Delta Tau PBC Series Hardware Reference Manual
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Delta Tau PBC Series Hardware Reference Manual

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HARDWARE REFERENCE GUIDE
Single Source Machine Control
Tel. (818) 998-2095 Fax. (818) 998-7807 //
Power Brick Controller
..............................................................................
www.deltatau.com
Power Brick Controller
PBC -
-
-
May 20, 2022
Document # MN-000295
DELTA TAU
Data Systems, Inc.
NEW IDEAS IN MOTION ...
Power // Flexibility // Ease of Use
0

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  • Page 1 HARDWARE REFERENCE GUIDE Power Brick Controller Power Brick Controller PBC - May 20, 2022 Document # MN-000295 DELTA TAU Data Systems, Inc. NEW IDEAS IN MOTION … ……………………………………………..…...………………. Single Source Machine Control Power // Flexibility // Ease of Use Tel. (818) 998-2095 Fax. (818) 998-7807 //...
  • Page 2 © 2022 Delta Tau Data Systems, Inc. All rights reserved. This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses are unauthorized without written permission of Delta Tau Data Systems, Inc. Information contained in this manual may be updated from time-to-time due to product improvements, etc., and may not conform in every respect to...
  • Page 3 Power Brick Controller User Manual Safety Instructions Qualified personnel must transport, assemble, install, and maintain this equipment. Properly qualified personnel are persons who are familiar with the transport, assembly, installation, and operation of equipment. The qualified personnel must know and observe the following standards and regulations: IEC364resp.CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4...
  • Page 4 Power Brick Controller User Manual MANUAL REVISION HISTORY DESCRIPTION DATE CHANGE APPROVED Preliminary 01/06/2015 DCDP Released 07/21/2015 DCDP Update P/N description 12/15/2015 Corrected serial clock/data pinouts 01/28/2016 DCDP Updated I/O & Flags electrical specifications Updated absolute power-on position Corrected serial clock/data pinouts Added factory reset, firmware reload procedures Added IP address change procedure DCDP...

  • Page 6: Table Of Contents

    Power Brick Controller User Manual Table of Contents INTRODUCTION ........................10 Documentation ........................10 Downloadable Power PMAC Script ..................11 Agency of Approval and Safety ....................12 SPECIFICATIONS ........................13 Part Number Designation ...................... 13 Power Brick Controller Configuration ..................16 Standard Configuration ........................16 Configuration Notes ..........................
  • Page 7 Power Brick Controller User Manual Resolver Counts per User Units ......................45 Resolver Absolute Power-On Position ....................46 X1 – X8: Encoder Feedback, Serial ..................48 Serial Encoder Control ........................50 Serial Encoder Command ........................51 SSI Configuration Example ......................... 52 EnDat 2.1/2.2 Configuration Example ....................
  • Page 8 Power Brick Controller User Manual X23: Fieldbus ........................109 ETH 0/1: Ethernet Connections ................... 110 ETH 2/3: EtherСAT Connections ..................111 USB Connections ........................ 112 USB 1 Host Port ..........................112 USB 2 Device Port ..........................113 RS-232 Connection ......................114 SD Card Connection ......................
  • Page 9 Power Brick Controller User Manual SPECIAL FUNCTIONS & TROUBLESHOOTING ............175 Step and Direction, PFM Output ..................175 Sinusoidal Encoder Bias Corrections ................... 178 Reversing Motor Jogging Direction ..................184 PLC Timer Delay ......................... 186 Encoder Count Error ......................187 Encoder Loss Detection ...................... 188 Digital Quadrature ...........................

  • Page 10: Introduction

    In conjunction with this manual, the following manuals are essential for the proper operation and use of the Power Brick Controller:  Power PMAC Software Reference Manual  Power PMAC User Manual These manuals are available for download, to registered members, at Delta Tau Forums. Introduction...

  • Page 11: Downloadable Power Pmac Script

    Power Brick Controller User Manual Downloadable Power PMAC Script Some code snippets may require the user to input specific information pertaining to their system application. They are denoted in a commentary ending with – User Input. Caution This manual contains downloadable code snippets in Power PMAC script. These examples can be copied and pasted into the editor area of the IDE software.

  • Page 12: Agency Of Approval And Safety

    Power Brick Controller User Manual Agency of Approval and Safety Item Description CE Mark EN61326-1 UKCA 2016 No. 1091 Introduction...

  • Page 13: Specifications

    Power Brick Controller User Manual SPECIFICATIONS Part Number Designation Option A Option B Option C Option D Option E 1 GB 1 GB 1 Ethernet (1 Gbps) 2 GB 4 GB 1 Extra Eth. / 8 GB 2 Extra Eth. / 3 Extra Eth.
  • Page 14 Power Brick Controller User Manual Option I for 4-axis Filtered PWM / True DAC Encoder Digital MACRO Nodes Analog Analog & Flags I/Os Servo / IOs Outputs Inputs Relays 32/16 32/16 16/12 48/24 48/24 32/24 Option I for 4-axis Direct PWM Encoder Digital MACRO Nodes...
  • Page 15 Power Brick Controller User Manual Option K Option L (ACC-84B) 1 – 4 5 – 8 1 – 4 5 – 8 Sinusoidal Resolver EnDat ACI-Sin Hiperface Sinusoidal Sinusoidal Yaskawa Sinusoidal Resolver Tamagawa Resolver Sinusoidal Panasonic Resolver Resolver Mitutoyo Resolver ACI-Sin BiSS B/C ACI-Sin...

  • Page 16: Power Brick Controller Configuration

    Power Brick Controller User Manual Power Brick Controller Configuration The Power Brick Controller comes standard with a powerful set of hardware and software capabilities, plus a full set of options. Standard Configuration 800 MHz Single-Core Power PC 460EX. 2 GB DDRAM3 active, 1 GB NAND Flash non-volatile. Memory 2 x Gbs Ethernet port for host communication.
  • Page 17 Power Brick Controller User Manual Options 1 GHz Single-Core Power PC 460EX. 2 GB DDRAM3 active, 4 or 8 GB NAND Flash non-volatile. Memory Communication 1 or 2 x additional Gbs Ethernet ports, EtherCAT compatible. Ports Additional 16 x Inputs, fully protected at 12 – 24 V sourcing or sinking (user wiring).

  • Page 18: Configuration Notes

    Power Brick Controller User Manual Configuration Notes o Quadrature encoders can always be wired in and processed regardless of the feedback options fitted. o The following serial encoder protocols are built into (standard) the Power Brick Controller – Gate3: HiperFace Kawasaki Tamagawa EnDat 2.1 / 2.2...

  • Page 19: Environmental Specifications

    Power Brick Controller User Manual Environmental Specifications Specification Description Range Minimum operating temperature 0°C (32°F) Ambient operating Temperature EN50178 Class 3K3 – IEC721-3-3 Maximum operating temperature 45°C (113°F) Minimum Storage temperature -25°C (-13°F) Storage Temperature Range EN 50178 Class 1K4 – IEC721-3-1/2 Maximum Storage temperature 70°C (158°F) Minimum Relative Humidity...

  • Page 20: Protection Specifications

    Power Brick Controller User Manual Protection Specifications Description Specifications Outside the range of [4 – 20] kHz, or on-time exceeds 1.4 msec PWM Out Of Range Specifications...

  • Page 21: Electrical Specifications

    Power Brick Controller User Manual Electrical Specifications 4 – 20 PWM Frequency Operating Range [kHz] ±5% Logic Power [VDC, A] VDC, 5 A Specifications...

  • Page 22: Receiving And Unpacking

    Power Brick Controller User Manual RECEIVING AND UNPACKING Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the Power Brick Controller is received, there are several things to be done immediately:  Observe the condition of the shipping container and report any damage immediately to the commercial carrier that delivered the package.

  • Page 23: Mounting

    Power Brick Controller User Manual MOUNTING The location of the Power Brick Controller is important. Installation should be in an area that is protected from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and other contaminants. Exposure to these can reduce the operating life and degrade performance of the drive. Several other factors should be carefully evaluated when selecting a location for installation: ...

  • Page 24: Cad Drawing

    Power Brick Controller User Manual CAD Drawing General Dimensions Dimensions are identical between all part numbers: 3x M4 14.62" 13.44" 15.00" 7.75" 4.00" 2.50" Mounting...

  • Page 25: 4-Axis Pbc Direct Pwm

    Power Brick Controller User Manual 4-Axis PBC Direct PWM Amp #1 General Purpose I/O Encoders #1-4 Amp #2 Flags & Limits Serial MACRO Amp #3 EtherCAT Ethernet Abort & WD Amp #4 RTETH Fieldbus Analog I/O Logic Power In Analog I/O Alt.

  • Page 26: 4-Axis Pbc True Dac / Filtered Pwm

    Power Brick Controller User Manual 4-Axis PBC True DAC / Filtered PWM Amp #1 General Purpose I/O Encoders #1-4 Amp #2 Flags & Limits Serial MACRO Amp #3 EtherCAT Ethernet Abort & WD Amp #4 RTETH Fieldbus Analog I/O Logic Power I Analog I/O Alt.

