Delta Tau 3Ax-602646-xUxx Hardware Reference Manual
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Delta Tau 3Ax-602646-xUxx Hardware Reference Manual

Delta Tau 3Ax-602646-xUxx Hardware Reference Manual

Delta tau data systems, inc. quad amplifier hardware reference manual
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HARDWARE REFERENCE MANUAL
^1
Quad Amp
^2
Single Source Machine Control
21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com
^3
4-Axis Digital Amplifier
^4
3Ax-602646-xUxx
^5
September 24, 2003
Power // Flexibility // Ease of Use

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  • Page 1 HARDWARE REFERENCE MANUAL Quad Amp Single Source Machine Control 21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com 4-Axis Digital Amplifier 3Ax-602646-xUxx September 24, 2003 Power // Flexibility // Ease of Use...

  • Page 2: Operating Conditions

    Copyright Information © 2003 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...

  • Page 3: Table Of Contents

    Quad Amp Hardware Reference Manual INTRODUCTION ...1 Related Technical Documentation ...1 Safety Summary ...1 Keep Away from Live Circuits ...1 Live Circuit Contact Procedures ...1 Quad Amp Basic Specifications...2 Physical Specifications ...2 Electrical Specifications ...2 Bus Supply, Control Supply and Shunt Specifications ...2 Protection ...6 Transient Voltage Filter...6 Transient Surge Suppressors ...6...
  • Page 4 Jumpers, Potentiometers, Test Points, and LEDs ...21 Grounding ...25 General ...25 Main Power Supply (DC Bus) ...25 Motor ...25 PMAC2 I-Variables Setup...25 Ix00 ...25 Ix01 ...25 Ix02 ...25 Ix25 ...25 Ix82 ...25 I900...25 I9n6...26 Start-Up Procedures ...26 Power On Sequence...26 P2Setup...26 TROUBLESHOOTING...29 Logic Fault Detection and Fault Codes ...29...

  • Page 5: Introduction

    The Quad Amp is designed to work in conjunction with the Delta Tau PMAC2 motion controller, which supports up to eight axes of motion control. The PMAC2 delivers Pulse Width Modulated (PWM) on/off signals to the Quad Amp power transistors.

  • Page 6: Quad Amp Basic Specifications

    Quad Amp Basic Specifications Physical Specifications Size (See Figure 1) • Height: 22.0 Inches • Width: 10.5 Inches • Length: 5.125 Inches (without mounting option) 9.031 Inches (with mounting option) Weight • 60 lb. (27.3 kg) Temperature Storage: -20 degrees C to +85 degrees C Operating: 0 degrees C to +60 degrees C (Unit is disabled if heat sink temperature exceeds 80 degrees C) Relative Humidity 10% to 95%, non-condensing...
  • Page 7 Quad Amp Hardware Reference Manual Main DC bus Voltage Internal Shunt Resistor Resistance Resistor power External Shunt Resistor (Optional) Resistance Resistor power Soft Start charge time Minimum output inductance 380/460/480V Quad Amplifier Specifications Main AC Input Voltage/Current (L1, L2, L3) Input voltage Input current/phase, continuous.
  • Page 8 Output Specifications for 120/208/230 VAC Amplifier Up to four blocks (options) can be selected in any power combination. The total power cannot exceed 33 When 30HP is selected only two additional axes may be used (three total instead of four). Quad Amp Hardware Reference Manual Figure 1 Quad Amp Specifications Note:...
  • Page 9 Quad Amp Hardware Reference Manual Opt 5 Opt 6 0.75 HP 1.5 HP Continuous 0.56 kW 1.1 kW HP(100%) Continuous current (RMS) 1.5 HP 3 HP Continuous 2 1.1 kW 2.2 kW HP(200%) 2.25 HP 4.5 HP Peak 2 sec 1.7 kW 3.4 kW HP(300%)

  • Page 10: Protection

    Quad Amp Hardware Reference Manual Protection There are several layers of protection built into the amplifier, including transient voltage filters, transient surge suppressors, fuses, a flyback diode, and a variety of fault detection circuits. These are discussed in the following paragraphs and in the Troubleshooting Chapter. Transient Voltage Filter The transient voltage RC filter is used as a means of suppressing inductive transients and is located across the single phase Control AC input voltage connector C3.

  • Page 11: Configurable Options

    Quad Amplifier. It indicates the rating of each axis, the AC operating voltage, and the control input voltage. Since every Quad Amplifier is a custom unit, Delta Tau would like to emphasize that each user should inspect the equipment and see that the correct unit has been supplied.
  • Page 12 Accessories Item 3A1-602582-100 Circuit Breaker 3A2-602582-100 Circuit Breaker 200-602739-024 PWM Input Cables 3A0-602757-100 External Shunt Resistor 3AO-602775-10X ACC8F When 30 HP is selected, only two additional axes may be used (three total, not four). When a total of 7.5 HP or greater is selected, use Acc-4 (external shunt resistors). 600V/1200V indicates VDC rating of the igbt and has no connection to the main AC input (operating) voltage.

