................................................................................ 84

E7 – E8: USB/Ethernet Reset Jumpers ................................................................................. 84

E10 – E12: Flash IC Jumpers ............................................................................................... 84

E13: Power-Up/Reset Load Firmware .................................................................................. 85

E14- E17: Ports Direction Control ......................................................................................... 85

APPENDIX C: BREAKOUT BOARD E-POINT JUMPERS ............................................... 86

J36: GPO E-Stop Automatic Feature .................................................................................... 86

J39: User Flag 4 E-Stop Status ............................................................................................. 86

APPENDIX D: POWER BOARD E-POINT JUMPERS ................................ ...................... 87

E1- E2- E3- E4: E-Stop and Reset Control ............................................................................ 87

Table Of Contents 6

Turbo Clipper Drive User Manual

INTRODUCTION

The Turbo Clipper Drive (Low Voltage), 12~60V(DC) bus power input, combines the
intelligence and capability of the Turbo PMAC2 motion controller with the latest MOSFET
technology, resulting in a compact 4-axis smart servo package. The flexibility of the Turbo
PMAC2 enables the Turbo Clipper Drive to drive Stepper, Brush, or Brushless motors with
unsurpassed pure digital DSP performance.
The Turbo Clipper Drive also features a wide variety of options varying from processor speeds
as high as 240MHz, multiple digital and analog inputs/outputs, USB2.0, Ethernet 100 Base T,
and serial communication.

Documentation

In conjunction with this hardware reference manual, the Turbo Software Reference Manual and
Turbo PMAC User Manual are essential for proper use, motor setup, and configuration of the
Turbo Clipper Drive. It is highly recommended to always refer to the latest revision of the

manuals found on Delta Tau’s website, under Support>documentation>Manuals: Delta Tau

Manuals Link

Turbo Clipper Drive Features

The Turbo Clipper Drive supports the following types of motors:

 Three-Phase DC Brushless
 DC Brush
 2-Phase Stepper

Some of the Turbo Clipper Drive’s outstanding features:

 4 channel direct digital PWM control
 Integral 4 servo amplifiers delivering 5Amps continous/15Amps peak per axis
 Protection: over voltage, under voltage, over temperature, short circuit, over current
 Motorola DSP 56k digital signal processor
 Turbo PMAC2 CPU
 Linear and circular interpolation
 256 fixed motion program buffers
 64 asynchronous PLC programs
 Rotary buffer support
 36-bit position range (± 64 billion counts)
 Adjustable S-curve acceleration and deceleration
 Cubic trajectory calculations, Splines, PVT
 Set and change parameters in real time and on-the-fly, alter destination moves
 Torque, Velocity and Position control
 Small space-saving footprint
 USB2.0, Ethernet 100 Base T
 Operation from PC or standalone

Introduction 7

Turbo Clipper Drive User Manual

Delta Tau Assembly Numbers (top to bottom):

Control Board (Clipper)

603871

Breakout Board

603926

Power Board

603925

CD 0 0 0 10C 4

-- -

04 00 0 0T

CPU Options - Turbo PMAC 2 Processor
C0 - 80Mhz, 8Kx24 Internal, 256Kx24SRAM, 1MB Flash (Default)

C3 - 80Mhz, 8Kx24 Internal, 1Mx24SRAM, 4MB Flash
F3 - 240Mhz, 192Kx24 Internal, 1Mx24SRAM, 4MB Flash

B

G

L

B

Turbo Clipper Drive Number Definition

Communication Options

TCD X - XX - XXX – X?X - XXXX

USB2 and Eth100 are included

Note: To use PMAC-NC software, DPRAM is required
0 - No Options, Default

D - (Clipper OPT-2) DPRAM option, size 8K x 16-bit wide
M - (Clipper Opt-15M) ModBus Ethernet Communication Protocol(Software) option
S - (Clipper OPT-2 and Opt-15M) DPRAM and Modbus Options Combined

G

00 - No Additional* Options
xx - Factory assigned digits for Additional* Options

Factory Assigned Options

K L

* If Opt. 10xx (specific firmware version) or any other Additional Option

is required, contact factory for digits K and L (Factory Assigned digits).
If Opt. 10xx is not ordered the latest firmware is used.