  • Page 27: 8-Axis Pbc Direct Digital Pwm

    Power Brick Controller User Manual 8-Axis PBC Direct Digital PWM Amp #1 General Purpose I/O Encoders #1-4 Amp #2 Flags & Limits Serial MACRO Amp #3 EtherCAT Ethernet Abort & WD Amp #4 Amp #7 Amp #5 Encoders #5-8 RTETH Amp #8 Fieldbus Amp #6...

  • Page 28: 8-Axis Pbc True Dac / Filtered Pwm

    Power Brick Controller User Manual 8-Axis PBC True DAC / Filtered PWM Amp #1 General Purpose I/O Encoders #1-4 Amp #2 Flags & Limits Serial MACRO Amp #3 EtherCAT Ethernet Abort & WD Amp #4 Amp #7 Amp #5 Encoders #5-8 RTETH Amp #8 Fieldbus...

  • Page 29: Connections And Software Setup

    Power Brick Controller User Manual CONNECTIONS AND SOFTWARE SETUP 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 Warning pertaining to the installation.

  • Page 30: Wiring The Dac Output

    Power Brick Controller User Manual Wiring the DAC Output Single Ended DAC Output Differential DAC Output DAC+ DAC+ Analog Analog DAC- Device Device Sinusoidal DAC Output DACA+ DACA- Sine-Wave DACB+ Amplifier DACB- Connections and Software Setup...

  • Page 31: Wiring The Amplifier Enable And Fault Signals

    Power Brick Controller User Manual Wiring the Amplifier Enable and Fault Signals The amplifier enable output signal can be either:  High true using the normally open contact (pin #4)  Low true using the normally closed contact (pin #3) Also, it can be either sourcing or sinking depending on the wiring scheme.
  • Page 32 Power Brick Controller User Manual Amplifier Enable Wiring Diagram High True Amplifier Enable Output Sourcing Sinking AMP ENA 12-24V AMP ENA AE COM Power Power Supply Supply 12-24V AMP FLT+ AMP FLT+ AMP FLT- AMP FLT- AMP ENA COM AMP FLT COM AMP FLT COM Low True Amplifier Enable Output Sourcing...

  • Page 33: Direct Pwm Option

    Power Brick Controller User Manual Direct PWM Option PWM AMP1 (36-pin Mini-D Connector) Pin # Symbol Function Description Notes Feedback 1 of 4 Fault Code Bits Optional Feedback 1 of 4 Fault Code Bits Optional ADC_CLK+ Command A/D Converter Clock ADC_STB+ Command A/D Converter Strobe...

  • Page 34: A10: Logic Power Input

    Power Brick Controller User Manual A10: Logic Power Input A10 is used to bring in the 24 Volt DC supply powering up the logic portion of the Power Brick Controller. This power can remain on regardless of the main AC bus power, allowing the signal electronics to be active while the main motor power is passive.

  • Page 35: X1 - X8: Encoder Feedback, Digital Quadrature

    Power Brick Controller User Manual X1 – X8: Encoder Feedback, Digital Quadrature The Power Brick Controller accepts digital quadrature (also known as incremental) encoder signals by default. It provides up to four counts per square cycle, and extends it using hardware-computed (ASIC) 1/T.
  • Page 36 Power Brick Controller User Manual Quadrature encoders provide two digital signals to determine the position of the motor. These signals are typically 5 VDC TTL/CMOS level. Each nominally with 50% duty cycle and 1/4 cycle apart. This format provides four distinct states per cycle of the signal, or per line of the encoder. The phase difference of the two signals permits the decoding electronics to discern the direction of travel, which would not be possible with a single signal.

  • Page 37: Configuring Quadrature Encoders

    Power Brick Controller User Manual Configuring Quadrature Encoders The Power Brick Controller default settings are configured for quadrature encoders. Minimal setup is required to configure them; quadrature encoder signals are processed as a single 32-bit read in the encoder conversion table (ECT). 1/T extension is done in the Gate3 "hardware". The default ECT settings for an incremental quadrature encoder look like: EncTable[1].type = // Single 32-bit read...
  • Page 38 Power Brick Controller User Manual Quadrature Encoder Count Error With quadrature encoders, the Power Brick Controller has the capability of trapping encoder count (loss) errors. This is described in detail in the Encoder Count Error section of this manual. Quadrature Encoder Loss Detection Loss of the feedback sensor signal is potentially a very dangerous condition in closed-loop control, because the servo loop no longer has any idea what the true physical position of the motor is –...

  • Page 39: X1 - X8: Encoder Feedback, Sinusoidal

    Power Brick Controller User Manual X1 – X8: Encoder Feedback, Sinusoidal The Power Brick Controller can process sinusoidal encoders (up to 1.2 V ), and provide high peak-peak resolution (x 16384) interpolated position data. X1-X8: D-sub DA-15F Mating: D-sub DA-15M Primary Alternate Use Pin#...

  • Page 40: Configuring Sinusoidal Encoders

    Power Brick Controller User Manual The Power Brick Controller can accept “sine” and “cosine” Encoder shield (solder to shell) signals (90° out of phase with each other), of 1-volt (peak- Sine + Sine - to-peak) magnitude. Due to their inherit susceptibility to Cosine + electrical noise, these signals are most commonly Cosine -...

  • Page 41: Sinusoidal Counts Per User Units

    Power Brick Controller User Manual The sine and cosine signals can be accessed through the following elements. This may be helpful in diagnostics, or plotting the Lissajous. Ch. # Signal Element Ch. # Signal Element Sine PowerBrick[0].Chan[0].AdcEnc[0] Sine PowerBrick[1].Chan[0].AdcEnc[0] Cosine PowerBrick[0].Chan[0].AdcEnc[1] Cosine PowerBrick[1].Chan[0].AdcEnc[1]...
  • Page 42 Power Brick Controller User Manual Bias Correction The Power Brick Controller has the capability of correcting for biases of the cosine / sine signals. These corrections are suitable when interpolating in the Gate3 without the ACI (Auto Correcting Interpolator) option. This procedure is described in the Sinusoidal Encoder Bias Corrections section of this manual.

  • Page 43: X1 - X8: Encoder Feedback, Resolver

    Power Brick Controller User Manual X1 – X8: Encoder Feedback, Resolver The Power Brick Controller can "optionally" accept resolver encoder input (up to 5 V ) and provide peak-peak interpolated position data. X1-X8: D-sub DA-15F Mating: D-sub DA-15M Primary Alternate Use Pin# Symbol Function...

  • Page 44: Setting Up Resolvers

    Power Brick Controller User Manual Setting up Resolvers Configuring a resolver requires setting up the excitation signal control. The excitation signal control element, PowerBrick[].ResolverCtrl, is a 4-channel saved component: Excitation Signal Control Channels 1 – 4 PowerBrick[0].ResolverCtrl Channels 5 – 8 PowerBrick[1].ResolverCtrl The excitation signal control element is a 32-bit element wherein the upper 12 bits carry meaningful information is broken down as follows:...

  • Page 45: Configuring Resolver Ect

    Power Brick Controller User Manual Utilizing the following expression, for channels 1 – 4 as an example: GLOBAL ResExcitDelay; GLOBAL ResExcitMag; GLOBAL ResExcitFreqDiv; ResExcitMag = 3 // [0 - 3] ResExcitFreqDiv = 0 // [0 - 3] ResExcitDelay = 65 // [0 - 255] PowerBrick[0].ResolverCtrl = ResExcitDelay*EXP2(24) + ResExcitMag*EXP2(22) + ResExcitFreqDiv*EXP2(20) And monitoring the magnitude of the signals in the lower 16 bits of...

  • Page 46: Resolver Absolute Power-On Position

    Power Brick Controller User Manual Resolver Absolute Power-On Position With resolvers, the absolute position is computed directly from the upper 16 bits of the AtanSumOfSqr register. It is set up using the following key structure elements:  Motor[].pAbsPos = PowerBrick[0].Chan[2].AtanSumOfSqr.a ...
  • Page 47 Power Brick Controller User Manual Bias Correction The resolver sine and cosine signals may be corrected for biases similarly to sinusoidal encoders. This is described in the Sinusoidal Encoder Bias Corrections section of this manual. Automatic correction for signal magnitude mismatch and phase offset at the cost of additional processor time can be obtained through use of a type 4 encoder conversion table entry.

  • Page 48: X1 - X8: Encoder Feedback, Serial

    Power Brick Controller User Manual X1 – X8: Encoder Feedback, Serial The PMAC3 style ASIC in the Power Brick Controller accepts a variety of serial encoder protocols. These protocols are built into the ASIC. X1-X8: D-sub DA-15F Mating: D-sub DA-15M Sigma Hiperfac Panasoni...
  • Page 49 Power Brick Controller User Manual Quadrature / sinusoidal encoders can be wired (except for the index C channel) and processed simultaneously with serial encoders. Note Pins #5, 6, 13, and 14 of the encoder feedback connectors (X1 – X8) share multiple functions: only one of these functions (per channel) can be used –...

  • Page 50: Serial Encoder Control

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

  • Page 51: Serial Encoder Command

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

  • Page 52: Ssi Configuration Example

    Power Brick Controller User Manual SSI Configuration Example Serial Encoder Control – SSI No trigger delay, rising edge of phase, and 2.5 MHz transmission. 0: Rising Protocol: =2 SSI = Delay µsec SerialMHz 1: Falling M Divisor N Divisor Trigger Delay Protocol 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...

