Delta Tau TURBO CLIPPER DRIVE User Manual

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^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. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com

Turbo Clipper Drive User Manual

© 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: (818) 717-5656 Fax: (818) 998-7807 Email: support@deltatau.com Website: http://www.deltatau.com

Operating Conditions

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

In the case of industrial applications, we expect our products to be protected from hazardous or conductive materials and/or environments that could cause harm to the controller by damaging components or causing electrical shorts. When our products are used in an industrial environment, install them into an industrial electrical cabinet or industrial PC to protect them from excessive or corrosive moisture, abnormal ambient temperatures, and conductive materials. If Delta Tau Data Systems, Inc. products are 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

PRELIMINARY MANUAL CREATION

07/01/10

M.Y

R.N

FORMATTING & CORRECTIONS

09/25/10

M.Y

R.N

MANUAL RELEASE

01/13/10

R.N

ASSEMBLY DRAWING

03/29/11

M.Y

R.N

CORRECTED PIN-OUT, PAGE 43

04/18/11

M.Y

R.N

FORMAT. FIXED LABES J37

12/18/12

R.N

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

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

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

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

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

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

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

D/A converter

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)

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

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

U Phase

Axis 1-4

GND

Ground

V Phase

Axis 1-4

W Phase

Axis 1-4 5 GND

Ground

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

24VDC

Input

Logic power input

+16~32VDC

24VDC RET

Common

Logic power return

Power Supply Return

24VDC

Input

Logic power input

+16~32VDC

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

+12~60VDC

Input

Bus power input VBus

+12~60VDC

+12~60VDC RET

Common

Bus power return 0Bus

+12~60VDC RET

Fuse (FRN/LPN)

Wire Gauge

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

Reset

Connect 1-2 to activate the reset.

Reset

E-STOP

Connect 3-4 to engage the E-Stop

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

J13

Board

Jumper

Function

Default

Power

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

Not Installed

Power

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

Not Installed

Power

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

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)

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

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

GRD

Input

Ground

+5 VDC

Input

5 volt Input

+12 VDC

Input

12 volt Input

-12 VDC

Input

-12 volt Input

J11-J14: D-sub DA-15F

Mating: D-sub DA-15M

2345

9101112

1314

Pin#

Symbol

Function

Description

CHA+

Input

Axis Encoder A+

CHB+

Input

Axis Encoder B+

CHC+

Input

Axis Encoder Index+

ENCPWR

Output

Encoder Power 5V

CHU+ / DIR+

In/Out

Halls U+ / Direction Output + for Stepper

CHW+/ PUL+

In/Out

Halls W+ / Pulse Output + for Stepper

2.5V

Output

2.5V Reference power

Stepper Enable

Input

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

CHA-

Input

Axis Encoder A-

CHB-

Input

Axis Encoder B-

CHC-

Input

Axis Encoder Index-

GND

Common

Common ground

CHV+ / DIR-

In/Out

Halls V+ / Direction Output- for Stepper

CHT+ / PUL-

In/Out

Halls T+ / Pulse Output- for Stepper

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

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

SIN +

Analog Input

Sinusoidal input+

2 COS +

Analog Input

Cosine input+

3 INDEX +

Input

Index input

Analog or TTL levels

ENCPWR

Output

Encoder power

+5VDC

GND

Digital ground

SIN -

Analog Input

Sinusoidal input-

7 COS -

Analog Input

Cosine input-

8 INDEX -

Input

Index input

Analog or TTL levels

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

24VDC FLA_PWR

Input

Flag Power (+24VDC)

24VDC FLA_RET

Input

Flag Return (Common)

Sourcing Configuration

Pin #

Symbol

Function

Description

24VDC FLA_RET

Input

Flag Return (Common)

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

PLIM +

Input

Positive Limit+

MLIM +

Input

Negative Limit+ 3 HOME +

Input

Home+

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

EQU_1+

Input

Position Compare 1+

EQU_2+

Input

Position Compare 2+

EQU_3+

Input

Position Compare 3+

EQU_4+

Input

Position Compare 4+

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

USER_1+

Input

User Flag 1+

USER_2+

Input

User Flag 2+

USER _3+

Input

User Flag 3+

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

Flag Supply

12-24VDC

24V

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

Sinking

24V

24 V Supply

J15

Breakout

Outside

FL_RT

FLA_PWR/RET FLA_RET/PWR

Load

Pos.Limit

Neg.Limit

Home

3 4 5 User 1

User 2

User 3

User 4

3 4 5 EQU 1

EQU 2

EQU 3

EQU 4

J16-J19

24V

24 V Supply

J15

Breakout

Outside

FL_RT

FLA_PWR/RET

FLA_RET/PWR

Load

Pos.Limit #n

Neg.Limit #n

Sourcing

12~24V

24V

User Flags and EQU Outputs

J16-J19

J21

J20

Wiring The Flags

Turbo Clipper Drive User Manual

World

Flags

Board

World

Board

Flags

Supply

Breakout Board: Wiring, Software Setup 28

Turbo Clipper Drive User Manual

J21: 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

Pin #

Symbol

Function

Description

+5V_5A

Output

5 volts in normal operation

B_WDO

Output

Ground

J23: Watchdog Output

This connector allows the user to send Ohm output from the Turbo Clipper Drive to the machine if a watchdog condition has occurred. This is an important safety feature because the Clipper Amp is totally disabled when it is in watchdog condition and this output will allow the other

machine’s hardware/logic to bring the process to a safe condition. In normal operation there is 5

volts between pin 1 and 2 and in the time of watchdog this will drop to zero.

Breakout Board: Wiring, Software Setup 29

Turbo Clipper Drive User Manual

Note

This feature is only available if the power board is not present.

J24: Molex (M) Molex Mating Connector Part #: 22-01-3037 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000R03-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

GRD

Output

Ground

DAC_PWM+

Output

DAC Output+

DAC_PWM-

Output

DAC Output-

M8000

DAC (V)

981

J24: DAC Output, 12-bit Filtered PWM

The Turbo Clipper board, ordered with Option-12, has an additional 12-bit filtered PWM output.

I6800= 981 ; PWM frequency ~30kHz I6801= 5 ; Phase Clock ~10kHz I6802= 3 ; Servo frequency ~2.5Hz I6816= 0 ; Output Model PWM I569= 981 ; DAC limit 10Vdc I502 =$07841A ; Only Second output is used M8000->Y:$7841A,8,16,S ; Supplementary Channel 2* Output A Command Value ; Min=0, Max= Ixx69

Testing The Filtered PWM DAC Output

Writing, directly to the suggested M-variable (i.e. M8000), produces corresponding voltages:

Breakout Board: Wiring, Software Setup 30

Turbo Clipper Drive User Manual

Note

This feature is only available if the power board is not present.

J25: Molex (M) Molex Mating Connector Part #: 22-01-3037 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000R03-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

GRD

Input

Ground

ADC_IN 1

Input

ADC Input 1

ADC_IN 2

Input

ADC Input 2

Input Voltage

Software Counts

Bipolar

-10

-2048

-5

-1024

+10

+2048

+1024

Input Voltage

Software Counts

Unipolar

+10

+2048

+1024

Note

These ADCs do not provide full resolution in Unipolar (0-10V, or 0-5V) mode. Only Bipolar inputs are supported for the full 12-bit (4096 count range) resolution.

J25: ADC Inputs

The Turbo Clipper board, ordered with Option-12, provides with two single ended 12-bit analog inputs. The ±10V input range corresponds to ±2048 software counts.

Setting Up The Analog Inputs:

Bipolar Mode

I7003 = 1746 ; Set ADC clock frequency at 4.9152 MHz I7006 = $1FFFFF ; ADC Strobe Word M105->Y:$78005,12,12,S ; ADC Input 1 on J25 pin 2 M205->Y:$7800D,12,12,S ; ADC Input 2 on J25 pin 3

Unipolar Mode

I7003 = 1746 ; Set ADC clock frequency at 4.9152 MHz I7006 = $1FFFFF ; ADC Strobe Word M105->Y:$78005,12,12,u ; ADC Input 1 on J25 pin 2 M205->Y:$7800D,12,12,u ; ADC Input 2 on J25 pin 3

Testing the Analog Inputs:

Breakout Board: Wiring, Software Setup 31

J26: Molex (M) Molex Mating Connector p/n#:22-01-3107 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: : 014-000W10-LHM DT Part #: 025-500114-PNM

Pin#

Symbol

Function

Description

IN_PWR/RET

RTNFL

Return Flag (Tie to 0V or 24V)

IN_COM_1

RTNFL

Return Flag (Tie to 0V or 24V)

JTHW_IN00

Input

DAT0

JTHW_IN01

Input

DAT1

JTHW_IN02

Input

DAT2

JTHW_IN03

Input

DAT3

JTHW_IN04

Input

DAT4

JTHW_IN05

Input

DAT5

JTHW_IN06

Input

DAT6

JTHW_IN07

Input

DAT7

J26: Thumbwheel Multiplexer Port Inputs

Turbo Clipper Drive User Manual

Breakout Board: Wiring, Software Setup 32

Turbo Clipper Drive User Manual

J27: Molex (M) Molex Mating Connector Part #: 22-01-3107 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: : 014-000W10-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

COM_EMT _1

RTNFL

Tie to Common 0V (Sinking)

COM_EMT_1

RTNFL

Tie to Common 0V (Sinking)

JTHW_OUT1+

Input

SEL 0

JTHW_OUT2+

Input

SEL 1

JTHW_OUT3+

Input

SEL 2

JTHW_OUT4+

Input

SEL 3

JTHW_OUT5+

Input

SEL 4 8 JTHW_OUT6+

Input

SEL 5

JTHW_OUT7+

Input

SEL 6

N/A

J27: Thumbwheel Multiplexer port Outputs (sinking)

Breakout Board: Wiring, Software Setup 33

Turbo Clipper Drive User Manual

J37: Molex (M) Molex Mating Connector Part #: 22-01-3107 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000W10-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

COM_COL_1

RTNFL

Tie to 24VDC (Sourcing)