Other Options
0 - No Options (Default)
1 - Opt. 11A HI-Speed Dig. Out PWM Laser Control

J

K

J

-

BB 0 0 5 00C 2

-- -

04 01 0 0C

CPU Options - Turbo PMAC 2 Processor
C0 - 80Mhz, 8Kx24 Internal, 256Kx24SRAM, 1MB Flash (Default)

C3 - 80Mhz, 8Kx24 Internal, 1Mx24SRAM, 4MB Flash
F3 - 240Mhz, 192Kx24 Internal, 1Mx24SRAM, 4MB Flash

B

G

L

B

Clipper with Breakout Board Part Number Definition

Communication Options

CBB X - XX - XXX – X?X - XXXX

USB2 and Eth100 are included

Note: To use PMAC-NC software, DPRAM is required
0 - No Options, Default

D - (Clipper OPT-2) DPRAM option, size 8K x 16-bit wide
M - (Clipper Opt-15M) ModBus Ethernet Communication Protocol(Software) option
S - (Clipper OPT-2 and Opt-15M) DPRAM and Modbus Options Combined

G

00 - No Additional* Options
xx - Factory assigned digits for Additional* Options

Factory Assigned Options

K L

* If Opt. 10xx (specific firmware version) or any other Additional Option is required, contact factory for digits K and L (Factory Assigned digits).

If Opt. 10xx is not ordered the latest firmware is used.

0 - No Options (Default)
1 - Opt. 11A HI-Speed Dig. Out PWM Laser Control

J

K

J

-

H

0 - No Options (Default)
1 - Opt. 12 2-channels 12-bit A/D converter & 1 12-bit

D/A converter

H

Other Options

SPECIFICATIONS

Part Number

Turbo Clipper Drive (Control+Breakout+Power)

Clipper & Breakout only (Control+Breakout, without Power)

Specification 8

Specification

Description

Range

Max ADC

Full Range ADC reading (RMS/Axis)
Used in I2T Calculation

33.85 Amps

Bus Power Supply
Input Voltage

12~60VDC

Continuous Input Current (RMS)

12.5A

Peak Input Current (RMS)

25A @ 1s

Logic Power Supply
Input Voltage

24VDC ±20%

Continuous Input Current

2~3A (RMS)

Output Current
Nominal Current per axis (RMS)

5A

Maximum Peak Current per axis (RMS)

15A @ 1s

Power Dissipation

240W per axis (modulation depth of 60%)

PWM Frequency

2K~40KHz / recommended 20KHz

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 w/
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)

-1%/m (-0.33%/ft)

3000 ~4000m (9840~13000ft)

-2%/m (-0.67%/ft)

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 external fan

Standard IP Protection

IP20
IP 55 can be evaluated for custom applications

Electrical Specifications

Environmental Specifications

Turbo Clipper Drive User Manual

Specification 9

Turbo Clipper Drive User Manual

RECEIVING AND UNPACKING

Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment.
Upon receipt of hardware, please follow carefully the instructions below for proper maintenance
and handling:
Observe the condition of the shipping container and report any damage immediately to the
commercial carrier.
Remove the hardware from the shipping container and remove all packing materials. Check all
shipping material for connector kits and documentation. Some components 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 unit received matches the part number listed on the purchase
order.
Inspect the drive for external physical damage that may have been sustained during shipping and
report damages immediately to the commercial carrier. Document any damage with photographs.
Electronic components in this unit are design-hardened to reduce static sensitivity. However, use
proper procedures when handling the equipment to avoid electrostatic discharges (ESD).
If the Turbo Clipper Drive is to be stored for several weeks before integration (i.e., spare part),
be sure that it is stored in a location that conforms to environmental specifications. Also, testing
of the unit is highly recommended before storing it for future use.