  • Page 53: Endat 2.1/2.2 Configuration Example

    Power Brick Controller User Manual EnDat 2.1/2.2 Configuration Example Serial Encoder Control – EnDat 2.1/2.2 No trigger delay, rising edge of phase, and 2.0 MHz transmission. 0: Rising Protocol: =3 EnDat = Delay µsec SerialMHz 1: Falling M Divisor N Divisor Trigger Delay Protocol 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4...
  • Page 54 Power Brick Controller User Manual With EnDat 2.2, bit 31 is the StartDelayComp control bit. Setting this bit to 1 starts a delay identification and compensation cycle which measures the propagation delay between the encoder and the controller. The delay is measured three times, and the average is used in the compensation. When these calculations are done, the StartDelayComp bit 31 is automatically cleared.

  • Page 55: Hiperface Configuration Example

    Power Brick Controller User Manual Hiperface Configuration Example Serial Encoder Control – Hiperface Because there is no explicit clock signal with Hiperface, the serial clock frequency is set 20 times higher than the bit transmission frequency to “oversample” the input data stream. For the default 9600 baud transmission of the Hiperface encoder, this clock frequency should be 9.6 x 20 = 192 kHz.
  • Page 56 Power Brick Controller User Manual Serial Data Registers – Hiperface The resulting position data, status, and error bits for Hiperface are found in the following Serial Data Registers: PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Possible Single/Multi-Turn Position...

  • Page 57: Yaskawa Sigma I Configuration Example

    Power Brick Controller User Manual Yaskawa Sigma I Configuration Example Serial Encoder Control – Sigma I Because there is no explicit clock signal with Sigma I, the serial clock frequency is set 20 times higher than the bit transmission frequency to “oversample” the input data stream. For the default 9600 baud transmission of the Sigma I encoder, this clock frequency should be 9.6 x 20 = 192 kHz.
  • Page 58 Power Brick Controller User Manual Serial Data Registers – Sigma I The resulting position data, status, and error bits for Sigma I are found in the following Serial Data Registers: PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Multi-Turn Position...

  • Page 59: Yaskawa Sigma Ii/Iii/V Configuration Example

    Power Brick Controller User Manual Yaskawa Sigma II/III/V Configuration Example Serial Encoder Control – Sigma II/III/V No trigger delay, rising edge of phase, and 4.0 MHz transmission. 0: Rising Protocol: =6 Sigma II/III/V = Delay µsec SerialMHz 1: Falling M Divisor N Divisor Trigger Delay Protocol...
  • Page 60 Power Brick Controller User Manual Yaskawa Sigma II (incremental 17-bit) PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Single-Turn Position Compensation Position PowerBrick[i].Chan[j].SerialEncDataB...

  • Page 61: Tamagawa Fa-Coder Configuration Example

    Power Brick Controller User Manual Tamagawa FA-Coder Configuration Example Serial Encoder Control – Tamagawa FA-Coder No trigger delay, rising edge of phase, and 2.5 MHz transmission 0: Rising Protocol: =7 Tamagawa = Delay µsec SerialMHz 1: Falling M Divisor N Divisor Trigger Delay Protocol 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4...

  • Page 62: Panasonic Configuration Example

    Power Brick Controller User Manual Panasonic Configuration Example Serial Encoder Control – Panasonic No trigger delay, rising edge of phase, and 2.5 MHz transmission 0: Rising Protocol: =8 Panasonic = Delay µsec SerialMHz 1: Falling M Divisor N Divisor Trigger Delay Protocol 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...
  • Page 63 Power Brick Controller User Manual Serial Data Registers – Panasonic The resulting position data, status, and error bits for Panasonic are found in the following Serial Data Registers. PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Multi-Turn Position Single-Turn Position...

  • Page 64: Mitutoyo Configuration Example

    Power Brick Controller User Manual Mitutoyo Configuration Example Serial Encoder Control – Mitutoyo No trigger delay, rising edge of phase, and 2.5 MHz transmission 0: Rising Protocol: =9 Mitutoyo = Delay µsec SerialMHz 1: Falling M Divisor N Divisor Trigger Delay Protocol 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...
  • Page 65 Power Brick Controller User Manual Serial Data Registers – Mitutoyo The resulting position data, status, and error bits for Mitutoyo are found in the following Serial Data Registers: PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Possible Single-Turn/Multi-turn Position PowerBrick[i].Chan[j].SerialEncDataB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...

  • Page 66: Kawasaki Configuration Example

    Power Brick Controller User Manual Kawasaki Configuration Example Serial Encoder Control – Kawasaki No trigger delay, rising edge of phase, and 2.5 MHz transmission. 0: Rising Protocol: =A Kawasaki = Delay µsec SerialMHz 1: Falling M Divisor N Divisor Trigger Delay Protocol 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...

  • Page 67: Serial Encoder Ongoing Position Setup

    Power Brick Controller User Manual Serial Encoder Ongoing Position Setup For the ongoing "incremental" position data, it is sufficient to process whatever position data (single-turn and/or multi-turn) is available in the Serial Encoder Data A register. The PMAC firmware does not require processing the entire bit length;...
  • Page 68 Power Brick Controller User Manual Example: A serial encoder with 20 bits of single-turn (or an equivalent 50 nm linear scale) position data located in Serial Encoder Data A register and starting at bit #4. The low nibble may contain other information, irrelevant to position data.
  • Page 69 Power Brick Controller User Manual Example: A serial encoder with 36 bits of single-turn (or an equivalent 1nm linear scale) position data located in Serial Encoder Data A and B registers consecutively. PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 PowerBrick[i].Chan[j].SerialEncDataB 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4...
  • Page 70 Power Brick Controller User Manual Example: A 29-bit serial encoder with 17 bits of single-turn and 12 bits of multi-turn position data starting at bit #0 of serial data A register and continuously extending to bit #28. PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Multi-Turn Position Data Single-Turn Position Data...
  • Page 71 Power Brick Controller User Manual Example: A 36-bit serial encoder with 24 bits of single-turn and 12 bits of multi-turn position data starting at bit #0 of Serial Encoder Data A register and continuously extending to bit #3 of serial data register B. PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...

  • Page 72: Serial Encoder Power-On Absolute Position Setup

    Power Brick Controller User Manual Serial Encoder Power-On Absolute Position Setup The absolute position is computed directly from the serial data registers, and set up using the following key structure elements:  Motor[x].pAbsPos, typically = PowerBrick[i].Chan[j].SerialEncDataA.a  Motor[x].AbsPosSf, typically = 1 with serial encoders ...
  • Page 73 Power Brick Controller User Manual Example: A serial encoder with 17 bits of binary single-turn (or linear scale), and no multi-turn, position data located in the lower fields of serial data A register. PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 17 bits 00: unsigned binary...
  • Page 74 Power Brick Controller User Manual Motor[1].HomeOffset = 0 Connections and Software Setup...
  • Page 75 Power Brick Controller User Manual Encoders with no multi-turn position data are set up as unsigned. Note Example: A 29-bit binary serial encoder with 17 bits of single-turn and 12 bits of multi-turn position data starting at bit #0 of serial data A register and continuously extending to bit #28. PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...
  • Page 76 Power Brick Controller User Manual Example: A 36-bit binary serial encoder with 24 bits of single-turn in the lower fields of serial data register A, and 12 bits of multi-turn position data in the lower fields of serial data register B. PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...
  • Page 77 Power Brick Controller User Manual Example: A 32-bit Gray code serial encoder with 20 bits of single-turn in serial data register A starting at bit #4, and 12 bits of multi-turn position data in serial data register B starting at bit #8. PowerBrick[i].Chan[j].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...
  • Page 78 Power Brick Controller User Manual Example: A 33-bit binary serial encoder (for example, Panasonic) with 17 bits of single-turn and 16 bits of multi-turn position data in the following fields: PowerBrick[].Chan[].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Single-Turn Position Data Multi-Turn Position Data...

  • Page 79: X9 - X12: Analog Inputs / Outputs

    Power Brick Controller User Manual X9 – X12: Analog Inputs / Outputs Each of the analog I/O connectors (X9, X10, X11, and X12) provides:  2 x 16-bit Analog Inputs  2 x ~14-bit Analog Outputs  2 x General Purpose Relays ...