  • Page 13: Getting Started

    Amplifier. Equipment Required The Quad Amplifier is installed in conjunction with other Delta Tau Data System components to form a Quad Amplifier System. The following table identifies the equipment which, when installed and connected together, constitute a typical Quad Amplifier System. Figure 2 shows the interconnection of the Quad Amplifier System components.

  • Page 14: Heat Dissipation

    Heat Dissipation The external mounting options (Opt3, Opt3A and Opt3B) allow the Quad Amplifier to be installed inside a cabinet, with the Quad Amplifier heat sink mounted external to the cabinet or in an air plenum. In the case of Opt 3B, provide good air circulation, in a plenum, with a minimum airflow across the heat sink of 70 CFM.

  • Page 15: Theory Of Operation

    Quad Amp Hardware Reference Manual THEORY OF OPERATION Operation The Quad Amplifier is a universal 4-axis 3-phase direct PWM drive which utilizes the latest in smart power technology from the world’s leading vendors and the cutting edge algorithms of the new PMAC2 controller family.

  • Page 16: Current Sense Board

    Quad Amp Hardware Reference Manual Current Sense Board The Current Sense Board has eight Hall Effect (LEM) modules for current sense and eight on-board A/D converters that transform four channels of motor current to digital form. Each channel provides information on two phases (A phase and B phase). The third phase is mathematically created in the PMAC2.

  • Page 17: Heat Dissipation

    The faster the motors are decelerated the greater the current. A spindle motor using 60 amps continuously will require a shunt that can dump at least that much current. Refer to the Delta Tau Soft Start and Shunt Resistor circuit board section of this manual for more information. Theory of Operation...
  • Page 18 Quad Amp Hardware Reference Manual Theory of Operation...

  • Page 19: Installation

    Quad Amp Hardware Reference Manual INSTALLATION Wiring the Quad Amplifier System Quad Amplifier Channel Connections The Quad Amplifier channels must be connected in a particular order for proper operation. It is essential that the timing of all signals associated with the Quad Amplifier logic board shares the ADC converter clocks for Quad v channels 1-2 and channels 3-4.

  • Page 20: Non-Standard Quad Amplifier Setup

    PMAC2, as well as to the encoders. The cables required to connect the Acc-8F to the PMAC2 PC are provided with each Acc-8F. Refer to the PMAC2 Acc-8F User Manual. PWM Input Cables 36-inch PWM input cables (Acc-8F, Opt 5) are available from Delta Tau Data Systems, Inc. One cable is required for each PWM axis. Connectors All Quad Amplifier connectors are identified in Figures 5 and 6 .

  • Page 21: Bottom View

    Quad Amp Hardware Reference Manual BUS+ E-STOP/READY EXTERNAL GROUND FAULT TRIP CONTROL AC VOLTAGE MOTOR OVERTEMP CONNECTOR Figure 5 and 6 Quad Amplifier Connector Locations Installation CHASSIS GROUND BUS- SHUNT OPTIONAL EXTERNAL SHUNT TOP VIEW MOTOR CABLES MOTOR AXIS 2 AXIS 4 GROUNDS AXIS 1...
  • Page 22 Pin# Symbol Function Fc_A1 Input Fc_C1 Input Clk0+ Input Convert0+ Input Atddaa1+ Output Atddab1+ Output Aena1+ Input Fault1+ Output Pwmatop1+ Input Pwmabot1+ Input Pwmbtop1+ Input Pwmbbot1+ Input Pwmctop1+ Input Pwmcbot1+ Input Common Pmac_+5 Input Fc_B1 Input Fc_D1 Input Clk0- Input Convert0- Input Atddaa1-...

  • Page 23: Main Ac Input Power

    Quad Amp Hardware Reference Manual Figure 7 Quad Amp Main Circuit Wiring Diagram Main AC Input Power Connect desired main input power to input terminals marked L1, L2, and L3 (see Figure 7). The power ground can be connected at the terminal marked CHAS GND or at the grounding screw, marked E, located on the end panel of the Quad Amplifier chassis.
  • Page 24 For 460 VAC Operation Jump pin 4 to pin 5. Power is applied to pins 1 and 8 via AC input connector C3. For 480 VAC Operation Jump pin 4 to pin 5 and pin 8 to pin 9. Power is applied to pins 1 and 10 via AC input connector C3. Figure 8 120V/208V/230V Quad Amplifier Transformer T201 Schematic Diagram Figure 9 380V/460V/480V Quad Amplifier Transformer T201 Schematic Diagram Quad Amp Hardware Reference Manual...