Use of Equipment

The following restrictions will ensure the proper use of the Turbo Clipper Drive:
The components built into electrical equipment or machines can be used only as integral
components of such equipment.
The Turbo Clipper Drive must not be operated on power supply networks without a ground or
with an asymmetrical ground.
If the Turbo Clipper Drive is used in residential areas, or in business or commercial premises,
implement additional filter measures.
The Turbo Clipper Drive may be operated only in a closed switchgear cabinet, taking into
account the ambient conditions defined in the environmental specifications.
Delta Tau guarantees the conformance of the Turbo Clipper Drive with the standards for
industrial areas stated in this manual only if Delta Tau components (cables, accessories, etc.) are
used.

Receiving and Unpacking 10

Turbo Clipper Drive User Manual

Mounting

The drive placement in the machine cabinet 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 conditions 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 control should be mounted on a smooth, non­flammable 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 amplifier, breakout board and clipper.
Temperature, humidity and Vibration specifications should also be taken in account.
The Turbo Clipper Drive can be mounted with a traditional 4-hole panel mount. This keeps the
heat sink and fan inside the mounting enclosure.
If multiple Turbo Clipper Drive Drives are used, they can be mounted side by side, leaving at
least 122 mm (~5 inches) center to center clearance. 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 panel should be unpainted and electrically conductive
to allow for reduced electrical noise interference. The back panel should be machined to accept
the mounting bolt pattern of the drive. Make sure that all metal chips are cleaned up before the
drive is mounted so there is no risk of getting metal chips inside the drive.
The drive is mounted to the back panel with four M4 screws and internal-tooth lock washers. It
is important that the teeth break through any anodization on the drive’s mounting gears to
provide a good electrically conductive path in as many places as possible. Mount the drive on
the back panel so there is airflow at both the top and bottom areas of the drive (at least three
inches).
CAD drawing below shows the location of screws for mounting the drive to plate and mounting
the breakout board to the drive.

Receiving and Unpacking 11

Breakout Board

(603926)

2.25

Power Board

Clipper Board

Ethernet

0.25

5.31

5.125

5.125

Heat Sink

CAD Drawing

Turbo Clipper Drive User Manual

(603871)

(603925)

Receiving and Unpacking 12

Turbo Clipper Drive User Manual

Receiving and Unpacking 13

Turbo Clipper Drive User Manual

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.

TB1-TB4: Molex (F)
Molex Mating Connector Part #: 39-01-2065 (M)
Molex Crimper Pin Part #: 39-00-0060

For Internal Use:
DT Part #: 014-390120-065
DT Part #: 014-555656-083

Pin #

Symbol

Description

1

U Phase

Axis 1-4

2

GND

Ground

3

V Phase

Axis 1-4

4

W Phase

Axis 1-4 5 GND

Ground

6

X Phase

Axis 1-4

Note

 DC Brushless motors: Use U, V and W. Leave X floating
 Stepper motors: Use U and W at one coil, V and X at the

other coil.

 Brush motors: Use U and W. Leave V and X floating.
 The cable wiring must be shielded and have a separate

conductor connecting the motor frame back to the
assembly ground.

POWER BOARD: WIRING, SOFTWARE SETUP

TB1-TB4: Motor Wiring

Motor phases are conversed in one of three conventions. Some motor manufacturers will call the
motor phases A, B, or C. Other motor manufacturers call them U, V, W. The Turbo Clipper
Drive outputs are called U, V, W, and X. For DC brushless motors (servo) use U,V and W, let X
float. For stepper motors, use U and W for one coil, V and X for the other coil. For DC Brush

motors, use U and W, float V and X. The motor’s frame drain wire and the motor cable shield

must be tied together and wired at the GND pin of the motor connector (Pin 5 or 2).