  • Page 80: Setting Up The Analog (Adc) Inputs

    Power Brick Controller User Manual Setting up the Analog (ADC) Inputs The analog inputs accept ±5 VDC differential signals, or ±10 VDC single-ended signals. Differential Analog Input Signal Single Ended Analog Input Signal AGND AGND ADC1- ADC1- ADC1+ ADC1+ For single-ended connections, tie the negative ADC pin to ground. Note The ADC software data resides in the upper 16 bits of the 32-bit structure element PowerBrick[i].Chan[j].AdcAmp[2].
  • Page 81 Power Brick Controller User Manual Raw ADC Data (In bits) Sys.WpKey = $AAAAAAAA // Disable Write-Protection PowerBrick[0].AdcAmpHeaderBits = 0 PowerBrick[1].AdcAmpHeaderBits = 0 PowerBrick[0].Chan[0].PackInData = // Unpack Input Data, ADC1 X9 PowerBrick[0].Chan[1].PackInData = // Unpack Input Data, ADC2 X9 PowerBrick[0].Chan[2].PackInData = // Unpack Input Data, ADC1 X10 PowerBrick[0].Chan[3].PackInData = // Unpack Input Data, ADC2 X10...
  • Page 82 Power Brick Controller User Manual Example Code: GLOBAL ADC1X9Volts = 0; // Voltage input, ADC1 X9 [volt] GLOBAL ADC2X9Volts = 0; // Voltage input, ADC2 X9 [volt] GLOBAL ADC1X10Volts = 0; // Voltage input, ADC1 X10 [volt] GLOBAL ADC2X10Volts = 0; // Voltage input, ADC2 X10 [volt] GLOBAL ADC1X11Volts = 0;...
  • Page 83 Power Brick Controller User Manual Using the ADC for Servo Feedback Using the ADC data for servo feedback requires bringing it into the Encoder Conversion Table (ECT) into which the motor’s position and velocity elements are assigned to. Example: EncTable[9].Type = EncTable[41].pEnc = PowerBrick[0].Chan[0].AdcAmp[2].a EncTable[41].pEnc1 = Sys.pushm EncTable[41].index1 =...

  • Page 84: Setting Up The Analog (Dac) Outputs

    Power Brick Controller User Manual Setting up the Analog (DAC) Outputs The analog outputs provide ±10 VDC signals interfacing to either differential or single-ended devices. Differential DAC Output Signal Single Ended DAC Output Signal AGND Analog Device This analog output circuitry is filtered PWM optimized (in hardware) for a PWM cut off frequency of about 15 kHz.
  • Page 85 Power Brick Controller User Manual Writing directly into PowerBrick[i].Chan[j].PWM[3] register to produce voltage output requires shifting left by 16 bits (or multiplying by 65536). Note The command output data must be in the “unpacked” format; PowerBrick[i].Chan[j].PackOutData = 0. Note The analog outputs are generated from the fourth output channel, phase D.
  • Page 86 Power Brick Controller User Manual The effective resolution of the analog output circuitry is about ~13.5 bits (±13380 software counts) spanning over the full output range of ±10 VDC (saturates at about ~10.5 Volts). Writing to the user defined DACnXxxInBits pointer produces the following voltage output: DACnXxxInBits Single Ended [VDC] Differential [VDC]...
  • Page 87 Power Brick Controller User Manual Example Code: GLOBAL DAC1X9Volts = 0; // DAC Channel 1, X9 [volts] GLOBAL DAC2X9Volts = 0; // DAC Channel 2, X9 [volts] GLOBAL DAC1X10Volts = 0; // DAC Channel 1, X10 [volts] GLOBAL DAC2X10Volts = 0; // DAC Channel 2, X10 [volts] GLOBAL...

  • Page 88: Setting Up The General Purpose Relays

    Power Brick Controller User Manual Setting up the General Purpose Relays This normally open general purpose relay operated structure element PowerBrick[i].Chan[j].OutFlagC. Channel / Channel / Structure element bit Structure element bit Connector Connector Relay 1, X9 PowerBrick[0].Chan[0].OutFlagC Relay 1, X9 PowerBrick[1].Chan[0].OutFlagC Relay 2, X9 PowerBrick[0].Chan[1].OutFlagC...
  • Page 89 Power Brick Controller User Manual The commons of the general purpose inputs / amp faults (pins #8, and #15) are tied internally to relay commons 1 and 2 respectively. If the relay is wired in sourcing mode, that general purpose input cannot be used.

  • Page 90: Setting Up The Gp Input

    Power Brick Controller User Manual Setting up the GP Input This input provides a general purpose input coming from an external device (e.g. amplifier fault). It is a single-ended 5 VDC TTL level input. The ground common of this input is tied internally to the corresponding general purpose relay (pins #12 and #5).

  • Page 91: X13: Axis 1 - 4 Limits, Flags, Equ

    Power Brick Controller User Manual X13: Axis 1 – 4 Limits, Flags, EQU X13 is used to wire the limits, flags, and EQU for axes 1 – 4. The limits  Positive overtravel limit and flags are auto-regulating in the 5 – 24 VDC range. The current draw ...

  • Page 92: X14: Axis 5 - 8 Limits, Flags, Equ

    Power Brick Controller User Manual X14: Axis 5 – 8 Limits, Flags, EQU X14 is used to wire the limits, flags, and EQU for axes 5 – 8. The limits  Positive overtravel limit and flags are auto-regulating in the 5 – 24 VDC range. The current draw ...

  • Page 93: Wiring The Limits And Flags

    Power Brick Controller User Manual Wiring the Limits and Flags The Power Brick Controller allows the use of sinking or sourcing limits and flags (per channel). The current flow could be from return to flag (sinking) or from flag to return (sourcing). The overtravel limits must be normally closed switches.

  • Page 94: Limits And Flags Suggested Pointers

    Power Brick Controller User Manual Limits and Flags Suggested Pointers Typically, and if the corresponding channel is activated (Motor[x].ServoCtrl = 1), the overtravel limits are monitored in the motor status window in the IDE software and the motor structure elements (i.e.
  • Page 95 Power Brick Controller User Manual Channels 5 – 8 Limits and Flags Suggested Pointers (X14) Ch5PlusLimit->PowerBrick[1].Chan[0].PlusLimit; // Channel 5 Positive Limit Ch5MinusLimit->PowerBrick[1].Chan[0].MinusLimit; // Channel 5 Negative Limit Ch5UserFlag->PowerBrick[1].Chan[0].UserFlag; // Channel 5 User Flag Ch5HomeFlag->PowerBrick[1].Chan[0].HomeFlag; // Channel 5 Home Flag Ch5EQU->PowerBrick[1].Chan[0].Equ; // Channel 5 EQU Ch6PlusLimit->PowerBrick[1].Chan[1].PlusLimit;...

  • Page 96: X15: Digital Inputs / Outputs

    Power Brick Controller User Manual X15: Digital Inputs / Outputs X15 (J17 internally) is used to wire the general purpose digital I/O (16 inputs, and 8 outputs). X15: D-sub DC-37F Mating: D-sub DC-37M Pin # Symbol Function Description GPIN1 Input Input 1 GPIN3 Input...

  • Page 97: X16: Digital Inputs / Outputs (Additional)

    Power Brick Controller User Manual X16: Digital Inputs / Outputs (Additional) X16 (J18 internally) is used to wire the additional general purpose digital I/Os (16 inputs, and 8 outputs). X16: D-sub DC-37F Mating: D-sub DC-37M Pin # Symbol Function Description GPIN17 Input Input 17...

  • Page 98: X25: Digital Inputs / Outputs (Additional)

    Power Brick Controller User Manual X25: Digital Inputs / Outputs (Additional) X25 (J12 internally) is used to wire further additional general purpose digital I/Os (16 inputs, and 8 outputs). X25: D-sub DC-37F Mating: D-sub DC-37M Pin # Symbol Function Description GPIN33 Input Input 33...

  • Page 99: About The Digital Inputs And Outputs

    Power Brick Controller User Manual About the Digital Inputs and Outputs All general purpose inputs and outputs are optically isolated. They operate in the 12 – 24 VDC range, and can be wired to be either sinking into or sourcing out of the Power Brick. Inputs The inputs use the PS2705-1NEC...

  • Page 100: Wiring The Digital Inputs And Outputs

    Power Brick Controller User Manual Wiring the Digital Inputs and Outputs Sourcing Inputs / Outputs Sinking Inputs / Outputs Power Power 12 – 24 VDC 12 – 24 VDC INPUT 1 / 17 INPUT 1 / 17 INPUT 2 / 18 INPUT 2 / 18 INPUT 3 / 19 INPUT 3 / 19...

  • Page 101: X15 Digital I/O Pointers

    Power Brick Controller User Manual X15 Digital I/O Pointers // X15 INPUTS Input1->PowerBrick[0].GpioData[0].0.1; // Input #1, X15 Pin#1 Input2->PowerBrick[0].GpioData[0].1.1; // Input #2, X15 Pin#20 Input3->PowerBrick[0].GpioData[0].2.1; // Input #3, X15 Pin#2 Input4->PowerBrick[0].GpioData[0].3.1; // Input #4, X15 Pin#21 Input5->PowerBrick[0].GpioData[0].4.1; // Input #5, X15 Pin#3 Input6->PowerBrick[0].GpioData[0].5.1;...

  • Page 102: X25 Digital I/O Pointers

    Power Brick Controller User Manual X25 Digital I/O Pointers // X25 INPUTS Input33->u.io:$C00000.8.1; // Input #33,X25 Pin#1 Input34->u.io:$C00000.9.1; // Input #34,X25 Pin#20 Input35->u.io:$C00000.10.1; // Input #35,X25 Pin#2 Input36->u.io:$C00000.11.1; // Input #36,X25 Pin#21 Input37->u.io:$C00000.12.1; // Input #37,X25 Pin#3 Input38->u.io:$C00000.13.1; // Input #38,X25 Pin#22 Input39->u.io:$C00000.14.1;...

  • Page 103: X17: Macro

    Power Brick Controller User Manual X17: MACRO If a MACRO option was selected, the Power Brick Controller provides the following connector for MACRO communications: MACRO SC-Style Fiber Connector Front View Pin # Symbol Function MACRO Ring Receiver MACRO Ring Transmitter Notes: The fiber optic version of MACRO uses 62.5/125 multi-mode glass fiber optic cable terminated in an SC-style connector.