  • Page 25: Bus Power Enable/Emergency Stop

    (See Figure 10). The shunt resistors should be a resistive (non-inductive) load of appropriate power and voltage rating for the bus and the regenerative load. External shunt resistors are available from Delta Tau as Quad Amplifier Acc-4. These resistors (two 4.25 ohm, 1400W resistors for 230 VAC operation and three 4.25 ohm, 1400W resistors for 380/460 VAC operation), when connected in series (8.5 ohms total), will...
  • Page 26 Figure 10 Logic I/O Board Jumper and LED Locations Name Position E1-E4 Symbol + 15 V + 5 V - 15 V AXIS 1 FLT AXIS 2 FLT AXIS 3 FLT AXIS 4 FLT AXIS 1 EN AXIS 2 EN AXIS 3 EN AXIS 4 EN PWR GOOD...
  • Page 27 Quad Amp Hardware Reference Manual Figure 11 Current Sense Board Jumper and LED Locations Name Position E1A-E4A E1B-E4B Symbol + 5 V + 15 V - 15 V Installation Description Enable Serial Fault Data, Phase A Enable Serial Fault Data, Phase B Clock Polarity Convert Polarity Description...
  • Page 28 Figure 62 Soft Start Board Jumper, Potentiometer, Test Point, and LED Locations Name Position 1-2 jumper 2-3 open Jumper Jumper Symbol` Description R4 & TP5 High line fault set point R2 & TP4 Over voltage fault set point Shunt IGBT turn-on set point Main IGBT turn-on set point Note: Main and shunt set points are line sensitive and will vary with line voltage.

  • Page 29: Grounding

    I-variables and other necessary parameters. The preferred method for tuning the amplifier is to use the P2 Setup software package available from Delta Tau. There are several PMAC2 I-variables we emphasize for proper operation of the Quad Amplifier.

  • Page 30: I9N6

    The Quad Amplifier has a built-in protection against accidentally setting I900 (PWM frequency) too high, and exceeding the PWM input frequency rating of the power blocks. I9n6 For machine interface channel n, I9n6 must be set to 0 to select PWM output format. If i9n6 is set to 1 or 3 while a ‘n’...
  • Page 31 Quad Amp Hardware Reference Manual During this tuning process, P2Setup also determines the commutation parameters and commands the PMAC appropriately. Power Block Option Continuous Hp Enter Max ADC value in P2-Setup, step Current Protection. Enter Peak Current and Continuous Current values, if applicable.
  • Page 32 Quad Amp Hardware Reference Manual Installation...

  • Page 33: Troubleshooting

    Quad Amp Hardware Reference Manual TROUBLESHOOTING Logic Fault Detection and Fault Codes The Quad Amplifier is capable of detecting and reporting a variety of fault conditions. These conditions are broken into two types: axis-specific and global. Axis-Specific Faults This type of fault is related to one axis only and typically is not something that would prevent the amplifier as a whole from continuing to operate.

  • Page 34: Led Fault Indicator

    Jumpers E1A, E1B, E2A, E2B, E3A, E3B, E4A, E4B must be installed on the current sense board so that the 4-bit fault code can be accessed at PMAC2 Gate Array Registers. Once such a condition occurs, the PLC notifies the user with an on-screen message and then disables itself.
  • Page 35 Quad Amp Hardware Reference Manual In the case of multiple axis-specific faults on one axis, the higher-numbered fault shall be indicated. In the case of axis-specific faults on multiple axes, the axis with the higher-numbered fault shall be displayed along with the decimal point indicting its axis number. In the case of axis-specific faults of the same number on multiple axes, the fault number shall be displayed and decimal point indication shall specify the higher-numbered axis.
  • Page 36 Quad Amp Hardware Reference Manual Call Delta Tau for an RMA. If not, examine if the 10-pin flat cable between the Soft Start and the I/O Logic board is connected on both sides and in good shape.

  • Page 37: Illustrated Repair Parts List

    The GAPL includes figure/index number; part number; description; true manufacturer and true manufacturer part number, if applicable, for each CRU of the Quad Amplifier. Replacement parts may be ordered from Delta Tau Data Systems, Inc. or by contacting the manufacturer or vendor listed. How to Use the Repair Parts List To effectively use the RPL, proceed as follows: 1.
  • Page 38 Quad Amp Hardware Reference Manual Figure 12 Delta Tau Data Systems 4 Axis Digital Amplifier Illustrated Repair Parts List...
  • Page 39 3.5” Dia. Cooling Fan 300W (for upgraded and high voltage power supplies) Clamping Diode 2 Pos. Plug (P1) Manu- Part Number facturer Assy Delta Tau Delta Tau Delta Tau Delta Tau Delta Tau Delta Tau Delta Tau Nichicon LNQ2G182MS Bussman...
  • Page 40 Bus Filter PCBA (OPT2) (For 600VDC Bus) Mounting Foot (Right) Mounting Foot (Left) Quad Amp Hardware Reference Manual Manu- Part Number facturer Assy 1-480700-0 1-480702-0 Delta Tau Delta Tau Delta Tau Marathon 1104S Marathon 985-GP-07 Marathon 1112S Elmwood 3450-88-142- L180...

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