Power board: Wiring, Software Setup 14

Turbo Clipper Drive User Manual

TB5: Molex (F)
Molex Mating Connector Part #: 43025 (M)
Molex Crimper Pin Part #: 43030-0008

For Internal Use:
DT Part #: 014-430250-600
DT Part #: 014-43030-008

Pin #

Symbol

Function

Description

Notes

1

24VDC

Input

Logic power input

+16~32VDC

2

NA

NA

NA

NA

3

24VDC RET

Common

Logic power return

Power Supply Return

4

24VDC

Input

Logic power input

+16~32VDC

5

NA

NA

NA

NA

6

24VDC RET

Common

Logic power return

Power Supply Return

TB5: 24-Volt Logic Power

An external 24Vdc power supply is required to power up the logic portion of the Turbo Clipper
Drive. This power can remain on, regardless of the main DC bus power, allowing the signal
electronics to be active while the main motor power control is inactive. The 24V is wired into
terminal block TB5. The polarity of this connection is extremely important. Carefully follow
the instructions in the wiring diagram. This connection can be made using 22 AWG wire
directly from a protected power supply. In situations where the power supply is shared with
other devices, it may be desirable to insert a filter in this connection.

The 24Volts power supply must be capable of providing 2~3Amps per Turbo Clipper Drive to
allow proper functionality. If multiple drives are sharing the same 24Volts power supply, it is
highly recommended to wire each drive back to the power supply terminals separately.

Power board: Wiring, Software Setup 15

TB6: Molex (F)
Molex Mating Connector Part #:: 50-84-1020 (M)
Molex Crimper Pin Part #: 002081001

For Internal Use:
DT Part #: 014-030f02-HSM
DT Part #: 014-002081-001

Pin #

Symbol

Function

Description

Notes

1

+12~60VDC

Input

Bus power input VBus

+12~60VDC

2

+12~60VDC RET

Common

Bus power return 0Bus

+12~60VDC RET

Fuse (FRN/LPN)

Wire Gauge

15

12 AWG

TB6: Bus Voltage

Recommended Fuse, and wire gauge:

Turbo Clipper Drive User Manual

Power board: Wiring, Software Setup 16

Turbo Clipper Drive User Manual

TB6: Molex (F)
Molex Mating Connector Part #: 430250-0400 (M)
Molex Crimper Pin Part #: 43030-0008

For Internal Use:
DT Part #: 014-430250-400
DT Part #: 014-43030-008

Pin #

Symbol

Description

1

Reset

Connect 1-2 to activate the reset.

2

Reset

3

E-STOP

Connect 3-4 to engage the E-Stop

4

E-STOP

Note

The built-in Emergency Stop circuitry disables the Mosfet
transistors but does NOT remove power from the DC bus. If this
additional level of protection is required, it is recommended to
add a separate external device to remove the DC Bus input from
the Turbo Clipper Drive.

J13: E-Stop, Reset

The Turbo Clipper Drive is equipped with a built-in Emergency Stop circuitry. It utilizes two
latching type relays to enable/disable the drive’s Mosfet transistors. Additionally, the following
safety and status features are implemented:

 The E-Stop status, by default, is conveyed to the Turbo Clipper via User Flag Input #4

(X:$78018,19).See jumper J39.

 The General Purpose Outputs (GPO), by default, is independent of the E-Stop status.

They can be disabled in an emergency stop condition. See jumper J36.

 The Turbo Clipper Drive has an E-Stop software controllable enable bit (Y:$78402,15,1).

It is a low true logic meaning =0 to engage E-Stop, =1 to disengage E-Stop, allowing the
user to trigger an emergency stop condition through software logic.

Power board: Wiring, Software Setup 17

Turbo Clipper Drive User Manual

The E-Stop button should be a normally-closed switch, so
that the circuit is closed when it is released and open when
it is pressed.
The Reset button should be a normally-open switch before
revision 103, so that the circuit is open when it is released
and closed when it is pressed. Revision 103 and after the
type of Reset button can be selectable via jumper E4.