  • Page 104: X18: Global Abort And Watchdog

    Power Brick Controller User Manual X18: Global Abort and Watchdog X18 has two essential functions:  Global abort input.  Watchdog output. X15: Phoenix 5-pin TB Female TB-5: 016-PL0F05-38P Mating: Phoenix 5-pin TB Male Pin # Symbol Function Notes ABORT- Input ABORT Return ABORT+...
  • Page 105 Power Brick Controller User Manual Global Abort Key Settings The global abort input is enabled / disabled in software through Sys.pAbortAll. = PowerBrick[0].GpioData[0].a Global abort input enabled Sys.pAbortAll Global abort input disabled Sys.pAbortAll = PowerBrick[0].GpioData[0].a // =0 global abort disabled Sys.AbortAllBit = // Default, do not change Sys.AbortAllCount =...

  • Page 106: Watchdog Relay

    Power Brick Controller User Manual Watchdog Relay The Watchdog relay(s) allows the user to connect to a safety circuit in order to bring the machine to a stop in a safe manner if a Watchdog condition occurs. Normally open or closed contacts are available: Normally Open Normally Closed 24 VDC...

  • Page 107: X19: External Encoder Supply

    Power Brick Controller User Manual X19: External Encoder Supply Typically, feedback devices power is supplied through the X1 – X8 connectors using the internal +5 VDC power supply. However, if the total feedback devices power budget exceeds ~ 2 amperes, this connector can be used to bring in the power supply from an external source.

  • Page 108: Functionality, Safety Considerations

    Power Brick Controller User Manual A jumper tying pins 1 and 2 is the default configuration. This is the configuration in which the Power Brick Controller is shipped. Note The controller (PMAC) 5 VDC logic is independent of this scheme, so if no encoder power is provided the PMAC will remain powered- up (provided the standard 24 volts is brought in).

  • Page 109: X20: Real-Time Ethernet Rteth0

    Power Brick Controller User Manual X20: Real-Time Ethernet RTETH0 Refer to the ACC-72EX Manual for this connector’s pinout and functionality. X21: Real-Time Ethernet RTETH1 Refer to the ACC-72EX Manual for this connector’s pinout and functionality. X22: FB Diagnostic Refer to the ACC-72EX Manual for this connector’s pinout and functionality. X23: Fieldbus Refer to the ACC-72EX Manual for this connector’s pinout and functionality.

  • Page 110: Eth 0/1: Ethernet Connections

    Power Brick Controller User Manual ETH 0/1: Ethernet Connections The Power Brick Controller comes with two Ethernet ports on the front panel: ETH 0 and ETH 1. Both ports can accept standard CAT-5 Ethernet cables with RJ-45 connectors. Both Ethernet ports provide transformer isolation to prevent ground-loop problems.

  • Page 111: Eth 2/3: Etherсat Connections

    Power Brick Controller User Manual ETH 2/3: EtherСAT Connections The user can order one to two EtherCAT Master Ports, ETH 2 and ETH 3, with the Power Brick controller. Both ports can accept standard CAT-5 Ethernet cables with RJ-45 connectors. Both EtherCAT ports provide transformer isolation to prevent ground-loop problems.

  • Page 112: Usb Connections

    Power Brick Controller User Manual USB Connections The Power Brick Controller board provides two USB ports on the front panel, one host port and one device port. Both provide USB 2.0 protocol communications. USB ports are not electrically isolated, so care must be taken in the grounding scheme when any separately powered device is connected to one of these ports.

  • Page 113: Usb 2 Device Port

    Power Brick Controller User Manual USB 2 Device Port The USB “device” port is labeled “USB 2” on the front panel. It is a “Micro-B” format connector located just below the USB host port. With this port, the Power PMAC CPU board acts as a peripheral device when it is powered off.

  • Page 114: Rs-232 Connection

    IDC 10-pin header at this end and a 9-pin D- sub connector at the other end will provide a standard RS-232 connection. The Delta Tau ACC-3L cable provides this connectivity.

  • Page 115: Sd Card Connection

    Power Brick Controller User Manual SD Card Connection The Power Brick Controller provides a socket for SD card insertion. This permits the use of standard “camera card” flash memory for many uses. It is even possible to boot the CPU from an SD card if the proper boot files are present on the card.

  • Page 116: Manual Motor Setup

    Power Brick Controller User Manual MANUAL MOTOR SETUP This section describes the step-by-step procedure for setting up motors with the Power Brick Controller. Logic (24 VDC) power, encoder, motor, and main DC bus power (for your amplifier(s)) must be wired properly, per the instructions in the connections section, prior to setting up any motor channel.

  • Page 117: Global Reset

    Power Brick Controller User Manual Global Reset Starting from factory default settings (issuing a global reset $$$*** followed by a Save and a $$$) is highly recommended. This ensures a good "clean" starting point. Manual Motor Setup...

  • Page 118: Dominant Clock Frequencies

    Power Brick Controller User Manual Dominant Clock Frequencies The choice of clock frequencies relies typically on the system requirements, hardware, and type of application. Phase: The phase clock governs the current loop calculation, current sensor readings, and user written phase routine. Typically, the maximum phase clock frequency should not exceed twice that of the PWM.

  • Page 119: Recommended Clock Frequencies

    Power Brick Controller User Manual Recommended Clock Frequencies The recommended clock frequency settings for the Power Brick Controller are 10 kHz Phase, 10 kHz PWM, and 5 kHz Servo.  The write protection Sys.WpKey must be disabled to write to these key gate and system elements. ...

  • Page 120: Data Unpacking

    Power Brick Controller User Manual Data Unpacking The ADC inputs and motor phase outputs’ data is packed by default in the Power PMAC firmware into single 32-bit registers. Typically, this improves the efficiency of the computation algorithms, especially in extremely high performance applications or with a large number of axes (up to 256). However, this enhancement may not be as noteworthy with the Power Brick Controller considering the significantly lower number of axes it is usually controlling.

  • Page 121: Verifying Encoder Feedback, Scaling To User Units

    Power Brick Controller User Manual Verifying Encoder Feedback, Scaling to User Units The absence of encoder data is potentially a very dangerous condition in closed-loop control, because the servo loop no longer has any idea what the true physical position of the motor is – usually it thinks it is "stuck"...

  • Page 122: Abort Input

    Power Brick Controller User Manual Abort Input If the +24 VDC abort input is not wired in or disabled in software (Sys.pAbortAll = 0), PMAC will try to close the loop on the motor every time it is enabled which could cause the motor the move or jump (if it has not been set up).

  • Page 123: Direct Digital Pwm Output

    Power Brick Controller User Manual Direct Digital PWM Output Having performed the following:  Global Reset (optional but recommended).  Set up the dominant clock frequencies.  Unpacked the ADC input and phase output data.  Verified encoder feedback. If the +24 VDC abort input is not wired in or disabled in software (Sys.pAbortAll = 0), PMAC will try to close the loop on the motor every time it is enabled which could cause the motor the move or jump (if it has not been set up).

  • Page 124: Common Pwm Output Motor Setup Elements

    Power Brick Controller User Manual Common PWM Output Motor Setup Elements The following, are common motor structure elements for setting up commutated motors (e.g. brushless) with Direct PWM output with the Power Brick Controller. // Overtravel limits (set Motor[].pLimits = 0 to disable) Motor[1].pLimits = PowerBrick[0].Chan[0].Status.a Motor[2].pLimits = PowerBrick[0].Chan[1].Status.a Motor[3].pLimits = PowerBrick[0].Chan[2].Status.a...

  • Page 125: Activate The Motors

    Power Brick Controller User Manual Activate the Motors // Activate Motors Motor[1].ServoCtrl = Motor[2].ServoCtrl = Motor[3].ServoCtrl = Motor[4].ServoCtrl = Motor[5].ServoCtrl = Motor[6].ServoCtrl = Motor[7].ServoCtrl = Motor[8].ServoCtrl = Manual Motor Setup...

  • Page 126: Pwm Output Scale Factor

    Power Brick Controller User Manual PWM Output Scale Factor The PWM scale factor, Motor[x].PwmSf, in commutated (e.g. brushless) motor control specifies the maximum command output (voltage limiter). With the Power Brick Controller, the nominal value is 16,384.  If the motor rated voltage is greater than > the input bus voltage: Motor[1].PwmSf = 16384 Motor[2].PwmSf =...

  • Page 127: Ongoing Phase Position

    Power Brick Controller User Manual Ongoing Phase Position Following are guidelines for setting up the ongoing phase position (Motor[].PhasePosSf) with various types of encoders. Some motor and encoder data sheet information is necessary to compute Motor[].PhasePosSf properly: NoOfPolePairs is the number of pair poles of a rotary motor. CountsPerRevolution is the number of raw quadrature encoder counts per revolution of a rotary motor.
  • Page 128 Power Brick Controller User Manual Serial Encoder Example: A serial encoder with 17 bits of single-turn ST data. Shift left 15 bits to MSB for rollover. PowerBrick[].Chan[].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Motor[].pPhaseEnc = PowerBrick[].Chan[].SerialEncDataA.a Motor[].PhaseEncLeftshift = 15...
  • Page 129 Power Brick Controller User Manual Linear: Motor[].PhasePosSf = 2048 * RES / (2 * ECL Example: A 36-bit serial encoder with 24 bits of single-turn ST and 12 bits of multi-turn position data starting at bit #0 of serial data A register and continuously extending to bit #3 of serial data register B. PowerBrick[].Chan[].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...