COM_COL_1

RTNFL

Tie to 24VDC (Sourcing)

JTHW_OUT1-

Output

SEL0 4 JTHW_OUT2-

Output

SEL 1

JTHW_OUT3-

Output

SEL 2

JTHW_OUT4-

Output

SEL 3

JTHW_OUT5-

Output

SEL 4

JTHW_OUT6-

Output

SEL 5

JTHW_OUT7-

Output

SEL 6

N/A

J37: Thumbwheel Multiplexer port Outputs (Sourcing)

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

The inputs and outputs on the thumbwheel multiplexer port (J26-J27-J37) can be used as discrete, non-multiplexed general purpose I/Os, and accessed through M-Variable pointers:

M40->Y:$78402,8,1 ; SEL0 Output M41->Y:$78402,9,1 ; SEL1 Output M42->Y:$78402,10,1 ; SEL2 Output M43->Y:$78402,11,1 ; SEL3 Output M44->Y:$78402,12,1 ; SEL4 Output M45->Y:$78402,13,1 ; SEL5 Output M46->Y:$78402,14,1 ; SEL6 Output M47->Y:$78402,15,1 ; SEL7 Output M48->Y:$78402,8,8,U ; SEL0-7 Outputs treated as a byte M50->Y:$78402,0,1 ; DAT0 Input M51->Y:$78402,1,1 ; DAT1 Input M52->Y:$78402,2,1 ; DAT2 Input M53->Y:$78402,3,1 ; DAT3 Input M54->Y:$78402,4,1 ; DAT4 Input M55->Y:$78402,5,1 ; DAT5 Input M56->Y:$78402,6,1 ; DAT6 Input M57->Y:$78402,7,1 ; DAT7 Input M58->Y:$78402,0,8,U ; DAT0-7 Inputs treated as a byte

Breakout Board: Wiring, Software Setup 34

6 7 8

J26

Sinking

24V

24 V Supply

Inputs

1-8

J30

Breakout

Outside

JTHW_IN01

PWR

COM

JTHW_IN02

JTHW_IN03

JTHW_IN04

JTHW_IN05

JTHW_IN06

JTHW_IN07

JTHW_IN08

6 7 8

J26

Sourcing

Inputs

1-8

J30

Breakout

Outside

JTHW_IN01

GRD

COM

JTHW_IN02

JTHW_IN03

JTHW_IN04

JTHW_IN05

JTHW_IN06

JTHW_IN07

JTHW_IN08

24 V Supply 24V

PWR/RET

RET/PWR

PWR/RET

Wiring The Thumbwheel As Discrete I/Os

Turbo Clipper Drive User Manual

World

Board

World

Board

Input

Breakout Board: Wiring, Software Setup 35

Turbo Clipper Drive User Manual

Sinking

3 4 5

J37

24V

24 V Supply

Breakout

Outside

JTHW_OUT01-

COM_COL _1

COM_COL_1

JTHW_OUT02-

JTHW_OUT03-

JTHW_OUT04-

JTHW_OUT05-

JTHW_OUT06-

JTHW_OUT07-

JTHW_OUT08Output 01

Output 02

Output 03

Output 04

Output 05

Output 06

Output 07

Output 08

J27

Sourcing

24V

24 V Supply

Breakout

Outside

JTHW_OUT01+

COM_EMT_1

JTHW_OUT02+

JTHW_OUT03+

JTHW_OUT04+

JTHW_OUT05+

JTHW_OUT06+

JTHW_OUT07+

JTHW_OUT08+ Output 01

Output 02

Output 03

Output 04

Output 05

Output 06

Output 07

Output 08

World

Board

World

Board

Output

Breakout Board: Wiring, Software Setup 36

J28: Molex (M) Molex Mating Connector pn#: 22-01-3107(F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000W10-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

IN_PWR/RET

RTNFL

Return Flag (Tie to 0V or 24V)

IN_COM_2

RTNFL

Return Flag (Tie to 0V or 24V)

JOPT_IN01

Input

Input 1

JOPT_IN02

Input

Input 2

JOPT_IN03

Input

Input 3

JOPT_IN04

Input

Input 4

JOPT_IN05

Input

Input 5

JOPT_IN06

Input

Input 6

JOPT_IN07

Input

Input 7

JOPT_IN08

Input

Input 8

J28: General Purpose Inputs

Turbo Clipper Drive User Manual

Breakout Board: Wiring, Software Setup 37

J29: Molex (M) Molex Mating Connector pn#: 22-01-3107 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000W10-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

COM_EMT_2

RTNFL

Tie to Common 0V (Sinking)

COM_EMT_2

RTNFL

Tie to Common 0V (Sinking)

JOPT_OUT1+

Output

Output 1 + 4 JOPT_OUT2+

Output

Output 2 +

JOPT_OUT3+

Output

Output 3 +

JOPT_OUT4+

Output

Output 4 +

JOPT_OUT5+

Output

Output 5 +

JOPT_OUT6+

Output

Output 6 +

JOPT_OUT7+

Output

Output 7 +

JOPT_OUT8+

Output

Output 8 +

J29: General Purpose Outputs (sinking)

Turbo Clipper Drive User Manual

Breakout Board: Wiring, Software Setup 38

Turbo Clipper Drive User Manual

J30: 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

12~24VDC IN_PWR

Input

Flag Power (+24VDC)

12~24VDC IN_RET

Input

Flag Return (Common)

Sourcing Configuration

Pin #

Symbol

Function

Description

12~24VDC IN_RET

Input

Flag Return (Common)

12~24VDC IN_PWR

Input

Flag Power (+24VDC)

J30: General Purpose I/O Power

The general purpose I/O(s) wiring is user configurable; it can be either sinking or sourcing.

Breakout Board: Wiring, Software Setup 39

J38: Molex (M) Molex Mating Connector pn#: 22-01-3107(F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000W10-LHM DT Part #: 025-500114-PNM

Pin#

Symbol

Function

Description

COM_COL_2

RTNFL

Tie to 24VDC (Sourcing)

COM_COL _2

RTNFL

Tie to 24VDC (Sourcing)

JOPT_OUT1-

Output

Output 1 - 4 JOPT_OUT2-

Output

Output 2 -

JOPT_OUT3-

Output

Output 3 -

JOPT_OUT4-

Output

Output 4 -

JOPT_OUT5-

Output

Output 5 -

JOPT_OUT6-

Output

Output 6 -

JOPT_OUT7-

Output

Output 7 -

JOPT_OUT8-

Output

Output 8 -

J38: General Purpose Outputs (sourcing)

Turbo Clipper Drive User Manual

Breakout Board: Wiring, Software Setup 40

3 4 5

J28

Sinking

24V

12~24 V

Inputs

1-8

J30

Breakout

Outside

JOPT_IN01

PWR

COM

JOPT_IN02

JOPT_IN03

JOPT_IN04

JOPT_IN05

JOPT_IN06

JOPT_IN07

JOPT_IN08

6 7 8

J28

Sourcing

Inputs

1-8

J30

Breakout

Outside

JOPT_IN01

GRD

COM

JOPT_IN02

JOPT_IN03

JOPT_IN04

JOPT_IN05

JOPT_IN06

JOPT_IN07

JOPT_IN08

12~24 V

24V

PWR/RET

RET/PWR

PWR/RET

Wiring the General Purpose I/Os

Turbo Clipper Drive User Manual

World

Supply

Board

World

Supply

Board

Input

Breakout Board: Wiring, Software Setup 41

Turbo Clipper Drive User Manual

Sinking

3 4 5

J29

24V

12~24 V

Breakout

Outside

JOPT_OUT01+

COM_EMT_2

JOPT_OUT02+

JOPT_OUT03+

JOPT_OUT04+

JOPT_OUT05+

JOPT_OUT06+

JOPT_OUT07+

JOPT_OUT08+ Output 01

Output 02

Output 03

Output 04

Output 05

Output 06

Output 07

Output 08

J38

Sourcing

24V

12~24 V

Breakout

Outside

JOPT_OUT01-

COM_COL_2

JOPT_OUT02-

JOPT_OUT03-

JOPT_OUT04-

JOPT_OUT05-

JOPT_OUT06-

JOPT_OUT07-

JOPT_OUT08Output 01

Output 02

Output 03

Output 04

Output 05

Output 06

Output 07

Output 08

World

Supply

Board

World

Supply

Board

Output

Breakout Board: Wiring, Software Setup 42

Turbo Clipper Drive User Manual

General Purpose I/Os, Suggested M-Variables

M1->Y:$78400,0 ; Digital Output 1 M2->Y:$78400,1 ; Digital Output 2 M3->Y:$78400,2 ; Digital Output 3 M4->Y:$78400,3 ; Digital Output 4 M5->Y:$78400,4 ; Digital Output 5 M6->Y:$78400,5 ; Digital Output 6 M7->Y:$78400,6 ; Digital Output 7 M8->Y:$78400,7 ; Digital Output 8

M9->Y:$78400,8 ; Digital Input 1 M10->Y:$78400,9 ; Digital Input 2 M11->Y:$78400,10 ; Digital Input 3 M12->Y:$78400,11 ; Digital Input 4 M13->Y:$78400,12 ; Digital Input 5 M14->Y:$78400,13 ; Digital Input 6 M15->Y:$78400,14 ; Digital Input 7 M16->Y:$78400,15 ; Digital Input 8

M32->X:$78400,0,8 ; Direction Control bits 0-7 (1=output, 0 = input) M34->X:$78400,8,8 ; Direction Control bits 8-15 (1=output, 0 = input) M40->X:$78404,0,24 ; Inversion control (0 = 0V, 1 = 5V) M42->Y:$78404,0,24 ; J9 port data type control (1 = I/O)

//In order to properly setup the digital I/Os, an initialization PLC must be written scanning //through once on power-up/reset, setting control statuses then disabling itself:

Open PLC 1 clear M32=$FF ; BITS 0-7 are assigned as output M34=$0 ; BITS 8-15 are assigned as input M40=$FF00 ; Define inputs and outputs M42=$FFFF ; All lines are I/O type DIS PLC1 ; Disable PLC1 (scanning through once on power-up/reset) Close

Breakout Board: Wiring, Software Setup 43

J31-J32: Molex (M) Molex Mating Connector Part #: 22-01-3067 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000R06-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

DGND

Common

Ground

+5V

Output

5 Volts

HW_A+

Input

Handwheel Quadrature A

HW_A-

Input

Handwheel Quadrature A/

HW _B+

Input

Handwheel Quadrature B

HW_B-

Input

Handwheel Quadrature B/

Quadratur

GND

5 V+

HW_A+

HW_A-

HW_B+

HW_B-

J31-J32: Handwheel Port(s)

Turbo Clipper Drive User Manual

A quadrature encoder type device is normally brought in to the handwheel port; it can be wired in either single-ended or differential mode. The ground has to be tied to the connectors’ ground, especially in single-ended applications.