Note

It is recommended to wire the E­Stop in series with the reset
circuit, so if the machine is in an
emergency stop condition, the
reset cannot be activated and has
no practical use.

E-STOP

Normally

Open

Normally

Closed

RESET

1

2

3

4

J13

Board

Jumper

Function

Default

Power

E1

Remove to enable the hard E-Stop function.
Install to disable the hard E-Stop function.

Not Installed

Power

E2

Remove to enable hard & soft E-Stop functions.
Install to disable hard & soft E-Stop functions.

Not Installed

Power

E3

Remove to enable the soft E-Stop function.
Install to disable the soft E-Stop function

(Soft E-Stop bit has to be set, and saved to 1).

Not Installed

Power

E4

Remove jumper to use normally-open Reset switch
between pin 1 and 2 of J13.
Install jumper to use normally-closed Reset switch
between pin 1 and 2 of J13.

Not Installed

Breakout

J36

Install jumper to disable the GPO E-Stop automatic
feature (outputs unaffected by E-Stop status).

Remove Jumper to enable the GPO E-Stop
automatic feature (turn outputs off when in E-Stop)

Installed

Breakout

J39

Jump 1 to 2 to use User Flag 4 as an E-Stop status
in software.

Jump 2 to 3 to use User Flag 4 as a general purpose
user input.

Jumpered

1-2

Wiring The E-Stop, And Reset Switch

Emergency Stop, Reset Jumpers Summary

The following table summarizes the E-Stop and Reset features. The hard E-Stop designates the
actual hardware E-Stop button. The soft E-Stop designates the software controllable E-Stop bit:

Power board: Wiring, Software Setup 18

Turbo Clipper Drive User Manual

Note

Upon releasing the E-Stop, the General Purpose Outputs (GPO)
state, otherwise handled by PLC/software, is re-established to
what it was prior to pressing the E-Stop.

Emergency Stop-Reset Example PLC

In addition to the automatic Emergency Stop functionality a PLC must be used to insure proper
and complete Emergency Stop function once the Mosfet transistors are disabled. During an
emergency stop condition, it is highly advised to implement the following:

 Kill motors.
 Turn off general purpose outputs (GPOs).
 Other functions insuring machine safety.

With E1, E2, E3, and E4 removed allowing both hardware and software E-Stop functionality.
J36 removed, to automatically turn off the general purpose outputs, and J39 set to 1-2 to allow
reading the E-Stop status through User flag4:

// Definition and Substitutions
#define Estop_Latch P8000 ; General purpose Latching flag
#define Estop_Enable M47 ; Software Controllable E-Stop Bit
Estop_Enable->Y:$78402,15,1 ; =0 E-Stop, =1 Not in E-Stop
Estop_Enable=1

#define Estop_Status M415 ; S-Stop Status Bit, using User Flag 4
Estop_Status->X:$78018,19 ; =1 E-Stop, =0 Not in E-Stop

Open PLC 1 Clear
// Is E-Stop Pressed?
If (Estop_Status=1)
Estop_Latch=0
Else
Estop_Latch=1
EndIF
Estop_Enable=1 ; Set once on power-up
While (1=1)
// Emergency Stop Engaged
If(Estop_Status = 1 and Estop_Latch = 0)
// Put Emergency Stop Functions Here
&1 CMD^K ; Kill all axes in Coordinate System 1
// Set desired Outputs state (post E-Stop) here
// if automatic GPO kill is enabled
Estop_Latch = 1
Else
// Emergency Stop Released
IF(Estop_Status = 0 and Estop_Latch = 1)
// Put Emergency Stop Release Functions Here
&1 CMD^A ; Enable all axes in Coordinate System 1
Estop_Latch = 0
P8002=P8002+1
EndIf
EndIf
Endwhile
Close

Power board: Wiring, Software Setup 19

Turbo Clipper Drive User Manual

Display

Description

Global Faults

Under Voltage Fault:
Indicates that the bus voltage is not present or less than 12Volts