  • Page 130: I2T Protection

    Power Brick Controller User Manual I2T Protection The Power Brick Controller can be set up to fault a motor if the time-integrated current levels exceed a certain threshold. This can protect the motor (and drive) from damage due to overheating. It integrates the square of current over time –...
  • Page 131 Power Brick Controller User Manual The max ADC, or full current reading, is specified by the amplifier manufacturer. If the current limits of the motor are given as peak values, there is no need to multiply by √2 (1.414). Caution If the motor current limits are given in RMS values, or using those of the amplifier: * 32768 * √2 * cos(30°) / MaxAdc Motor[].MaxDac = PeakCurrent...

  • Page 132: Adc Offsets

    Power Brick Controller User Manual ADC Offsets The Power PMAC firmware has an auto-calibration routine for current offsets (Motor[].IaBias, and Motor[].IbBias) compensation built into the firmware using Motor[].CurrentNullPeriod. If this is already performed on the amplifier side, then it is not needed here. Otherwise, the current null or offsets finding period is set in terms of phase cycles.

  • Page 133: Current Loop Tuning

    Power Brick Controller User Manual Current Loop tuning Current loop tuning of brushless motors is carried out similarly to any Power PMAC digital current loop configuration. Current loop tuning is typically performed using the tuning tool in the IDE software. With some basic knowledge of motor and amplifier parameters, it is possible to calculate the current-loop gains empirically.
  • Page 134 Power Brick Controller User Manual Current-Loop Natural Frequencies in the range of 200 – 500 Hz are adequate for most applications. With higher performance motors (e.g. linear), the current loop’s natural frequency can be pushed higher. However, tightening the current loop with a lower performance system could have deteriorating effects on the overall position closed-loop performance.

  • Page 135: Motor Phasing

    Power Brick Controller User Manual Motor Phasing When commutating a synchronous multi-phase motor such as a permanent-magnet brushless servo motor, the commutation algorithm must know the absolute position of the rotor within a single commutation cycle so it knows the magnetic field orientation of the rotor. The process of establishing this absolute position sense is known as "phase referencing"...
  • Page 136 Power Brick Controller User Manual The following phasing methods are discussed in this section: o Automatic Stepper Phasing o Manual "Force" Phasing o Custom "PLC" Phasing Choosing a phasing method depends on the feedback device used with the brushless motor. The following table is a summary of the suggested phasing method to use with respect to each type of feedback device: Initial Phasing / Final Implementation /...
  • Page 137 Power Brick Controller User Manual Automatic Stepper Phasing The automatic Stepper phasing technique is one of two phase referencing routines built-into the Power PMAC firmware (the other one is the four-guess technique, not discussed here). The automatic stepper method can be used with any type of feedback device. It is simple to set up and can establish a very accurate phase reference.
  • Page 138 Power Brick Controller User Manual Manual "Force" Phasing The manual phasing method consists of locking up the motor tightly onto the zero position of the commutation cycle by forcing current into the offset of its B phase. This manual phasing works with any type of feedback device.
  • Page 139 Power Brick Controller User Manual Custom "PLC" Phasing Some system may require a more specialized phasing technique due to uneven loads or friction along the travel. This manual phasing PLC may be more desirable for advanced users due to flexibility and more customization capabilities.
  • Page 140 Power Brick Controller User Manual GLOBAL Mtr1PhasingMag = Motor[1].I2TSet; GLOBAL Mtr1PhaseAPos = 0; GLOBAL Mtr1PhaseBPos = 0; GLOBAL Mtr1PhasingDis = 0; GLOBAL Mtr1DisThres = 2048 * EncTable[1].ScaleFactor / (5 * Motor[1].PhasePosSf); GLOBAL Mtr1PhasingPass = 0; OPEN CustomPhasingPLC Mtr1PhasingPass = 0 Motor[1].PhaseFound = 0 Motor[1].IaBias = 0 Motor[1].IbBias = 0 COUT...

  • Page 141: Open Loop Test

    Power Brick Controller User Manual Open Loop Test The open loop test is a critical step in verifying the proper implementation of the:  Current loop  Commutation  Encoder decode/sense  Encoder functionality The open loop test can be executed using the open-loop test tab in the tuning utility in the IDE software. The test amplitude depends on the load/gearing of the motor.
  • Page 142 Power Brick Controller User Manual A positive command should create a velocity and position counting in the positive direction; a negative command should create a velocity and position counting in the negative direction. This is typically observed in the response plot as a velocity saw tooth. A successful open-loop test response looks like: Open-loop Test Troubleshooting Tips The open loop test can fail in two ways: ...

  • Page 143: Position Loop Tuning

    Power Brick Controller User Manual Position Loop Tuning Position loop tuning is performed using the tuning utility in the IDE Software. Do not attempt to close the position loop or perform position loop tuning on a motor which open-loop test has failed. This may lead to dangerous runaway conditions.
  • Page 144 Power Brick Controller User Manual The Position-loop interactive tuning is the fully fletched tuning interface, introducing all the gains used in the servo algorithm, various pre-configured command profiles, and filter tools. The two most common move profiles used in tuning are Step and Parabolic. Interactive Tuning An acceptable step move response would look like: Desirable characteristics to note: minimal overshoot, zero steady-state error, natural frequency >...
  • Page 145 Power Brick Controller User Manual And an acceptable parabolic move response would look like: Desirable characteristics to note: following error (green curve above) centered about 0 with minimal amplitude. With higher resolution encoders, the Motor[x].Servo.MaxPosErr may need to be set to a higher than the default value allowing larger position error in the servo filter.

  • Page 146: Absolute Power-On Phasing

    Power Brick Controller User Manual Absolute Power-On Phasing Absolute power-on phasing is configurable with feedback devices providing an absolute reference capability; devices such as hall sensors, resolvers, or absolute serial encoders. The absolute power-on phasing allows the phasing (figuring out the commutation rotor-angle position) of a motor without the need of a search move (motion) or energizing the motor.
  • Page 147 Power Brick Controller User Manual Hall Effect Phasing Digital Hall Effect sensors can be used for computing a rough absolute phase reference on power-up without the need for a phasing search move. They provide absolute information about where the motor is positioned with respect to its commutation cycle.
  • Page 148 Power Brick Controller User Manual These settings can be configured using the plot utility in the IDE software. Moving or jogging the motor by hand in the positive direction while gathering Motor[].PhasePos and the corresponding PowerBrick[].Chan[].UVW should produce the following: 2048 / 12 If the transition is 1-3 Motor[].AbsPhasePosSF =...
  • Page 149 Power Brick Controller User Manual Alternately, following example configures Motor[].AbsPhasePosSf, Motor[].AbsPhasePosOffset automatically.  Enable the PLC  Move the motor at a slow to average speed (by hand or using jog commands) in the positive direction of the encoder.  Once Motor[].AbsPhasePosOffset is posted, your Halls settings are finished.
  • Page 150 Power Brick Controller User Manual Hall Phasing Correction (Fine Phasing) Inherently, digital hall sensors have an error of about ±30° resulting in a loss of torque of about 15%. Correcting for hall sensors’ error can be achieved with a simple procedure. For better efficiency, this correction is strongly recommended for all applications using hall sensors for "absolute"...
  • Page 151 Power Brick Controller User Manual Absolute Serial Encoder Phasing With absolute serial encoders, the four key elements for setting up absolute phasing are:  Motor[].pAbsPhasePos = PowerBrick[].Chan[].SerialEncDataA.a  Motor[].AbsPhasePosFormat = 00 Numerical binary = 02 Gray code, convert to Binary = 04 Halls 120 degree spacing Number of bits to use = 05 Halls 60 degree spacing...
  • Page 152 Power Brick Controller User Manual Example: A serial encoder with 17 bits of single-turn position data located in the lower fields of serial data A register. PowerBrick[].Chan[].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Motor[].pAbsPhasePos = PowerBrick[].Chan[].SerialEncDataA.a Motor[].AbsPhasePosFormat = $00001100...
  • Page 153 Power Brick Controller User Manual Example: A serial encoder with 36 bits of single-turn position data located in serial data A and B registers consecutively. We will use the lower 32 bits; that is the maximum allowed number of bits for the power- on absolute commutation.
  • Page 154 Power Brick Controller User Manual Example: A 36-bit serial encoder with 24 bits of single-turn and 12 bits of multi-turn position data starting at bit #0 of serial data A register and continuously extending to bit #3 of serial data register B. PowerBrick[].Chan[].SerialEncDataA 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0...
  • Page 155 Power Brick Controller User Manual Absolute Resolver Phasing With resolvers, the four key elements for setting up absolute phasing are:  Motor[].pAbsPhasePos = PowerBrick[].Chan[].AtanSumOfSqr.a  Motor[].AbsPhasePosFormat = $00001010  Motor[].AbsPhasePosSf Rotary Motor: = 2048 * NoOfPolesPairs / (ResPolePairs * 65536) Where: ...