The encoder data can be exported to the Encoder Conversion Table allowing direct access with an M-variable or used as a master position for a specific motor (Ixx05). Example:

I8000=$78410 ; Entry 1: 1/T extension of location $78410 MACRO IC 1 M8010->X:$3501,0,24,S ; ECT 1st entry result I8001=$78418 ; Entry 2: 1/T extension of location $78418 MACRO IC 2 M8011->X:$3502,0,24,S ; ECT 2nd entry result

e Encoder

Breakout Board: Wiring, Software Setup 44

J33-J34: Molex (M) Molex Mating Connector Part #: 22-01-3067 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000R06-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

DGND

Common

Ground

+5V

Output

5 Volts

PUL~+

Output

Pulse Plus

PUL~-

Output

Pulse Minus

DIR~+

Output

Direction Plus

DIR~-

Output

Direction Minus

Step1

Step2

Results

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

Turbo Clipper Drive User Manual

The Turbo Clipper Drive offers two additional Step and Direction (Pulse Frequency Modulation) outputs, using the supplementary channels. These signals can be connected in either differential or single-ended configuration for 5V input drives. Using the Delta Tau Calculator or referring to the Turbo Software Reference Manual, the desired maximum PFM Frequency and pulse width can be chosen. DT Calculator Link

Breakout Board: Wiring, Software Setup 45

Turbo Clipper Drive User Manual

M8000

PFM [KHz]

1213

2427

Step1 : Choose Max PFM clock by changing the PFM clock divider in the calculator Step2 : Choose PFM Pulse Width by changing I7m04 in the calculator

For a PFM clock range 0-20 KHz, and a pulse width of ~20 μsec:

I6803=2290 ; PFM Clock divider equal to 6 I6804=13 ; PFM Pulse Width Control equal to 13

The output frequency control Ixx69 specifies the maximum command output value that corresponds to the maximum PFM Frequency.

I6826=3 ; MACRO IC0 Channel2 Output Mode Select. C PFM M8000->Y:$7841C,8,16,S ; Supplementary Channel 2* Output C Command Value ; Min=0, Max= Calculated Ixx69

Testing The PFM Output

Writing, directly to the suggested M-variable (i.e. M8000), values proportional to Ixx69 produces corresponding frequencies:

Breakout Board: Wiring, Software Setup 46

Turbo Clipper Drive User Manual

Example:

Axis 5-6 to drive stepper amps, w/ PFM clock range 0-20 KHz and pulse width of ~20 μsec:

I6803=2290 ; PFM Clock divider equal to 6 I6804=13 ; PFM Pulse Width Control equal to 13 // Supplementary Channel 1, and 2 Settings: I6816,2,10=3 ; Supp. channel 1-2 output mode, PFM I6810,2,10=8 ; Supp. channel 1-2 Encoder Decode, Internal Pulse and Direction I500,2,100=1 ; Motors 5,6 active I511,2,100=0 ; Motors 5,6 disable fatal following error

I502=$78414 ; Motor #5 output to point to output c for PFM I8004=$C78410 ; Encoder Conversion table to read, C for no extension I503=$3505 I504=$3505 I524=$120001 ; Disable amp fault and overtravel limits I525=$78410 ;

I602=$7841C ; #2 output to point to output c for PFM I8005=$C78418 ; Encoder Conversion table to read, C for no extension I603=$3506 I604=$3506 I624=$120001 ; Disable amp fault and over travel limit I625=$78418

The position-Loop PID Gains are calculated using the following equations: Ixx30=660000/Ixx08*PFM Clock[MHz] Ixx31=0 Ixx32 = 6660* ServoFreq( kHz ) Ixx33...Ixx35=0

// Position-Loop PID Gains: I530,2,100=11190 ; Motors 5-6 Proportional Gain I531,2,100=0 ; Motors 5-6 Derivative Gain I532,2,100=151515 ; Motors 5-6 Velocity FeedForward Gain I533,2,100=0 ; Motors 5-6 Integral Gain I534,2,100=0 ; Motors 5-6 Integral Mode I535,2,100=0 ; Motors 5-6 Acceleration FeedForward Gain

Breakout Board: Wiring, Software Setup 47

J35: Molex (M) Molex Mating Connector Part #: 22-01-3067 (F) Molex Crimper Pin Part #: 08-50-0114

For Internal Use: DT Part #: 014-000R06-LHM DT Part #: 025-500114-PNM

Pin #

Symbol

Function

Description

DGND

Common

Ground

+5V

Output

5 Volts

PGOUT0+

Output

Programmable output 0+

PGOUT0-

Output

Programmable output 0-

PGOUT1+

Output

Programmable output 1+

PGOUT1-

Output

Programmable output 1-

J35: Programmable Output

Turbo Clipper Drive User Manual

Clipper’s Option 11 consists of a programmable lattice chip which can be programmed based upon customer’s requirements for laser control. Refer to Turbo Clipper Hardware Reference

Manual for more descriptions.

Breakout Board: Wiring, Software Setup 48

Turbo Clipper Drive User Manual

External Amp 1-4: D-Sub DE-9F

Mating: D-Sub DE-9M

12345

6789

Pin#

Symbol

Function

Description

GND

Common

Ground

DAC-

Output

DAC Output -

GND

Common

Ground

DIR+

Output

Direction Plus Output

FALT-

Input

Amp Fault

DAC+

Output

DAC Output+

+5V_5A

Output

5 volts Output

PUL+

Output

Pulse Plus Output

AENA-

Output

Amp Enable

External Amp 1-4:

If the power board is attached to the assembly, these connectors are not used in most cases. A good usage for them is driving a high power motor with a 3rd party amplifier in either pulse and direction (PFM) or Filtered PWM (DAC) mode.

If the power board is not attached to the stack, these connectors serve as the traditional connection to the drive(s) and are set up as any Turbo PMAC2 for pulse and direction (PFM) or Filtered PWM (DAC) output.

Pulse and direction Setup Example, channels 1-4:

I100,4,100=1 ; Motor 1-4 activation I7016,4,10=3 ; Servo IC 0 Channel 1-4 output mode, PFM I7010,4,10=8 ; Servo IC 0 Channel 1-4 Encoder Decode ; Internal pulse and direction I102=$78004 ; Mtr1 output to point to channel 1 output c for PFM I202=$7800c ; Mtr2 output to point to channel 2 output c for PFM I302=$78014 ; Mtr3 output to point to channel 3 output c for PFM I402=$7801C ; Mtr4 output to point to channel 4 output c for PFM I8000=$C78000 ; C for Incremental Encoder, mode switch = no extension I8001=$C78008 ; C for Incremental Encoder, mode switch = no extension I8002=$C78010 ; C for Incremental Encoder, mode switch = no extension I8003=$C78018 ; C for Incremental Encoder, mode switch = no extension I103,2,1=$3501 ; I203,2,1=$3502 ; I303,2,1=$3503 ; I403,2,1=$3504 ;

I124,4,100=$120001 ; Disable amp fault and overtravel limits I125=$78000 ; I225=$78008 ; I325=$78010 ; I425=$78018 ; I111,4,100=0 ; Disable fatal following error

Breakout Board: Wiring, Software Setup 49

Turbo Clipper Drive User Manual

Filtered PWM (DAC) output Example, channels 1-4:

I7000= 981 ; PWM frequency ~30kHz I7001= 5 ; Phase Clock ~10kHz I7002= 3 ; Servo frequency ~2.5Hz I7016,4,10= 0 ; Output Mode PWM I169,4,100= 981 ; DAC limit 10Vdc I102 =$078002 ; M8000->Y:$78002,8,16,S ; Servo IC 0 ch1 Output A Command Value Min=0, Max= I169 I202=$07800A ; M8000->Y:$7800A,8,16,S ; Servo IC 0 ch2 Output A Command Value Min=0, Max= I269 I302=$078012 ; M8000->Y:$78012,8,16,S ; Servo IC 0 ch3 Output A Command Value Min=0, Max= I369 I202=$07801A ; M8000->Y:$7801A,8,16,S ; Servo IC 0 ch4 Output A Command Value Min=0, Max= I469

Breakout Board: Wiring, Software Setup 50

Turbo Clipper Drive User Manual

Pin #

Symbol

Function

VCC

N.C.

D-

Data-

D+

Data+

Gnd

GND

Shell

Shield

Shell

Shield

CLIPPER BOARD: WIRING, SOFTWARE SETUP

USB 2.0 Connector

This connector uses a USB A-B cable to establish communication between the PC and the Turbo Clipper Drive Drive. This type of USB cable could be purchased at any local electronics or computer store. It may be ordered from Delta Tau as well.

RJ45, Ethernet Connector

This connector is used to establish communication over Ethernet between the PC and the Turbo Clipper Drive Drive. A crossover cable is required if you are going directly to the Clipper board from the PC Ethernet card, and not through a hub. Delta Tau strongly recommends the use of RJ45 CAT5e or better shielded cable. Newer network cards have the Auto-MDIX feature that eliminates the need for crossover cabling by performing an internal crossover when a straight cable is detected during the auto-negotiation process. For older network cards, one end of the link must perform media dependent interface (MDI) crossover (MDIX), so that the transmitter on one end of the data link is connected to the receiver on the other end of the data link (a crossover/patch cable is typically used). If an RJ45 hub is used, then a regular straight cable must be implemented. Maximum length for Ethernet cable should not exceed 100m (330ft).