Over Voltage Fault:
Indicates that the bus voltage has exceeded 60Volts

Over Temperature Fault:
Indicates that the Board has exceeded 65°C

Axis n Faults (n=1 thru 4)

n

Axis n Over load Fault:
Indicates that the current rating (5/15A) of the drive has been exceeded

n

Axis n Over Current Fault:
Indicates that the peak current value has exceeded the permissible limit(20Amps)

D1: AMP STATUS

The Turbo Clipper Drive utilizes a scrolling single-digit 7-segment display to exhibit faults to the
outside world. When control and DC bus power are applied, the Drive will display a solid dot
indicating that the software and hardware are running normally.

Error Codes

Power board: Wiring, Software Setup 20

Turbo Clipper Drive User Manual

Caution

This connector is only used if the power board is not present. It
is utilized to bring in logic power to the control (Clipper) and
breakout boards.

TB1: Molex (F)
Molex Mating Connector Part #:: 39-01-2045 (M)
Molex Crimper Pin Part #: 39-00-0060

For Internal Use:
DT Part #: 014-390120-045
DT Part #: 014-555656-083

Pin #

Symbol

Function

Notes

1

GRD

Input

Ground

2

+5 VDC

Input

5 volt Input

3

+12 VDC

Input

12 volt Input

4

-12 VDC

Input

-12 volt Input

J11-J14: D-sub DA-15F

Mating: D-sub DA-15M

2345

9101112

67

1314

8

15

1

Pin#

Symbol

Function

Description

1

CHA+

Input

Axis Encoder A+

2

CHB+

Input

Axis Encoder B+

3

CHC+

Input

Axis Encoder Index+

4

ENCPWR

Output

Encoder Power 5V

5

CHU+ / DIR+

In/Out

Halls U+ / Direction Output + for Stepper

6

CHW+/ PUL+

In/Out

Halls W+ / Pulse Output + for Stepper

7

2.5V

Output

2.5V Reference power

8

Stepper Enable

Input

Tie to pin#4 (5V) to enable stepper output

9

CHA-

Input

Axis Encoder A-

10

CHB-

Input

Axis Encoder B-

11

CHC-

Input

Axis Encoder Index-

12

GND

Common

Common ground

13

CHV+ / DIR-

In/Out

Halls V+ / Direction Output- for Stepper

14

CHT+ / PUL-

In/Out

Halls T+ / Pulse Output- for Stepper

15

N/C

-

Reserved for future use

BREAKOUT BOARD: WIRING, SOFTWARE SETUP

TB1: External Power Supply

J11-J14: Encoder Feedback, Digital A Quad B

Breakout Board: Wiring, Software Setup 21

Turbo Clipper Drive User Manual

Note

Spacing specs between DB-Connectors can be found in
Appendix section.

12345678

9101112131415

CHA+
CHA­CHB+
CHB­CHC+
CHC­+5VDC
GND

12345678

9101112131415

CHA+

CHB+

CHC+

+5VDC
GND

1.2KΩ

1.2KΩ

1.2KΩ

Differential Quadrature Encoder Wiring

Single-Ended Quadrature Encoder Wiring

Note

For single-ended encoders, tie the negative pins (i.e. CHAn-) to
reference (Pin#7) in series with a 1Kohm resistor.

The standard encoder input channels on the Turbo Clipper Drive Drive are designed for
differential quadrature feedback. To use single-ended encoders, the negative pins (i.e. CHAn-)
have to be tied to reference (Pin#7) in series with a 1Kohm resistor.

Quadrature encoders provide two digital signals to determine the position of the encoder/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 encoder signals can enhance noise immunity by providing common mode noise
rejection. Modern design standards virtually mandate their use in industrial systems.