  • Page 156: True Dac Output (±10 Vdc)

    Power Brick Controller User Manual True DAC Output (±10 VDC) Having performed the following:  Global Reset (optional but recommended).  Set up the dominant clock frequencies.  Unpacked the ADC input and phase output data.  Verified encoder feedback. If the +24 VDC abort input is not wired in or disabled in software (Sys.pAbortAll = 0), PMAC will try to close the loop on the motor every time it is enabled which could cause the motor the move or jump...

  • Page 157: Common Non-Commutated Motor Setup Elements

    Power Brick Controller User Manual Common Non-Commutated Motor Setup Elements The following, are common motor structure elements for setting up motors using the True DAC output type with the Power Brick Controller. Typically, when using DAC output, the amplifier commutates the motor, and PMAC does not need to, so associated settings can be omitted.

  • Page 158: Pwm Output Scale Factor - Motor[X].Pwmsf

    Power Brick Controller User Manual PWM Output Scale Factor – Motor[x].PwmSf The PWM scale factor, Motor[x].PwmSf, in non-commutated motor control should always be set to the maximum value, which is 32,767. // PWM Scale Factor Motor[1].PwmSf = 32767 Motor[2].PwmSf = 32767 Motor[3].PwmSf = 32767...

  • Page 159: I2T Protection - Motor[X].I2Tset, I2Ttrip, Maxdac

    Power Brick Controller User Manual I2T Protection – Motor[x].I2TSet, I2TTrip, MaxDac The Power Brick Controller can be set up to trigger a fault if the time-integrated command output exceeds a certain threshold. This can protect the motor (and drive) from damage due to overheating. It integrates the square of the command over time –...

  • Page 160: Open Loop Test

    Power Brick Controller User Manual Open Loop Test The open loop test is a critical step in verifying the proper implementation of the:  Encoder decode/sense  Encoder functionality The open loop test can be executed using the open-loop test tab in the tuning utility in the IDE software. The test amplitude depends on the load/gearing of the motor.
  • Page 161 Power Brick Controller User Manual A positive command should create a velocity and position counting in the positive direction; a negative command should create a velocity and position counting in the negative direction. This is typically observed in the response plot as a velocity saw tooth. A successful open-loop test response looks like: Open-loop test troubleshooting tips The open loop test can fail in two ways: ...

  • Page 162: Position Loop Tuning

    Power Brick Controller User Manual Position Loop Tuning Position loop tuning is performed using the tuning utility in the IDE Software. Do not attempt to close the position loop or perform position loop tuning on a motor which open-loop test has failed. This may lead to dangerous runaway conditions.
  • Page 163 Power Brick Controller User Manual The Position Loop Interactive Tuning is the fully fletched tuning interface, introducing all the gains used in the servo algorithm, various pre-configured command profiles, and filter tools. The two most common move profiles used in tuning are Step and Parabolic. Interactive Tuning An acceptable step move response would look like: Desirable characteristics to note: minimal overshoot, zero steady-state error, natural frequency >...
  • Page 164 Power Brick Controller User Manual And an acceptable parabolic move response would look like: Desirable characteristics to note: following error (green curve above) centered about 0 with minimal amplitude. With higher resolution encoders, the Motor[x].Servo.MaxPosErr may need to be set to a higher than the default value allowing larger position error in the servo filter.

  • Page 165: Filtered Pwm Output (±10 Vdc)

    Power Brick Controller User Manual Filtered PWM Output (±10 VDC) Having performed the following:  Global Reset (optional but recommended).  Unpacked the ADC input and phase output data.  Verified encoder feedback. If the +24 VDC abort input is not wired in or disabled in software (Sys.pAbortAll = 0), PMAC will try to close the loop on the motor every time it is enabled which could cause the motor the move or jump (if it has not been set up).

  • Page 166: Filtered Pwm Recommended Clock Settings

    Power Brick Controller User Manual Filtered PWM Recommended Clock Settings In this mode, the ±10 VDC analog output is obtained by passing the digital PWM signal through a low pass filter. This technique, although not as performing as a true digital to analog converter, is more than adequate for most servo applications.

  • Page 167: Common Motor Setup Elements

    Power Brick Controller User Manual Common Motor Setup Elements The following, are common motor structure elements for setting up motors using Filtered PWM with the Power Brick Controller. // Activate Motors Motor[1].ServoCtrl = Motor[2].ServoCtrl = Motor[3].ServoCtrl = Motor[4].ServoCtrl = Motor[5].ServoCtrl = Motor[6].ServoCtrl = Motor[7].ServoCtrl = Motor[8].ServoCtrl =...

  • Page 168: I2T Protection - Motor[X].I2Tset, I2Ttrip, Maxdac

    Power Brick Controller User Manual I2T Protection – Motor[x].I2TSet, I2TTrip, MaxDac The Power Brick Controller can be set up to trigger a fault if the time-integrated command output exceeds a certain threshold. This can protect the motor (and drive) from damage due to overheating. It integrates the square of the command over time –...

  • Page 169: Dac Offsets

    Power Brick Controller User Manual DAC Offsets Some DACs output a nonzero amount of current even when zero is commanded. This may cause problems (e.g. a constant position offset) when you try to tune the servo loop. One can correct for this with Motor[].DacBias.

  • Page 170: Open Loop Test

    Power Brick Controller User Manual Open Loop Test The open loop test is a critical step in verifying the proper implementation of the:  Encoder decode/sense  Encoder functionality The open loop test can be executed using the open-loop test tab in the tuning utility in the IDE software. The test amplitude depends on the load/gearing of the motor.
  • Page 171 Power Brick Controller User Manual A positive command should create a velocity and position counting in the positive direction; a negative command should create a velocity and position counting in the negative direction. This is typically observed in the response plot as a velocity saw tooth. A successful open-loop test response looks like: Open-loop test troubleshooting tips The open loop test can fail in two ways: ...

  • Page 172: Position Loop Tuning

    Power Brick Controller User Manual Position Loop Tuning Position loop tuning is performed using the tuning utility in the IDE Software. Do not attempt to close the position loop or perform position loop tuning on a motor which open-loop test has failed. This may lead to dangerous runaway conditions.
  • Page 173 Power Brick Controller User Manual The Position-loop interactive tuning is the fully fletched tuning interface, introducing all the gains used in the servo algorithm, various pre-configured command profiles, and filter tools. The two most common move profiles used in tuning are Step and Parabolic. Interactive Tuning An acceptable step move response would look like: Desirable characteristics to note: minimal overshoot, zero steady-state error, natural frequency >...
  • Page 174 Power Brick Controller User Manual And an acceptable Parabolic move response would look like: Desirable characteristics to note: following error (green curve above) centered about 0 with minimal amplitude. With higher resolution encoders, the Motor[x].Servo.MaxPosErr may need to be set to a higher than the default value allowing larger position error in the servo filter.

  • Page 175: Special Functions & Troubleshooting

    Power Brick Controller User Manual SPECIAL FUNCTIONS & TROUBLESHOOTING Step and Direction, PFM Output The Power Brick Controller has the capability of generating step and direction output signals – a.k.a. PFM (Pulse Frequency Modulation) – for general purpose usage or control of external devices such as stepper amplifiers.
  • Page 176 Power Brick Controller User Manual PFM Output Signal Settings 1. Chose the maximum PFM frequency in MHz from the table below (only). This frequency must be faster than the maximum desired speed if controlling an external stepper amplifier/motor, or faster than the maximum desired frequency of whichever device it is connected to.
  • Page 177 Power Brick Controller User Manual Controlling an External Stepper Amplifier / Motor "Closing the loop" or jogging a motor driven by an external amplifier requires the following settings. Example for Channel #1/ Motor #1: PowerBrick[0].Chan[0].EncCtrl = 8 // Internal Pulse And Direction PowerBrick[0].Chan[0].TimerMode = 3 // Read as PFM when looped back in with EncCtrl = 8 Motor[1].ServoCtrl = 1...