Clipper Board: Wiring, Software Setup 51

Turbo Clipper Drive User Manual

RS-232: D-sub DE-9F

Mating: D-Sub DE-9M

12345

6789

N.C.

DTR

TXD

CTS

RXD

RTS

DSR

N.C.

GND

Pin#

Symbol

Function

Description

Notes

N.C.

TXD

Output

Receive data

Host transmit Data

RXD

Input

Send data

Host receive Data

DSR

Bi-directional

Data set ready

Tied to “DTR”

GND

Common

Common GND

DTR

Bi-directional

Data term ready

Tied to “DSR”

CTS

Input

Clear to send

Host ready bit

RTS

Output

Req. to send

PMAC ready bit

N.C

I54

Baud Rate

I54

Baud Rate

9600

*12

38,400

14,400

57,600

19,200

76,800

28,800

115,200

RS232: Serial Communication Port

An optional serial RS-232 communication port is available on the Turbo Clipper Drive drives. This port can be used as a primary communication mean or employed as a secondary port that allows simultaneous communication.

The baud rate for the RS-232 serial port is set by variable I54. At power-up reset, The Turbo Clipper Drive sets the active baud based on the setting of I54 and the CPU speed I52. Note that the baud rate frequency is divided down from the CPU’s operational frequency. The factory default baud rate is 38400. This baud rate will be selected automatically on re-initialization of the Turbo Clipper Drive, either in hardware using the re-initialization (RESET SW) button or in software using the $$$*** command.

To change the baud rate setting on the Turbo Clipper Drive Drive, set I54 to the corresponding value of desired frequency. Issue a SAVE and recycle power on the unit. For odd baud rate settings, refer to the Turbo Software Reference Manual.

*Default Setting

Clipper Board: Wiring, Software Setup 52

Turbo Clipper Drive User Manual

Note

The Geo Brick LV Setup Software generates this PLC

automatically as you select and setup motors. Choosing “save settings” before exiting the setup window will save the PLC to

the Turbo Clipper Drive.

MOTOR TYPE & PROTECTION POWER-ON PLCS

The current firmware version of the Turbo Clipper Drive requires motor mode setup, and clearing faults (local protection setup) on power-up. These tasks can be combined in a single PLC to execute once on power-up. The motor mode setup tells the firmware what type of motor (i.e. brush, brushless, stepper) is connected to which channel. Clearing faults (local protection setup) can be done by re-enabling the PLC whenever needed.

Stepper Motor Power-On PLC

End Gat ; End gather Del Gat ; Delete gather data Close ; Close (any) open buffer I5=I5|2 ; Allow background PLCs to execute Open plc 1 clear ; Open buffer Disable PLCC 0..31 ; Disable all Compiled PLCs Disable plc 0 ; Disable Foreground PLC Disable plc 2..31 ; Disable all other Background PLCs I5111=1000*8388608/I10 While (I5111>0) Endw ; 1 sec Delay CMD"wx$78014,$F8CDFE" ; Axis1 Clear Fault (Stepper) CMD"wx$78014,$F84DFE" ; Axis1 Local protection & type (Stepper) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$F9CDFE" ; Axis2 Clear Fault (Stepper) CMD"wx$78014,$F94DFE" ; Axis2 Local protection & type (Stepper) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$FACDFE" ; Axis3 Clear Fault (Stepper) CMD"wx$78014,$FA4DFE" ; Axis3 Local protection & type (Stepper) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$FBCDFE" ; Axis4 Clear Fault (Stepper) CMD"wx$78014,$FB4DFE" ; Axis4 Local protection & type (Stepper) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay Enable plc 2..31 ; Re-enable all other Background PLCs Enable plc 0 ; Re-enable Foreground PLC Enable plcc 0..31 ; Re-enable Compiled PLCs Disable plc 1 ; Disable PLC1 Close ; close currently open buffer

Motor Type & Protection Power On PLCs 53

Turbo Clipper Drive User Manual

Note

It is possible to mix and match motor types by choosing the corresponding axis motor type setup and local protection in the power-on PLC. See example below.

Brushless/Brush Motor Power-On PLC

End Gat ; End gather Del Gat ; Delete gather data Close ; Close (any) open buffer I5=I5|2 ; Allow background PLCs to execute Open plc 1 clear ; Open buffer Disable PLCC 0..31 ; Disable all Compiled PLCs Disable plc 0 ; Disable Foreground PLC Disable plc 2..31 ; Disable all other Background PLCs I5111=1000*8388608/I10 While (I5111>0) Endw ; 1 sec Delay CMD"wx$78014,$F8CCFE" ; Axis1 Clear Fault (brushless/brush) CMD"wx$78014,$F84CFE" ; Axis1 Local protection & type (brushless/brush) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$F9CCFE" ; Axis2 Clear Fault (brushless/brush) CMD"wx$78014,$F94CFE" ; Axis2 Local protection & type (brushless/brush) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$FACCFE" ; Axis3 Clear Fault (brushless/brush) CMD"wx$78014,$FA4CFE" ; Axis3 Local protection & type (brushless/brush) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$FBCCFE" ; Axis4 Clear Fault (brushless/brush) CMD"wx$78014,$FB4CFE" ; Axis4 Local protection & type (brushless/brush) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay Enable plc 2..31 ; Re-enable all other Background PLCs Enable plc 0 ; Re-enable Foreground PLC Enable plcc 0..31 ; Re-enable Compiled PLCs Disable plc 1 ; Disable PLC1 Close ; Close currently open buffer

Hybrid Motor Power-On PLC Example

A Clipper Drive has 2 steppers on axes 1 and 2, two brushless or brush motors on axes 3 and 4;

End Gat ; End gather Del Gat ; Delete gather data Close ; Close (any) open buffer I5=I5|2 ; Allow background PLCs to execute

Open plc 1 clear ; Open buffer Disable PLCC 0..31 ; Disable all Compiled PLCs Disable plc 0 ; Disable Foreground PLC Disable plc 2..31 ; Disable all other Background PLCs I5111=1000*8388608/I10 While (I5111>0) Endw ; 1 sec Delay CMD"wx$78014,$F8CDFE" ; Axis1 Clear Fault (Stepper) CMD"wx$78014,$F84DFE" ; Axis1 Local protection & type (Stepper) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$F9CDFE" ; Axis2 Clear Fault (Stepper) CMD"wx$78014,$F94DFE" ; Axis2 Local protection & type (Stepper) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$FACCFE" ; Axis3 Clear Fault (brushless/brush) CMD"wx$78014,$FA4CFE" ; Axis3 Local protection & type (brushless/brush) I5111=100*8388608/I10 While (I5111>0) Endw ; 100 msec Delay CMD"wx$78014,$FBCCFE" ; Axis4 Clear Fault (brushless/brush) CMD"wx$78014,$FB4CFE" ; Axis4 Local protection & type (brushless/brush) Enable plc 2..31 ; Re-enable all other Background PLCs Enable plc 0 ; Re-enable Foreground PLC Enable plcc 0..31 ; Re-enable Compiled PLCs Disable plc 1 ; Disable PLC1 Close ; Close currently open buffer

Motor Type & Protection Power On PLCs 54

Turbo Clipper Drive User Manual

Note

For encoder-driven motors (none steppers), this section assumes that feedback device(s) have been setup properly, and that moving the motor/encoder shaft by hand shows correct data in the position window.

Encoder/Motor Wiring

Motor Type & Protection PLC

(Add, remove axes as necessary)

Encoder Software Setup. Verify Feedback, Rotate Shaft By Hand.

(Not applicable for steppers)

Factory default Reset $$$***, Save, $$$

(Recommended for fresh installation)

Motor Setup By Type For Each Channel

Dominant Clock Settings

(Once per unit setup)

MOTOR SETUP GUIDELINES

This section provides with manual (step by step) motor setup guidelines for stepper, DC brushless, and brush motors. This motor setup segment should be the last of a few necessary steps to properly configure a motor with Turbo Clipper Drive drives.

Motor Setup Flow Chart

Motor Setup Guidelines 55

Turbo Clipper Drive User Manual

Ohms



sec



sec

)(









 HzPWM

PWM

Dominant Clock Settings

The choice of clock settings usually relies on system requirements, and type of application.

Calculating Minimum PWM Frequency

The minimum PWM frequency of a system is based on the time constant of the motor. In general, the lower the time constant, the higher the PWM frequency should be. The motor time constant is calculated dividing the motor inductance by the resistance (phase-phase). The minimum PWM Frequency is then determined using the following relationship:

Example: A motor with an inductance of 2.80 mH, resistance of 14  (phase-phase) yields a time constant of 0.200 milliseconds. Therefore, the minimum PWM Frequency is ~15.9KHz.

The most commonly used and recommended clock settings for Turbo Clipper Drive drives are 20 KHz PWM, 10 KHz Phase, and 5 KHz Servo:

I7000=1473 ; Servo IC0 Max Phase/PWM Frequency Control I7001=3 ; Servo IC0 Phase Clock Frequency Control I7002=1 ; Servo IC0 Servo Clock Frequency Control

I10=1677653 ; Servo Interrupt Time

Clock Calculations

These clock calculations are used in and imperative for subsequent section(s) in selected downloadable Turbo PMAC scripts. Whether default, recommended, or custom clock settings are chosen, these calculations should be downloaded and saved.

I15=0 ; Trigonometric calculation in degrees #define MaxPhaseFreq P7000 ; Max Phase Clock [KHz] #define PWMClk P7001 ; PWM Clock [KHz] #define PhaseClk P7002 ; Phase Clock [KHz] #define ServoClk P7003 ; Servo Clock [KHz]

MaxPhaseFreq=117964.8/(2*I7000+3) PWMClk=117964.8/(4*I7000+6) PhaseClk=MaxPhaseFreq/(I7001+1) ServoClk=PhaseClk/(I7002+1)

Motor Setup Guidelines 56

Turbo Clipper Drive User Manual

Setting Up Stepper Motor, Direct Micro-Stepping

Before you start

 It is always recommended to start a fresh setup from factory default settings, $$$***

followed by a Save and a $$$.