Breakout Board: Wiring, Software Setup 22

Turbo Clipper Drive User Manual

12345678

9101112131415

+5VDC
GND
CHU+
CHV+
CHW+

Note

At this point of the setup, you should be able to move the

motor/encoder shaft by hand and see ‘motor’ counts in the

position window

Hall-Effect Sensor Wiring

Motor Activation: Ixx00

Digital Quadrature Encoders use the 1/T incremental entry in the encoder conversion table.
Position and Velocity pointers are by default valid and in most cases no special software setup is
required, activating the motor(s) is sufficient to see encoder counts in the position window when
the motor/encoder shaft is moved by hand.

I100,4,100=1 ; Motors 1-4 activated

Breakout Board: Wiring, Software Setup 23

Turbo Clipper Drive User Manual

J9-J12: D-Sub DE-9F

Mating: D-Sub DE-9M

12345

6789

Pin #

Symbol

Function

Description

Notes

1

SIN +

Analog Input

Sinusoidal input+

2 COS +

Analog Input

Cosine input+

3 INDEX +

Input

Index input

Analog or TTL levels

4

ENCPWR

Output

Encoder power

+5VDC

5

GND

Digital ground

6

SIN -

Analog Input

Sinusoidal input-

7 COS -

Analog Input

Cosine input-

8 INDEX -

Input

Index input

Analog or TTL levels

9

VREF

2.5V Output

A-D reference output

Position And Velocity Pointers

Channels 1-4

I103=$3503 I104=$3503
I203=$3506 I204=$3506
I303=$3509 I304=$3509
I403=$350C I404=$350C

Note

At this point of the setup, you should be able to move the

motor/encoder shaft by hand and see ‘motor’ counts in the

position window

ACC-51S: Sinusoidal Feedback (Optional)

The accessory ACC-51S allows the Turbo Clipper Drive to interface to up to 4 sinusoidal
feedback devices. This high resolution interpolator circuitry accepts inputs from sinusoidal or
quasi-sinusoidal encoders (1-Volt peak to peak) and provides encoder position data. It creates
4,096 steps per sine-wave.

// Channel 1
I8000=$FF8000 ; High resolution interpolator
I8001=$078B00 ; A/D converter address
I8002=$000000 ; Bias Term and Entry result
// Channel 2
I8003=$FF8008 ; High resolution interpolator
I8004=$078B02 ; A/D converter address
I8005=$000000 ; Bias Term and Entry result
// Channel 3
I8006=$FF8010 ; High resolution interpolator
I8007=$078B04 ; A/D converter address
I8008=$000000 ; Bias Term and Entry result
// Channel 4
I8009=$FF8018 ; High resolution interpolator
I8010=$078B06 ; A/D converter address
I8011=$000000 ; Bias Term and Entry result

I100,4,100=1 ; Axis 1-4 active

Position and Velocity feedback pointers should now be set to the corresponding ECT result:

Breakout Board: Wiring, Software Setup 24

Turbo Clipper Drive User Manual

J15: Molex (M)
Molex Mating Connector Part #:: 22-01-3027 (F)
Molex Crimper Pin Part #: 08-50-0114

For Internal Use:
DT Part #: 014-000R02-LHM
DT Part #: 025-500114-PNM

Sinking Configuration

Pin #

Symbol

Function

Description

1

24VDC FLA_PWR

Input

Flag Power (+24VDC)

2

24VDC FLA_RET

Input

Flag Return (Common)

Sourcing Configuration

Pin #

Symbol

Function

Description

1

24VDC FLA_RET

Input

Flag Return (Common)

2

24VDC FLA_PWR

Input

Flag Power (+24VDC)

J16/J17/J18/J19: Molex (M)
Molex Mating Connector Part #: 22-01-3047 (F)
Molex Crimper Pin Part #: 08-50-0114

For Internal Use:
DT Part #: 014-000R04-LHM
DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

1

PLIM +

Input

Positive Limit+

2

MLIM +

Input

Negative Limit+ 3 HOME +

Input

Home+

4

FLA_PWR/RET

Common

Flag PWR/RET

Note

 For 5V flags: Install RP3, RP7, RP11, RP15 (1 kΩ sip).
 SIPs are 8-pin, four independent Resistors.
 For 12-24V flags: Empty bank (default).