  • Page 178: Sinusoidal Encoder Bias Corrections

    Power Brick Controller User Manual Sinusoidal Encoder Bias Corrections Before computing the sub-count interpolated position with the arctangent calculation, the PMAC3-style ASIC can add in offset terms to the measured values in the ADC registers to compensate for voltage biases in the encoder and/or receiving circuitry.
  • Page 179 Power Brick Controller User Manual The Sine and Cosine offset structure elements are PowerBrick[].Chan[].AdcOffset[0] and PowerBrick[].Chan[].AdcOffset[1], respectively. Compensating for these offsets is done by reading the Sine – PowerBrick[].Chan[].AdcEnc[0] – and Cosine – PowerBrick[].Chan[].AdcEnc[1] – signals while moving the motor (preferably slowly) in open loop –...
  • Page 180 Power Brick Controller User Manual WHILE(1) // ================== ENCODER 1 BIAS CORRECTIONS =================== // (SineCycles == 0) MaxEnc1Sine = Enc1Sine MinEnc1Sine = Enc1Sine MaxEnc1Cosine = Enc1Cosine MinEnc1Cosine = Enc1Cosine (Enc1Sine > MaxEnc1Sine){MaxEnc1Sine = Enc1Sine} (Enc1Sine < MinEnc1Sine){MinEnc1Sine = Enc1Sine} (Enc1Cosine > MaxEnc1Cosine){MaxEnc1Cosine = Enc1Cosine} (Enc1Cosine <...
  • Page 181 Power Brick Controller User Manual // ================== ENCODER 4 BIAS CORRECTIONS =================== // (SineCycles == 0) MaxEnc4Sine = Enc4Sine MinEnc4Sine = Enc4Sine MaxEnc4Cosine = Enc4Cosine MinEnc4Cosine = Enc4Cosine (Enc4Sine > MaxEnc4Sine){MaxEnc4Sine = Enc4Sine} (Enc4Sine < MinEnc4Sine){MinEnc4Sine = Enc4Sine} (Enc4Cosine > MaxEnc4Cosine){MaxEnc4Cosine = Enc4Cosine} (Enc4Cosine <...
  • Page 182 Power Brick Controller User Manual // ================== ENCODER 7 BIAS CORRECTIONS =================== // (SineCycles == 0) MaxEnc7Sine = Enc7Sine MinEnc7Sine = Enc7Sine MaxEnc7Cosine = Enc7Cosine MinEnc7Cosine = Enc7Cosine (Enc7Sine > MaxEnc7Sine){MaxEnc7Sine = Enc7Sine} (Enc7Sine < MinEnc7Sine){MinEnc7Sine = Enc7Sine} (Enc7Cosine > MaxEnc7Cosine){MaxEnc7Cosine = Enc7Cosine} (Enc7Cosine <...
  • Page 183 Power Brick Controller User Manual   Write the computed offsets into the corresponding channel’s elements (upper 16 bits): PowerBrick[0].Chan[0].AdcOffset[0] = Enc1SineOffset * 65536 // Channel 1 Sine Offset PowerBrick[0].Chan[0].AdcOffset[1] = Enc1CosineOffset * 65536 // Channel 1 Cosine Offset PowerBrick[0].Chan[1].AdcOffset[0] = Enc2SineOffset * 65536 // Channel 2 Sine Offset PowerBrick[0].Chan[1].AdcOffset[1] = Enc2CosineOffset * 65536 // Channel 2 Cosine Offset...

  • Page 184: Reversing Motor Jogging Direction

    Power Brick Controller User Manual Reversing Motor Jogging Direction Choosing the direction sense is possible during the normal setup of a motor. Oftentimes, users wish to reverse the direction sense after the motor has been set up. Following, are the necessary steps with respect to each type of encoder.
  • Page 185 Power Brick Controller User Manual For non-commutated motors, with ±10V output, it is best to simply swap the DAC+ and DAC- leads going into the amplifier. Then changing the encoder decode control accordingly. Note Special Functions & Troubleshooting...

  • Page 186: Plc Timer Delay

    Power Brick Controller User Manual PLC Timer Delay The following subprogram is a generic routine which is commonly called from PLC programs to insert a time delay in the logic process. OPEN SUBPROG Timer (time) LOCAL EndTime; EndTime = Sys.Time + time WHILE (EndTime >...

  • Page 187: Encoder Count Error

    Power Brick Controller User Manual Encoder Count Error The Power Brick Controller is fitted with an encoder count error detection circuitry which supports Quadrature, Sinusoidal, Resolver, and HiperFace encoders. The encoder count circuitry reports bad transitions of the quadrature signals. If both the A and B channels of the quadrature data change state at the decode circuitry (post-filter) in the same hardware sampling clock cycle, unrecoverable...

  • Page 188: Encoder Loss Detection

    Power Brick Controller User Manual Encoder Loss Detection Loss of the feedback sensor signal is potentially a very dangerous condition in closed-loop control, because the servo loop no longer has any idea what the true physical position of the motor is – usually it thinks it is “stuck”...

  • Page 189: Digital Quadrature

    Power Brick Controller User Manual Digital Quadrature With digital quadrature encoders (must be differential) the encoder loss circuitry monitors each quadrature input pair with an exclusive-or XOR gate: In normal operation mode, the two quadrature inputs should be in opposite logical states – that is one high and one low –...

  • Page 190: Sinusoidal | Resolver | Hiperface Encoders

    Power Brick Controller User Manual Sinusoidal | Resolver | HiperFace Encoders Analog sinusoidal encoders and resolvers provide simultaneous sine and cosine signals into the analog-to- digital converters of the Power Brick Controller interface circuitry. In proper operation, the sum of the squares of the converted values for these two signals should be roughly constant, and significantly different from zero.

  • Page 191: Serial Encoders

    Power Brick Controller User Manual Serial Encoders The Power Brick Controller provides interfaces for many of the most popular serial encoder protocols. For most of these interfaces, the receiving logic can detect that no data has been received in response to the cycle’s “position request”...

  • Page 192: Digital Tracking Filter

    Power Brick Controller User Manual Digital Tracking Filter The encoder conversion table’s (ECT) software tracking filter is a digital low-pass filter with an integrator which is useful for reducing measurement noise (floor level and occasionally electrical) without introducing steady-state error at constant velocity or position. It is particularly useful for applications involving: ...
  • Page 193 Power Brick Controller User Manual This PLC example is very simple to use:  Specify the desired cutoff frequency (~30 – 2000 Hz)  Specify the desired damping ratio (typically 1.0) For example, for a 1,000 Hz cutoff frequency, and 1 damping ratio will produce: These index values copied into EncTable[].index1, EncTable[].index2, and EncTable[].index4 respectively will apply the desired filtering.

  • Page 194: Ptc Motor Thermal Input

    Power Brick Controller User Manual PTC Motor Thermal Input The PTC motor thermal Input (pin #8 of X1-X8 connectors) is typically used to bring in motor over- temperature thermistor signal(s) into the Power Brick Controller. Proper action can then be taken to safely stop operation if the motor is overheated.

  • Page 195: Led Status

    Power Brick Controller User Manual LED Status Symbol Description Status Indication Green Normal Mode Operation Watchdog Fault – Watchdog Green MACRO connected / Operational MACRO Link MACRO MACRO not connected / Ring broken Green PMAC Ready, Boot Complete RDY/WD Ready/Watchdog Fault –...

  • Page 196: Reloading Power Pmac Firmware

    Power PMAC Firmware can be reloaded by means of the IDE or a USB flash drive/SD card. Reloading Firmware Method 1: IDE To install the latest firmware through the IDE, click on Delta TauConfigureDownload Firmware: Under the “PowerPMAC Firmware” tab, click the “Download Firmware” button. On clicking the button, the IDE will ask whether it is acceptable to issue $$$*** (Global Reset) before updating the firmware.
  • Page 197 Power Brick Controller User Manual The firmware filename should be "powerpmac.deb": Wait for the IDE to finish downloading the firmware file and then for Power PMAC to reboot. If it does not reconnect successfully after rebooting, click “Communication Setup” (see the red box in the image below): Then, click “Apply”...
  • Page 198 Power Brick Controller User Manual If you still cannot communicate, cycle power on the UMAC rack and use the “Communication Setup” button in the IDE again until you can connect. Reloading Firmware Method 2: USB Drive/SD Card  Connect a USB memory stick/SD Card to a PC using any OS which can work with FAT32 partition....

  • Page 199: Changing Network (Ip Address) Settings

    Power Brick Controller User Manual Changing Network (IP Address) Settings Through the Power PMAC IDE If you want to change Power PMAC’s IP Address from within the IDE, click ToolsOptions… Near the bottom of the screen in the left pane, click PowerPMACNetwork Settings and then the following window should appear: This area reports messages and changes from the Options...
  • Page 200 Power Brick Controller User Manual Through USB Below is the procedure for using a USB flash drive to detect/change the Power PMAC IP address: 1. Connect the USB memory stick/SD Card to your PC using any OS which can work with FAT32 partition.

  • Page 201: Restoring Factory Default Configuration

    Power Brick Controller User Manual Restoring Factory Default Configuration Restoring Power Brick’s settings to factory default can be done in two ways. Method 1 (to be used when communicating): Enter $$$*** into the IDE Terminal Window. Issue a SAVE, followed by a $$$ to maintain the factory default settings.

  • Page 202: Watchdog Faults

    Power Brick Controller User Manual Watchdog Faults Two types of Watchdog Faults can occur. The first is a “Soft Watchdog” which occurs when the CPU is starved of processing time and cannot reset the background (when Sys.WDTFault = 2) or the foreground (when Sys.WDTFault = 1) Watchdog timer.

  • Page 203: Appendix A: Digital Inputs Schematic

    Power Brick Controller User Manual APPENDIX A: DIGITAL INPUTS SCHEMATIC Appendix A: Digital Inputs Schematic...

  • Page 204: Appendix B: Digital Outputs Schematic

    Power Brick Controller User Manual APPENDIX B: DIGITAL OUTPUTS SCHEMATIC Appendix B: Digital Outputs Schematic...

  • Page 205: Appendix C: Analog I/Os Schematics

    Power Brick Controller User Manual APPENDIX C: ANALOG I/OS SCHEMATICS Appendix C: Analog I/Os Schematics...
  • Page 206 Power Brick Controller User Manual Appendix C: Analog I/Os Schematics...

  • Page 207: Appendix D: Limits & Flags Schematic

    Power Brick Controller User Manual APPENDIX D: LIMITS & FLAGS SCHEMATIC Appendix D: Limits & Flags Schematic...

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