 Don’t forget to create/edit the motor type and protection power-on PLC.  Parameters with Comments ending with -User Input require the user to enter information

pertaining to their system/hardware.

 Downloading and using the suggested M-variables is highly recommended.  Detailed description of motor setup parameters can be found in the Turbo SRM Manual

Turbo SRM Link

The traditional direct-microstepping technique controlled with sinusoidal outputs from the Turbo PMAC is not appropriate for motors controlled with direct-PWM outputs such as in Turbo Clipper Drive Drives. A new technique permits direct microstepping along with direct-PWM motor control.

This technique creates a simulated position sensor and feedback loop by numerically integrating the (velocity) command output from the servo loop. This integration requires two entries in the encoder conversion table. The resulting simulated position value can be used for both motor phase commutation and servo-loop feedback. Alternately, a load encoder could be used for position-loop feedback while this simulated value is used for commutation.

Encoder Conversion Table Setup

The first entry in the encoder conversion table (ECT) for each stepper motor must read the servoloop output like an absolute encoder. This is done with a “parallel-read” entry of a Y/X double register (the data is in X), unshifted and unfiltered; specifying the use of 24 bits of the 48-bit Y/X register, starting 24 bits from the low end. This is effectively like reading a 24-bit DAC register.

The second entry in the ECT for each stepper motor integrates the result of the first entry.

Motor Setup Guidelines 57

Turbo Clipper Drive User Manual

Motor #

Address (X-Memory)

$0000BF

$00013F

$0001BF

$00023F

Motor (Quadrature/torque) command value Registers

Motors 1-4 Stepper Setup Encoder Conversion Table

I8000=$6800BF ; Parallel read of Y/X:$BF I8001=$18018 ; Use 24 bits starting at X bit 0 I8002=$EC0001 ; Integrate result from I8001 I8003=$68013F ; Parallel read of Y/X:$13F I8004=$18018 ; Use 24 bits starting at X bit 0 I8005=$EC0004 ; Integrate result from I8004 I8006=$6801BF ; Parallel read of Y/X:$1BF I8007=$18018 ; Use 24 bits starting at X bit 0 I8008=$EC0007 ; Integrate result from I8007 I8009=$68023F ; Parallel read of Y/X:$23F I8010=$18018 ; Use 24 bits starting at X bit 0 I8011=$EC000A ; Integrate result from I8010

Position, Velocity Pointers: Ixx03, Ixx04

The position and velocity pointers (no external encoder used) will be set to the integration result:

I103=$3503 I104=$3503 ; Motor 1 position and velocity feedback I203=$3506 I204=$3506 ; Motor 2 position and velocity feedback I303=$3509 I304=$3509 ; Motor 3 position and velocity feedback I403=$350C I404=$350C ; Motor 4 position and velocity feedback

Motor Activation, Commutation Enable: Ixx00, Ixx01

I100,4,100=1 ; Motors 1-4 active I101,4,100=1 ; Motors 1-4 Commutation Enabled

Command Output Address: Ixx02

I102=$078002 ; Motor 1 Output Address I202=$07800A ; Motor 2 Output Address I302=$078012 ; Motor 3 Output Address I402=$07801A ; Motor 4 Output Address

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

I182=$078006 ; Motor 1 Current Feedback Address I282=$07800E ; Motor 2 Current Feedback Address I382=$078016 ; Motor 3 Current Feedback Address I482=$07801E ; Motor 4 Current Feedback Address I184,4,100=$FFFC00 ; Motors 1-4 Current Loop Feedback Mask, 14-bit I172,4,100=512 ; Mtrs 1-4 Commutation Phase Angle.2-Phase opposite voltage & current sign

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Flag Address, Mode Control: Ixx25, Ixx24

I125=$078000 ; Motor 1 Flag Address I225=$078008 ; Motor 2 Flag Address I325=$078010 ; Motor 3 Flag Address I425=$078018 ; Motor 4 Flag Address I124=$800401 ; Motor 1 Flag Control. High True Amp Fault, disable 3rd Harmonic I224=$800401 ; Motor 2 Flag Control. High True Amp Fault, disable 3rd Harmonic I324=$800401 ; Motor 3 Flag Control. High True Amp Fault, disable 3rd Harmonic I424=$800401 ; Motor 4 Flag Control. High True Amp Fault, disable 3rd Harmonic

Commutation Address, Cycle size: Ixx83, Ixx70, Ixx71

I183=$3503 ; Motor 1 on-going Commutation Address (ECT Integration Result) I283=$3506 ; Motor 2 on-going Commutation Address (ECT Integration Result) I383=$3509 ; Motor 3 on-going Commutation Address (ECT Integration Result) I483=$350C ; Motor 4 on-going Commutation Address (ECT Integration Result) I170,4,100=1 ; Motors 1-4 Single cycle size I171,4,100=65536 ; Microsteps per Ixx70 commutation cycles

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Maximum Achievable Motor Speed, Output Command Limit: Ixx69

In Micro-Stepping, the maximum achievable speed is proportional to the Servo clock and Motor Step angle. A faster Servo Clock results in higher achievable motor speeds.

To ensure the safety of the application and reliability of the micro-stepping technique, the smaller value of the Theoretical versus Calculated output command limit Ixx69 must be chosen.

Theoretical Ixx69

Sine Table: 2048 Electrical Length = 2048*32 (5-bit shift) = 65536 Max Electrical Length per Servo Cycle = Electrical Length/6 = 10922.66667 Micro-Stepping Theoretical Ixx69 = Max Electrical Length per Servo Cycle/256 = 42.6667

Calculated Ixx69

Servo Clock (KHz): 8 Stepper Angle: 1.8° Motor Speed (rpm): 1500 Electrical Cycles per Revolution = 360 / (4*Stepper Angle) Maximum-Achievable Motor Speed (RPM) =

(Servo Clock*1000) / (Electrical Cycles per Revolution*6)*60

Calculated Ixx69 =

Max Motor Speed* Electrical Cycles per Revolution/ 60 * 2048/6/(Servo Clock *1000)

#define StepAngle 1.8 ; Step Angle [Degrees] –User Input #define MotorSpeed 1500 ; Motor Speed Spec [RPM] –User Input #define ElecCyclePerRev P7004 ; Electrical Cycle Per Revolution ElecCyclePerRev=360/(4* StepAngle) #define MaxMtrSpeed P7005 ; This is the maximum achievable motor speed MaxMtrSpeed=( ServoClk*1000)/( ElecCyclePerRev*6)*60 #define CalculatedIxx69 P7006 ; Calculated Ixx69 CalculatedIxx69= MotorSpeed*ElecCyclePerRev/60*2048/6/(ServoClk*1000)

Setting up 1.8° Step Motors specified at 1500 rpm and a Servo Clock of 8 KHz results in a maximum achievable speed (P7001) of 1600 rpm and a calculated Ixx69 (P7002) of 53.3334. So for this type of motor we will use the Theoretical Ixx69, being less than the calculated one.

I169,4,100=42.667 ; Motors 1 thru 4 Output Command Limit

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PWM Scale Factor: Ixx66

If Motor Rated Voltage > Bus Voltage:

I166=1.10*I7000 ; Motor #1 PWM Scale Factor. Set to 10% above PWM Count. I266=I166 I366=I166 I466=I166 ; Assuming same motor(s) as motor #1

If Bus Voltage > Motor Rated Voltage: Ixx66 acts as a voltage limiter. In order to obtain full voltage output it is set to about 10% over PWM count divided by DC Bus/Motor voltage ratio:

#define DCBusInput 60 ; DC Bus Voltage -User Input

#define Mtr1Voltage 24 ; Motor 1 Rated Voltage [VDC]-User Input #define Mtr2Voltage 24 ; Motor 2 Rated Voltage [VDC]-User Input #define Mtr3Voltage 24 ; Motor 3 Rated Voltage [VDC]-User Input #define Mtr4Voltage 24 ; Motor 4 Rated Voltage [VDC]-User Input

I166=1.10*I7000*Mtr1Voltage/DCBusInput ; Motor 1 PWM Scale Factor I266=1.10*I7000*Mtr2Voltage/DCBusInput ; Motor 2 PWM Scale Factor I366=1.10*I7000*Mtr3Voltage/DCBusInput ; Motor 3 PWM Scale Factor I466=1.10*I7000*Mtr4Voltage/DCBusInput ; Motor 4 PWM Scale Factor

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Note

Software I2T is handled by Turbo PMAC. The Turbo Clipper Drive has a built-in hardware I2T protection as an additional layer of safety.

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

The lower values (tighter specifications) of the Continuous/Instantaneous current ratings between the Turbo Clipper Drive and motor are chosen to setup I2T protection.

If the peak current limit chosen is that of the Turbo Clipper Drive (15 Amps) then the time allowed at peak current is set to 2 seconds.

If the peak current limit chosen is that of the Motor, check the motor specifications for time allowed at peak current.

Examples:

 For setting up I2T on a Turbo Clipper Drive driving a 3/9-Amp motor, 3 amps continuous

and 9 amps instantaneous will be used as current limits. And time allowed at peak is that of the motor.

 For setting up I2T on a Turbo Clipper Drive driving a 4/16-Amp motor, 4 amps

continuous and 15 amps instantaneous will be used as current limits. And time allowed at peak is 2 seconds.