J15: Flag(s) Power Supply

The flag(s) wiring is user configurable; it can be either sinking or sourcing.

J16-J19: Axis 1 thru 4 Limits & Home Flags

The Turbo Clipper Drive limits and flags circuitry offers a flexible 12-24Volts or 5Volts
connectivity. In its default configuration, the flags and limits are 12-24Volts inputs. If you are
using 5Volt flags and limits, make sure you have ordered the appropriate option before wiring
any flags.

Breakout Board: Wiring, Software Setup 25

J20: Molex (M)
Molex Mating Connector Part #: 22-01-3057 (F)
Molex Crimper Pin Part #: 08-50-0114

For Internal Use:
DT Part #: 014-000R05-LHM
DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

1

EQU_1+

Input

Position Compare 1+

2

EQU_2+

Input

Position Compare 2+

3

EQU_3+

Input

Position Compare 3+

4

EQU_4+

Input

Position Compare 4+

5

GND

Common

Ground

J21: Molex (M)
Molex Mating Connector Part #: 22-01-3057 (F)
Molex Crimper Pin Part #: 08-50-0114

For Internal Use:
DT Part #: 014-000R05-LHM
DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

1

USER_1+

Input

User Flag 1+

2

USER_2+

Input

User Flag 2+

3

USER _3+

Input

User Flag 3+

4

USER _4+

Input

User Flag 4+ 5 GND

Common

Ground

J20: Axis 1 thru 4 EQU Outputs

J21: Axis 1 thru 4 User Flags

Turbo Clipper Drive User Manual

Breakout Board: Wiring, Software Setup 26

Turbo Clipper Drive User Manual

J15:Power Supply Input

Sinking/Sourcing

Pin#1

Pin#2

Sinking

24VDC+

+24VDC RET

Sourcing

+24VDC RET

24VDC+

Flag Supply

12-24VDC

24V

Return

Flag

Sourcing
Separate

Supply

0V

Flag Supply

12-24VDC

24V

0V

Return

Flag

Sinking

Separate

Supply

Limits and Flags (Axis1- 4) Suggested M-Variables

M115->X:$078000,19 ; User 1 flag input status
M116->X:$078000,9 ; EQU1, ENC1 compare output value
M120->X:$078000,16 ; Home flag 1 input status
M121->X:$078000,17 ; Positive Limit 1 flag input status
M122->X:$078000,18 ; Negative Limit 1 flag input status

M215->X:$078008,19 ; User 2 flag input status
M216->X:$078008,9 ; EQU2, ENC2 compare output value
M220->X:$078008,16 ; Home flag 2 input status
M221->X:$078008,17 ; Positive Limit 2 flag input status
M222->X:$078008,18 ; Negative Limit 2 flag input status

M315->X:$078010,19 ; User 3 flag input status
M316->X:$078010,9 ; EQU3, ENC3 compare output value
M320->X:$078010,16 ; Home flag 3 input status
M321->X:$078010,17 ; Positive Limit 3 flag input status
M322->X:$078010,18 ; Negative Limit 3 flag input status

M415->X:$078018,19 ; User 4 flag input status
M416->X:$078018,9 ; EQU4, ENC4 compare output value
M420->X:$078018,16 ; Home flag 4 input status
M421->X:$078018,17 ; Positive Limit 4 flag input status
M422->X:$078018,18 ; Negative Limit 4 flag input status

The Turbo Clipper Drive allows the use of sinking or sourcing limits and flags. The opto-isolator
IC used is a PS2705-1NEC quad phototransistor output type. This IC allows the current to flow
from return to flag (sinking) or from flag to return (sourcing).

The flags can be sinking and/or sourcing per channel depending on the Flag Input Power Supply
J15 wiring.

Breakout Board: Wiring, Software Setup 27