The rule of thumb for Stepper magnetization current is Ixx77 = Ixx57/√2 Motors 1 thru 4 have 5-amp continuous, 15-amp peak current limits. With a servo clock of 8

KHz, I2T protection and magnetization current would be set to:

#define ContCurrent 5 ; Continuous Current Limit [Amps] –User Input #define PeakCurrent 15 ; Instantaneous Current Limit [Amps] –User Input #define MaxADC 33.85 ; Turbo Clipper Drive full range ADC reading (electrical specifications) ;#define ServoClk P7003 ; [KHz] Computed in Dominant Clock Settings Section #define I2TOnTime 2 ; Time allowed at peak Current [sec] #define VoltOutLimit P7007 ; This is Ixx69 normally used in direct digital PWM

I157=INT(32767*(ContCurrent*1.414/MaxADC)*cos(30)) I177=I157/SQRT(2) VoltOutLimit=INT(32767*(PeakCurrent*1.414/MaxADC)*cos(30)) I158=INT((VoltOutLimit*VoltOutLimit-I157*I157)*ServoClk*1000*I2TOnTime/(32767*32767))

I257=I157 I277=I177 I258=I158 I357=I157 I377=I177 I358=I158 I457=I157 I477=I177 I458=I158

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

I180=0 I173=0 I174=0 ; I280=0 I273=0 I274=0 ; I380=0 I373=0 I374=0 ; I480=0 I473=0 I474=0 ;

I181=$3503 ; Motor 1 Power-On Commutation, Integrated Output #1 I281=$3506 ; Motor 2 Power-On Commutation, Integrated Output #2 I381=$3509 ; Motor 3 Power-On Commutation, Integrated Output #3 I481=$350C ; Motor 4 Power-On Commutation, Integrated Output #4 I191,4,100=$500000 ; Mtrs 1-4 Pwr-on Pos. format Read 16 (11+5) bits of X register Ixx81

Position-Loop PID Gains: Ixx30…Ixx39

I130,4,100=1024 ; Motor 1-4 PID Proportional Gain I131,4,100=0 ; Motor 1-4 PID Derivitive Gain I132,4,100=85 ; Motor 1-4 PID Velocity Feedforward Gain I133,4,100=1024 ; Motor 1-4 PID Integral Gain I134,4,100=1 ; Motor 1-4 PID Integration Mode I135,4,100=0 ; Motor 1-4 PID Acceleration Feedforward Gain I136,4,100=0 ; Motor 1-4 PID Notch Filter Coefficient N1 I137,4,100=0 ; Motor 1-4 PID Notch Filter Coefficient N2 I138,4,100=0 ; Motor 1-4 PID Notch Filter Coefficient D1 I139,4,100=0 ; Motor 1-4 PID Notch Filter Coefficient D2

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Note

Some stepper motors have unconventional specifications making top speeds unattainable with the basic micro-stepping technique. Adjusting the direct current on the fly might be necessary (i.e. using open servo).

Current-Loop Gains: Ixx61, Ixx62, Ixx76

The current-loop tuning can be performed as in any Turbo PMAC digital current loop setup. The PMACTuningPro2 automatic or interactive utility can be used to fine-tune the current loop gains. Ixx61=0.005, Ixx62=0, and Ixx76=0.05 is a good/safe starting point for interactive current-loop tuning. Typically, an acceptable current-loop step response would look like the following:

Number Of Counts Per Revolution (Stepper Motors)

With a count equal to a micro-step, and 512 micro-steps per 1.8-degree full step (2048 per cycle), you should expect to see 360*512/1.8= 102,400 counts per revolution of the motor.

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Setting Up DC Brushless Motor

Before you start

 It is always recommended to start a fresh setup from factory default settings, $$$***

followed by a Save and a $$$.

 Don’t forget to create/edit the motor type and protection power-on PLC  At this point of the setup it is assumed that the encoder has been wired and configured

correctly in the Encoder Feedback section. And that moving the motor/encoder shaft by hand shows encoder counts in the position window.

 Parameters with Comments ending with -User Input require the user to enter information

pertaining to their system/hardware.

 Downloading and using the suggested M-variables is highly recommended.  Detailed description of motor setup parameters can be found in the Turbo SRM Manual.

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

I124,4,100=$800001 ; Motors 1-4 Flag control, High true amp fault (Turbo Clipper Drive specific) I172,4,100=683 ; Motors 1-4 Commutation phase angle (Turbo Clipper Drive specific) I184,4,100=$FFFC00 ; Motors 1-4 Current-Loop Feedback Mask Word (Turbo Clipper Drive specific)

PWM Scale Factor: Ixx66

If Motor Rated Voltage > Bus Voltage:

I166=1.10*I7000 ; Motor #1 PWM Scale Factor. Set to 10% above PWM Count. I266=I166 I366=I166 I466=I166 ; Assuming same motor(s) as motor #1

If Bus Voltage > Motor Rated Voltage: Ixx66 acts as a voltage limiter. In order to obtain full voltage output it is set to about 10% over PWM count divided by DC Bus/Motor voltage ratio:

#define DCBusInput 60 ; DC Bus Voltage -User Input

Current Feedback Address: Ixx82

I182=$078006 ; Motor 1 Current Feedback Address I282=$07800E ; Motor 2 Current Feedback Address I382=$078016 ; Motor 3 Current Feedback Address I482=$07801E ; Motor 4 Current Feedback Address

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Note

Software I2T is handled by Turbo PMAC. The Turbo Clipper Drive drive has a built-in hardware I2T protection as an additional layer of safety.

Commutation Position Address, Commutation Enable: Ixx83, Ixx01

Digital Quadrature Feedback (Default)

I183=$078001 ; Motor 1 On-going Commutation Position Address I283=$078009 ; Motor 2 On-going Commutation Position Address I383=$078011 ; Motor 3 On-going Commutation Position Address I483=$078019 ; Motor 4 On-going Commutation Position Address I101,4,100=1 ; Motors 1-4 Commutation Enabled, from X-register

Sinusoidal

I183=I104 ; Motor 1 On-going Commutation Position Address I283=I204 ; Motor 2 On-going Commutation Position Address I383=I304 ; Motor 3 On-going Commutation Position Address I483=I404 ; Motor 4 On-going Commutation Position Address I101,4,100=1 ; Motors 1-4 Commutation Enabled, from X-register

I2T Protection: Ixx57, Ixx58, Ixx69

The lower values (tighter specifications) of the Continuous/Instantaneous current ratings between the drive and the motor are chosen to setup I2T protection. Examples;

Examples:

 For setting up I2T on a Turbo Clipper Drive driving a 3/9-Amp motor, 3 amps continuous

and 9 amps instantaneous will be used as current limits. And time allowed at peak is that of the motor.

 For setting up I2T on a Turbo Clipper Drive driving a 4/16-Amp motor, 4 amps

continuous and 15 amps instantaneous will be used as current limits. And time allowed at peak is 2 seconds.

Motors 1 thru 4 are specified to 5-amp continuous, 10-amp peak current limits.

;#define ServoClk P7003 ; [KHz] Computed in Dominant Clock Settings Section #define ContCurrent 5 ; Continuous Current Limit [Amps] –User Input #define PeakCurrent 15 ; Instantaneous Current Limit [Amps] –User Input #define MaxADC 33.85 ; Turbo Clipper Drive full range ADC reading (electrical specifications) #define I2TOnTime 2 ; Time allowed at peak Current [sec]

I157=INT(32767*(ContCurrent*1.414/MaxADC)*cos(30)) I169=INT(32767*(PeakCurrent*1.414/MaxADC)*cos(30)) I158=INT((I169*I169-I157*I157)*ServoClk*1000*I2TOnTime/(32767*32767))

I257=I157 I258=I158 I269=I169 I357=I157 I358=I158 I369=I169 I457=I157 I458=I158 I469=I169

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Commutation Cycle Size: Ixx70, Ixx71

The ratio of Ixx70/Ixx71 represents the number of encoder counts per electrical cycle. These parameters are set up with respect to the encoder type and resolution: Digital Quadrature Feedback Ixx70= {Number of pair poles of the motor} Ixx71= {Number of counts per revolution}

Sinusoidal Feedback

Ixx70= {Number of pair poles of the motor} Ixx71= {Number of counts per revolution}/32 ; Commutation done using quadrature data

ADC Offsets: Ixx29, Ixx79

The ADC offsets importance may vary from one system to another, depending on the motor(s) type and application requirements. They can be left at default of zero especially if a motor setup is to be reproduced on multiple machines by copying the configuration file of the first time integration. However, they should ultimately be set to minimize measurement offsets from the A and B-phase current feedback circuits, respectively (read in Suggested M-variables Mxx05, Mxx06).

Current-Loop Gains: Ixx61, Ixx62, Ixx76

The current-loop tuning is done as in any Turbo PMAC digital current loop setup. The PMACTuningPro2 automatic or interactive utility can be used to fine-tune the Current-Loop. An acceptable Current-Loop step response would look like:

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Open-Loop Test, Encoder Decode: I7mn0

Having a satisfactory current loop, the motor can now be manually phased (i.e. custom, 2-guess, stepper method) as described in the subsequent Motor Phasing section. The open-loop test is critical to verify the direction sense of the encoder counting versus the command output. A positive command should create a positive velocity and a position counting in the positive direction; a negative command should create a negative velocity and a position counting in the negative direction. The open-loop test can be done manually from the terminal window while gathering position, velocity data. However, the PMACTuningPro2 Software provides with a built-in automatic open loop utility that is convenient to use.

Acceptable Open-Loop Result, Correct Encoder Decode (I7mn0)

The open-loop test is usually performed on an unloaded motor. The open loop command output is adjustable, start off with a conservative 1 to 2 percent command output (i.e. #nO2) value and increment gradually until you see a satisfactory result.

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Open-Loop Test Failed, Incorrect Encoder Decode (I7mn0)

If the open-loop test fails, redo motor rough phasing and try again. If the failure persists (inverted saw tooth, as shown in the plot above), or you observe oscillations in the response instead of a saw tooth, then most likely the direction sense of the encoder is opposite to the Brick command output. If the motor locks in position (with an open loop command) like a stepper motor, then the phasing is either incorrect or the direction of a serial is reversed and the commutation is failing.

Troubleshooting failed Open-Loop tests:

 Change I7mn0 to 3 from 7 (default) or vice-versa  Make Sure Ixx70, Ixx71 are correct

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WARNING

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

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

Turbo Clipper Drive supports a variety of phasing methods. This section discusses the following phasing methods:

 Manual/Custom  2-Guess  Stepper  Hall Effect (Digital quadrature encoders)

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Manual Phasing Method: Useful for troubleshooting and testing for “good” phase finding

output value used in 2-guess or stepper method. It can be used regardless of the type of feedback. The manual phasing method consists of locking the motor tightly to one of its phases and resetting the Phase position register in PMAC. It is useful for troubleshooting, rough phasing and testing for a “good” phase finding output value. Steps to follow, or implement in a PLC:

a. Record the values of Ixx29, and Ixx79 to restore them at the end of test. b. Set Ixx29=0, and write a positive value to Ixx79 then issue a #nO0. 500 is a reasonable conservative starting value for Ixx79. Adjust appropriately (most likely increase) to force the motor (unloaded) to lock tightly onto a phase. c. Set Phase Position register to zero, Suggested M-Variable Mxx71=0 d. Issue a #nK to kill the motor e. Restore Ixx29, and Ixx79 to their original values f. Clear Phasing search error bit, Suggested M-Variable Mxx48=0 g. The motor is now ready to jog/close the loop

Motor 1 Manual Phasing Example PLC:

#define Mtr1PhasePos M171 ; Motor 1 Phase Position Register, Suggested M-Variable Mtr1PhasePos->X:$B4,0,24,S #define Mtr1PhaseErrBit M148 ; Mtr1 Phasing Search Error Bit, Suggested M-Variable Mtr1PhaseErrBit->Y:$C0,8

Open plc 3 clear I5112=500*8388608/I10 while(I5112>0) Endw P129=I129 P179=I179 ; Store Ixx29, and Ixx79 I129=0 I179=1000 ; Set Ixx29=0 and Ixx79 to positive value (adjustable) I5112=100*8388608/I10 while(I5112>0) Endw ; 100 msec delay CMD"#1o0" ; Issue 0% open loop command output I5112=3000*8388608/I10 while(I5112>0) Endw ; 3 seconds delay to allow motor to settle Mtr1PhasePos=0 ; Set phase register to zero I5112=500*8388608/I10 while(I5112>0) Endw ; 1/2 second delay CMD"#1K" ; Kill Motor I5112=100*8388608/I10 while (I5112>0) Endw ; 100 msec delay I129=P129 I179=P179 ; Restore Ixx29 and Ixx79 to original values Mtr1PhaseErrBit=0 ; Clear Phasing search error bit I5112=500*8388608/I10 while (I5112>0) Endw ; 1/2 second delay Dis plc 3 ; Disable PLC, run only once close

2-Guess Phasing Method: Rough phasing method for motors with relatively small loads or

quick setups for testing. Typical (example) values: Ixx73=1200 ; Phase Finding Output Value (Adjustable). Units of 16-bit DAC Ixx74=8 ; Units of Servo Cycles Ixx80=4 ; 2-guess method, no absolute position read, no power-on phasing

Stepper Phasing Method: Finer than the 2-guess method, usually used on motors with

significant loads. Typical (example) values: Ixx73=1200 ; Phase Finding Output Value (Adjustable). Units of 16-bit DAC Ixx74=80 ; Units of Servo Cycles * 256 Ixx80=6 ; Stepped method, no absolute position read, no power-on phasing

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Hall Effect Phasing (Digital Quadrature Encoders):

Digital hall sensors provide three digital signals that are a function of the position of the motor shaft, each nominally with 50% duty cycle, and nominally 1/3 cycle apart (This format is often called 120° spacing; the Turbo Clipper Drive Drive has no automatic hardware or software features to work with 60° spacing.) The 120° spacing format provides six distinct states per cycle of the signal. Typically, one cycle of the signal set corresponds to one electrical cycle, or pole pair of the motor. These sensors can then provide absolute (if low resolution) information about where the motor is in its commutation cycle, and eliminate the need to do a power-on phasing search operation. The 3-phase digital Hall effects can be used with the Turbo Clipper Drive as low-resolution position/velocity sensors but typically they are used to accomplish a rough power-up phasing.

Hall sensors have an error of about ±30° resulting a loss in torque of about 15%, it will need to be corrected (fine phasing) for top operation.

Hall Effect phasing with the Brick can be setup following these steps:

a. Set Ixx81=0, and Ixx91=0 (which effectively are the parameters to be configured for

hall effect phasing)

b. Phase the motor as best as possible using custom, 2-guess, or stepper method c. Jog the motor slowly (with rough PID gains), or move in open loop in the positive

direction of the encoder while plotting (Mxx28) Halls UVW versus Phase Position (Mxx71).

d. Setting up the detailed plot, Scaling and Processing of Halls UVW, Phase Position

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The scale factor is used to scale the phase position to 0 - 360°. It is equal to 360/Ixx71.

$700000 Masking enables reading W, V, and U bits 20, 21, and 22 respectively

e. Gathering, and plotting data for a short travel of the motor should look like

(remember to kill the motor when the gathering is finished):

Primarily, we are interested in two occurrences on the plot; the transition of the halls data between states 1 & 3, and the point of intersection of Mxx28 and Mxx71 at this transition, which represents the Hall Effect Zero (HEZ).

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Power-On Phase Position Address

Ixx81 Hall Effect

Channel 1

$78000

Channel 2

$78008

Channel 3

$78010

Channel 4

$78018

If the Halls transition goes from 3 to 1 (with positive movement of the motor) as shown in the plot, bit #22 of Ixx91 is set to 1 for reversed direction. Use this definition in deriving Ixx91:

#define Mtr1UVTrans3_1 M7025 ; Reversed direction: 3 to 1 Mtr1UVTrans3_1->* Mtr1UVTrans3_1=$C00000

If the Halls transition goes from 1 to 3 (with positive movement of the motor), bit #22 of Ixx91 is set to 0 for standard direction. Use this definition in deriving Ixx91:

#define Mtr1UVTrans1_3 M7025 ; Standard direction: 1 to 3 Mtr1UVTrans1_3->* Mtr1UVTrans1_3=$800000

The HEZ is derived from plot, showing about 5 degrees in the example plot. f. Setting Ixx81, Deriving Ixx91

Channel 1 is setup for Hall Effect phasing. The example plot reveals that the direction is reversed, and the HEZ is about 5 degrees:

I181=$78000 ; Channel 1 Power-On Phase Position Address #define HEZ P7025 ; Hall Effect Zero HEZ=5 ; Degrees –User Input #define HEZTemp P7026 ; Temporary User Variable HEZTemp = INT(((HEZ%360)/360)*64) ; Processing Hall Effect Zero I191=(HEZTemp*65536)+Mtr1UVTrans3_1 ; Shift 16 bits left and set transition bit

Resulting I191=$C00000

g. Save Ixx81, Ixx91 parameters to the Turbo Clipper Drive after satisfactory testing;

meaning cycling power a few times, moving the motor to random locations attempt to phase and issue jog or open loop commands reliably.

h. Hall Effect fine phasing (optional): The idea is to phase the motor manually as tight

as possible, and use a point of reference (known repeatable location) along the travel of the motor to record the phase position (Mxx71). This is a one-time test per installation. On subsequent power-ups, the motor is phased using Hall Effect sensors and moved to that reference point, where the phase position is overwritten by the value recorded from the manual-phasing reference test. The most repeatable reference location is usually the home position of the motor, which is most reliably achieved using position capture with a combination of flag and index pulse.

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Note

The automatic software utility requires jogging the motor; make sure the motor is phased (custom, 2-guess, or stepper method) and that the position-loop PID tuning is acceptable.

WARNING

Remember to perform an Open Loop Test (if you have not already) before trying to close the loop to make sure that the encoder decode (I7mn0) is correct. Essentially a positive open loop command should result in position direction (of the encoder) motion and vice-versa.

Example: Channel 1 is driving a motor with home capture done using home flag and index pulse high true. The recorded phase position from manual phasing reference test was found to be 330, and stored (saved) in a user defined variable. Setup and fine phasing example PLC:

I7012=3 ; Motor 1 Capture Control, Index high and Flag high I7013=0 ; Motor 1 Capture Control flag select, Home Flag

#define Mtr1DesVelZero M133 ; Motor 1 Desired-velocity-zero bit, Suggested M-Variable Mtr1DesVelZero->X:$0000B0,13,1 ; #define Mtr1InPosBit M140 ; Motor 1 Background in-position bit, Suggested M-Variable Mtr1InPosBit->Y:$0000C0,0,1 ; #define Mtr1PhasePos M171 ; Motor 1 Phase Position Register, Suggested M-Variable Mtr1PhasePos->X:$B4,0,24,S ; #define Mtr1RecPhasePos P7027 ; Mtr1RecPhasePos=330 ; Recorded Phase Position (Manual phasing reference test)

Open plc 3 clear I5311=500*8388608/I10 while(I5311>0)Endw ; 1/2 sec delay CMD"#1$" ; Phase motor, using Hall Effect Sensors I5311=50*8388608/I10 while(I5311>0)Endw ; 50 msec Delay While(Mtr1DesVelZero=0 or Mtr1InPosBit=0) Endw ; Wait until motor settles, and in position CMD"#1hm" ; Issue a home command I5311=50*8388608/I10 while(I5311>0)Endw ; 50 msec Delay While(Mtr1DesVelZero=0 or Mtr1InPosBit=0)Endw ; Wait until motor settles, and in position Mtr1PhasePos =Mtr1RecPhasePos ; Adjust Phase Position I5311=500*8388608/I10 while(I5311>0)Endw ; 1/2 sec delay CMD"#1K" ; Kill Motor (Optional) Disable plc 3 ; Execute only once Close

Delta Tau provides an automatic Hall Effect setup software utility as an alternative to the manual Hall Effect setup. This can be found at Delta Tau Forums Online.

Position-Loop PID Gains: Ixx30…Ixx39

The position-loop tuning is done as in any Turbo PMAC PID-Loop setup. The PMACTuningPro2 automatic or interactive utility can be used for fine tuning.

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Position Step Response

Position Parabolic Response

Good Open Loop Test

Acceptable Step and Parabolic position responses should look like the following:

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Setting Up DC Brush Motor

Before you start

 It is always recommended to start a fresh setup from factory default settings, $$$***

followed by a Save and a $$$.

 Don’t forget to create/edit the motor type and protection power-on PLC  At this point of the setup it is assumed that the encoder has been wired and configured

correctly in the Encoder Feedback section. And that moving the motor/encoder shaft by hand shows encoder counts in the position window.

 Parameters with Comments ending with -User Input require the user to enter information

pertaining to their system/hardware.

 Downloading and using the suggested M-variables is highly recommended.  Detailed description of motor setup parameters can be found in the Turbo SRM Manual.

Phasing Search Error Bit, Current-Loop Integrator Output

On power-up, the phasing search error bit has to be cleared to allow motor move commands to DC Brush motor. This can be added to the power-on PLC. Also, the current-loop integrator output should not be allowed to build up over time. The motor (non-existent) direct current-loop output should be zero-ed periodically.

M148->Y:$C0,8,1 ; Motor 1 Phasing error fault bit M248->Y:$140,8,1 ; Motor 2 Phasing error fault bit M348->Y:$1C0,8,1 ; Motor 3 Phasing error fault bit M448->Y:$240,8,1 ; Motor 4 Phasing error fault bit M601->Y:$BC,0,24,U ; Motor 1 Direct Current-Loop Integrator Output M602->Y:$13C,0,24,U ; Motor 2 Direct Current-Loop Integrator Output M603->Y:$1BC,0,24,U ; Motor 3 Direct Current-Loop Integrator Output M604->Y:$23C,0,24,U ; Motor 4 Direct Current-Loop Integrator Output Open plc 2 clear If (M148=1) CMD"M148,4,100=0" ; Clear Phasing Error Bit EndIF M601=0 M602=0 M603=0 M604=0 ; Zero Current-Loop Integrator Output Close ; This PLC has to be active always

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

I124,4,100=$800001 ; Motors 1-4 Flag control, High true amp fault (Turbo Clipper Drive specific) I101,4,100=1 ; Motors 1-4 Commutation enabled I172,4,100=512 ; Motors 1-4 Commutation phase angle (Turbo Clipper Drive specific) I184,4,100=$FFFC00 ; Motors 1-4 Current-Loop Feedback Mask Word(Turbo Clipper Drive specific)

Motor Setup Guidelines 77

Turbo Clipper Drive User Manual

PWM Scale Factor: Ixx66

If Motor Rated Voltage > Bus Voltage:

I166=1.10*I7000 ; Motor #1 PWM Scale Factor. Set to 10% above PWM Count. I266=I166 I366=I166 I466=I166 ; Assuming same motor(s) as motor #1

If Bus Voltage > Motor Rated Voltage: Ixx66 acts as a voltage limiter. In order to obtain full voltage output it is set to about 10% over PWM count divided by DC Bus/Motor voltage ratio:

#define DCBusInput 60 ; DC Bus Voltage -User Input

Current Feedback Address: Ixx82

I182=$078006 ; Motor 1 Current Feedback Address I282=$07800E ; Motor 2 Current Feedback Address I382=$078016 ; Motor 3 Current Feedback Address I482=$07801E ; Motor 4 Current Feedback Address

Commutation Cycle Size: Ixx70, Ixx71

Set to zero with DC brush motors, commutation is done mechanically.

I170=0 I171=0 ; Motor 1 size and number of commutation cycles I270=0 I271=0 ; Motor 2 size and number of commutation cycles I370=0 I371=0 ; Motor 3 size and number of commutation cycles I470=0 I471=0 ; Motor 4 size and number of commutation cycles

Motor Setup Guidelines 78

Turbo Clipper Drive User Manual

Note

Software I2T is handled by Turbo PMAC. The Turbo Clipper Drive drive has a built-in hardware I2T protection as an additional layer of safety.

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

The lower values (tighter specifications) of the Continuous/Instantaneous current rating between the drive and the motor are chosen to setup I2T protection.

Examples:

 For setting up I2T on a Turbo Clipper Drive driving a 3/9-Amp motor, 3 amps continuous

and 9 amps instantaneous will be used as current limits. And time allowed at peak is that of the motor.

 For setting up I2T on a Turbo Clipper Drive driving a 4/16-Amp motor, 4 amps

continuous and 15 amps instantaneous will be used as current limits. And time allowed at

Motors 1 thru 8 are specified to 5-amp continuous, 10-amp peak current limits:

#define ServoClk P7003 ; [KHz] Computed in Dominant Clock Settings Section

#define I2TOnTime 2 ; Time allowed at peak Current [sec]

I157=INT(32767*(ContCurrent*1.414/MaxADC)*cos(30)) I169=INT(32767*(PeakCurrent*1.414/MaxADC)*cos(30)) I158=INT((I169*I169-I157*I157)*ServoClk*1000*I2TOnTime/(32767*32767))

I257=I157 I258=I158 I269=I169 I357=I157 I358=I158 I369=I169 I457=I157 I458=I158 I469=I169

peak is 2 seconds.

ADC Offsets: Ixx29, Ixx79

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

Tuning (fine) the current loop with DC brush motors is neither critical nor required. Set Ixx61 to a conservative value (i.e. 0.001) and perform an open-loop test. Essentially a positive open loop command should result in position direction (of the encoder) motion and vice-versa:

Reversed Encoder Decode. I7mn0 needs adjustment

Motor Setup Guidelines 79

Turbo Clipper Drive User Manual

Once the Encoder Decode is verified, increment Ixx61 gradually and redo the Open-Loop test until a solid saw tooth response is observed. Note that further increasing Ixx61 will not improve the performance.

Correct Encoder Decode-Acceptable Open-Loop Response

Position-Loop PID Gains: Ixx30…Ixx39

The position-loop tuning is done as in any Turbo PMAC PID-Loop setup. The PMACTuningPro2 automatic or interactive utility can be used to fine-tune the PID-Loop. Acceptable Step and Parabolic position responses would look like:

Motor Setup Guidelines 80

Turbo Clipper Drive User Manual

Position Step Move

Position Parabolic Move

Motor Setup Guidelines 81

2345

9101112

1314

2345

9101112

1314

1.541±.015

3.115±.05

2345

6789

1 2345

6789

1.213+.015

2.45±.05

.18

#4-40 FEMALE SCREWLOCK

QTY 2 per connector

Steel, Zinc Plated

.126

DIA

.235

DIA

LOCKWASHER

QTY 2 per connector

Clear Chromate

APPENDIX A

D-Sub Connector Spacing Specifications

J11-J14: DA-15 Connectors for encoder feedback

DE-9 Connectors for External Amps

Turbo Clipper Drive User Manual

Screw Lock Size for all D-sub connectors

Appendix A 82

Turbo Clipper Drive User Manual

E-Point

Description

Default

Factory use only; the board will not operate with E0 installed.

Not

Installed

E-Point

Description

Default

 Remove Jumper for normal operation.  Jump 1-2 for re-initialization on power-up.

Not

Installed

E-Point

Description

Default

 Remove Jumper for normal operation.  Install Jumper to disable watchdog timer.

Not

Installed

E Point

Description

Default

For factory use only; the board will not communicate via Ethernet or USB if jumper E5 is installed.

Not

Installed

E Point

Description

Default

For factory use only; the board will not communicate via Ethernet unless Jumper is installed on pins 1 to 2.

Jumpered

1-2

APPENDIX B: CLIPPER BOARD E-POINT JUMPERS

E0: Forced Reset Control

E3: Re-Initialization On Reset Control

E4: Watchdog Disable Jumper

E5: Reserved for factory use only

Revision 102 or newer

Revision 101 or older

Appendix B 83

E-Point

Description

Default

 Remove jumper to disable Option-12 ADC inputs, which is

necessary for reading current feedback signals from digital amplifiers.

 Install Jumper to read ADC inputs (Only used when power board is

not present)

Not

Installed

E-Point

Description

Default

Install E7 for normal operation (factory use only, do not remove)

Jumpered

 Install E8 to reload communication Boot/Firmware, or change IP

address.

 Remove E8 for normal operation.

Not

Installed

E Point

Description

Default

E10

E12

 Remove E10, jumper E11, and E12 to read flash IC on power-

up/reset.

 Other combinations are for factory use only.

E10 Not Installed

E11-E12

Jumpered

E6: ADC Inputs Enable

E7 – E8: USB/Ethernet Reset Jumpers

Turbo Clipper Drive User Manual

E10 – E12: Flash IC Jumpers

Appendix B 84

E Point

Description

Default

E13

 Jump pin 1 to 2 to reload Turbo PMAC2 firmware.  Remove jumper for normal operation.

Not

Installed

E Point

Description

Default

E14

 Install jumper to make DATx lines inputs.  Remove jumper to make DATx lines outputs.

Jumpered

E15

 Install jumper to make SELx lines inputs.  Remove jumper to make SELx lines outputs.

Not

Installed

E16

 Install jumper to make MOx lines inputs.  Remove jumper to make MOx lines outputs.

Not

Installed

E17

 Install jumper to make MIx lines inputs.  Remove jumper to make MIx lines outputs.

Jumpered

E13: Power-Up/Reset Load Firmware

E14- E17: Ports Direction Control

Turbo Clipper Drive User Manual

Appendix B 85

Turbo Clipper Drive User Manual

E-Point

Description

Default

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)

Jumpered

E-Point

Description

Default

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

APPENDIX C: BREAKOUT BOARD E-POINT JUMPERS

J36: GPO E-Stop Automatic Feature

J39: User Flag 4 E-Stop Status

Appendix C 86

Turbo Clipper Drive User Manual

E-Point

Description

Default

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

Not

Installed

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

Not

Installed

 Remove jumper to enable the soft E-Stop function.  Install jumper to disable the soft E-Stop function (Soft E-Stop

bit has to be set, and saved to 1).

Not

Installed

 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

APPENDIX D: POWER BOARD E-POINT JUMPERS

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

Appendix D 87

Delta Tau TURBO CLIPPER DRIVE User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual