Delta Tau Geo Direct PWM Amplifier Owner's manual

Type
Owner's manual
Single Source Machine Control Power // Flexibility // Ease of Use
21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com
^1 INSTALLATION MANUAL
^2 Geo Direct PWM Amplifier
^3 Direct PWM Amplifier
^4 500-603700-xIxx
^5 October 17, 2018
DELTA TAU
Data Systems, Inc.
NEW IDEAS IN MOTION …
Copyright Information
© 2018 Delta Tau Data Systems, Inc. All rights reserved.
This document is furnished for the customers of Delta Tau Data Systems, Inc. Other uses
are unauthorized without written permission of Delta Tau Data Systems, Inc.
Information contained in this manual may be updated from time-to-time due to product
improvements, etc., and may not conform in every respect to former issues.
To report errors or inconsistencies, call or email:
Delta Tau Data Systems, Inc. Technical Support
Phone: (818) 717-5656
Fax: (818) 998-7807
Email: support@deltatau.com
Website: http://www.deltatau.com
Operating Conditions
All Delta Tau Data Systems, Inc. motion controller products, accessories, and amplifiers
contain static sensitive components that can be damaged by incorrect handling. When
installing or handling Delta Tau Data Systems, Inc. products, avoid contact with highly
insulated materials. Only qualified personnel should be allowed to handle this
equipment.
In the case of industrial applications, we expect our products to be protected from
hazardous or conductive materials and/or environments that could cause harm to the
controller by damaging components or causing electrical shorts. When our products are
used in an industrial environment, install them into an industrial electrical cabinet or
industrial PC to protect them from excessive or corrosive moisture, abnormal ambient
temperatures, and conductive materials. If Delta Tau Data Systems, Inc. products are
directly exposed to hazardous or conductive materials and/or environments, we cannot
guarantee their operation.
WARNING
A Warning identifies hazards that could result in personal injury
or death. It precedes the discussion of interest.
A Caution identifies hazards that could result in equipment damage. It
precedes the discussion of interest.
A Note identifies information critical to the understanding or use of
the equipment. It follows the discussion of interest.
EN
Dispose in accordance with applicable regulations.
REVISION HISTORY
REV.
DESCRIPTION
DATE
CHANGE
APPROVAL
1
Added Power On/Off procedures,
Power PMAC section,
Refurbished entire manual
11/15/2013
RN
RN
2
Added KC Conformity
10/17/18
SM
RN
Geo Direct PWM Amplifier
Table Of Contents 4
Table of Contents
INTRODUCTION......................................................................................................................... 6
SPECIFICATIONS....................................................................................................................... 7
PART NUMBER ................................................................................................................................. 7
ENVIRONMENTAL SPECIFICATIONS .................................................................................................. 7
ELECTRICAL SPECIFICATIONS .......................................................................................................... 8
230 VAC Drives Single Axis .................................................................................................... 8
230 VAC Drives Dual Axis .................................................................................................... 10
480 VAC Drives Single Axis .................................................................................................. 11
480 VAC Drives Dual Axis .................................................................................................... 13
AGENCY APPROVAL AND SAFETY .................................................................................................. 14
RECEIVING AND UNPACKING ............................................................................................ 15
USE OF EQUIPMENT ....................................................................................................................... 15
MOUNTING, PHYSICAL LAYOUT ....................................................................................... 16
GPX012 ......................................................................................................................................... 17
Low Profile, Single Width, No Fan .......................................................................................... 17
GPL032 ......................................................................................................................................... 18
Single Width, No Fan ............................................................................................................... 18
GPX05X, GPX102, GPL101, GPH032 .......................................................................................... 19
Single Width with Fan .............................................................................................................. 19
GPX201, GPX301, GPX152, GPH102 ........................................................................................... 20
Double Width, Two Fans ......................................................................................................... 20
CONNECTOR PINOUTS AND WIRING ............................................................................... 21
J1: MAIN BUS POWER INPUT .......................................................................................................... 21
Recommended Main Bus Power Wiring/Protection ................................................................ 22
Recommended Bus Power Fuse and Wire Gauge .................................................................... 25
J4: 24 VDC LOGIC CONTROL ......................................................................................................... 26
J2 J3: MOTOR WIRING ................................................................................................................ 27
Motor Cable, Noise Elimination .............................................................................................. 28
Motor Selection ........................................................................................................................ 29
J5: EXTERNAL SHUNT RESISTOR .................................................................................................... 31
Recommended Shunt Resistors ................................................................................................. 32
Shunt Resistor Layout .............................................................................................................. 33
X1 X2: PWM CONNECTORS ....................................................................................................... 34
X3: DISCRETE I/O FOR MOTOR THERMALS .................................................................................... 35
X4: SAFETY RELAY ....................................................................................................................... 36
POWER ON/OFF PROCEDURES ........................................................................................... 37
Geo Direct PWM Amplifier
Table Of Contents 5
Cycling Main Bus Power ......................................................................................................... 37
PWM FREQUENCY .................................................................................................................. 39
POWER PMAC3 DRIVE SETUP ............................................................................................. 40
KEY GATE PARAMETERS ............................................................................................................... 40
KEY CHANNEL PARAMETERS ......................................................................................................... 41
POWER PMAC2 DRIVE SETUP ............................................................................................. 43
KEY GATE PARAMETERS ............................................................................................................... 43
KEY CHANNEL PARAMETERS ......................................................................................................... 44
TURBO PMAC2 DRIVE SETUP.............................................................................................. 46
KEY GATE PARAMETERS ............................................................................................................... 46
KEY CHANNEL PARAMETERS ......................................................................................................... 47
DRIVE COMMAND STRUCTURE ......................................................................................... 49
DEFAULT MODE ............................................................................................................................. 49
ENHANCED MODE .......................................................................................................................... 50
TROUBLESHOOTING ............................................................................................................. 52
LED STATUS.................................................................................................................................. 52
7-SEGMENT DISPLAY ..................................................................................................................... 52
Error Codes .............................................................................................................................. 53
APPENDIX A: CABLE/CONNECTOR KITS ........................................................................ 55
PWM CABLES ............................................................................................................................... 55
CONNECTOR KITS .......................................................................................................................... 55
CABLE KITS ................................................................................................................................... 56
Geo Direct PWM Amplifier
Introduction 6
INTRODUCTION
The Geo Direct PWM amplifiers provide a 1- or 2-axis motor power using highly integrated IGBT based
power circuitry. They support a wide variety of motors and power ranges. The Geo Direct PWM
amplifiers interface directly with Delta Tau’s PMAC2 or PMAC3 style digital ASICs, typically found in
the axis expansion cards inside a Turbo or Power UMAC rack.
The Geo Direct PWM Drive takes the actual power-transistor on/off signals from PMAC, while providing
digital phase-current feedback and status for closed-loop operation. The interface to the direct PWM
amplifier is through a standard 36-pin Mini-D style cable.
The Geo Direct PWM amplifiers are capable of driving brush, brushless, or induction motors. They
operate in the 100 VAC 480 VAC (156 678 DC) range at 50/60Hz, while providing full protection:
Over voltage
Under voltage
Over temperature
PWM frequency limit
Motor over temperature input
Short circuit (phase phase)
Over current
Safety relay circuit
Geo Direct PWM Amplifier
Specifications 7
SPECIFICATIONS
Part Number
Main AC Voltage Input:
L = 115 - 230 VAC
H = 300 - 480 VAC Number of Axes:
1 = Single Axis
2 = Dual Axis
P
Continuous/Peak Current Rating (Sinusoidal Amp rms)
G 0 0 0
0 = No Safety Relay
1 = Safety Relay
01 = 1.5 / 4.5
03 = 3 / 9
05 = 5 / 10
10 = 10 / 20
15 = 15 / 30
20 = 20 / 40
30 = 30 / 60
Environmental Specifications
Description
Specifications
Operating Temperature
0 to 45°C
Above 45°C,de-rate current output by 2.5% per °C
Storage Temperature
-25°C to +70°C
Humidity
10% to 90% non-condensing
Operating Altitude
~3300 Feet (1000 m)
De-rate current output by 1.1% per additional 330 feet (100m)
Air Flow Clearances
~3 inches (76.2mm) above and below unit for air flow
Operating Environment
Pollution Degree 2 or equivalent
Geo Direct PWM Amplifier
Specifications 8
Electrical Specifications
230 VAC Drives Single Axis
GxL051
GxL101
GxL151
GxL201
GxL301
Main Input Power
Main AC Input
[VAC
rms]
110-20% 240+10% (~87 264)
Rated Input Current @ 240VAC 3ɸ
[A rms]
3.3
6.6
9.9
13.2
19.8
Frequency
[Hz]
50/60 Hz
Rated Input Power
[Watts]
1315
2629
3944
5259
7888
Main Bus Capacitance
[µf]
3380
5020
6800
AC Input Phase Requirement
1Φ or 3Φ
Output
Continuous Current Output per
Axis
[A rms]
5
10
15
20
30
Peak Current Output per Axis @ 2
sec
[A rms]
10
20
30
40
60
Power Output per Axis
[Watts]
1195
2390
3585
4780
7171
Bus Protection
Nominal DC Bus
[VDC]
325
Over-Voltage Trip Level
[VDC]
410
Under-Voltage Lockout Level
[VDC]
137
Shunt Resistor
Shunt Turn-On Voltage
[VDC]
392
Shunt Turn-Off Voltage
[VDC]
372
Shunt Resistor (300 W max)
GAR78
GAR48
GAR48-3
Logic Power
Input Voltage
[VDC]
20 27
Input Current
[A rms]
2
Inrush Current
[A]
4
Current Feedback
Full Scale Reading
[A]
16.26
32.53
48.79
65.05
97.58
Resolution
[bits]
12
Transistor Control
Recommended PWM Frequency
[KHz]
12
10
8
Minimum Dead time
[µs]
1
Charge Pump Time (% of PWM
Period)
5
Geo Direct PWM Amplifier
Specifications 9
All values are at ambient temperature of 0 45°C (113 F) unless
otherwise stated.
Geo Direct PWM Amplifier
Specifications 10
230 VAC Drives Dual Axis
GxL012
GxL032
GxL052
GxL102
GxL152
Main Input Power
Main AC Input
[VAC
rms]
110-20% 240+10% (~87 264)
Rated Input Current @ 240VAC 3ɸ
[A rms]
1.98
3.96
6.6
13.2
19.8
Frequency
[Hz]
50/60 Hz
Rated Input Power
[Watts]
789
1578
2629
5259
7888
Main Bus Capacitance
[µf]
3380
5020
AC Input Phase Requirement
1Φ or 3Φ
Output
Continuous Current Output per
Axis
[A rms]
1.5
3
5
10
15
Peak Current Output per Axis @ 2
sec
[A rms]
4.5
9
10
20
30
Power Output per Axis
[Watts]
359
717
1195
2390
3585
Bus Protection
Nominal DC Bus
[VDC]
325
Over-Voltage Trip Level
[VDC]
410
Under-Voltage Lockout Level
[VDC]
137
Shunt Resistor
Shunt Turn-On Voltage
[VDC]
392
Shunt Turn-Off Voltage
[VDC]
372
Shunt Resistor (300 W max)
GAR78
GAR48
Logic Power
Input Voltage
[VDC]
20 27
Input Current
[A rms]
2
Inrush Current
[A]
4
Current Feedback
Full Scale Reading
[A]
7.32
14.64
16.26
32.53
48.79
Resolution
[bits]
12
Transistor Control
Recommended PWM Frequency
[KHz]
16
12
10
Minimum Dead time
[µs]
1
Charge Pump Time (% of PWM
Period)
5
All values are at ambient temperature of 045°C (113 F) unless
otherwise stated.
Geo Direct PWM Amplifier
Specifications 11
480 VAC Drives Single Axis
GxH051
GxH101
GxH151
GxH201
GxH301
Main Input Power
Main AC Input
[VAC
rms]
375-20% 480+10% (~300 525)
Rated Input Current
[A rms]
3.3
6.6
9.9
13.2
19.8
Frequency
[Hz]
50/60 Hz
Rated Input Power
[Watts]
2744
5487
8231
10974
16461
Main Bus Capacitance
[µf]
845
1255
1700
AC Input Phase Requirement
1Φ or 3Φ
Output
Continuous Current Output per
Axis
[A rms]
5
10
15
20
30
Peak Current Output per Axis @ 2
sec
[A rms]
10
20
30
40
60
Power Output per Axis
[Watts]
2494
4988
7482
9977
14965
Bus Protection
Nominal DC Bus
[VDC]
678
Over-Voltage Trip Level
[VDC]
828
Under-Voltage Lockout Level
[VDC]
137
Shunt Resistor
Shunt Turn-On Voltage
[VDC]
784
Shunt Turn-Off Voltage
[VDC]
744
Shunt Resistor (300 W max)
GAR78
GAR48
GAR48-3
Logic Power
Input Voltage
[VDC]
20 27
Input Current
[A rms]
2
Inrush Current
[A]
4
Current Feedback
Full Scale Reading
[A]
16.26
32.53
48.79
65.05
97.58
Resolution
[bits]
12
Transistor Control
Recommended PWM Frequency
[KHz]
12
10
8
Minimum Dead time
[µs]
1.6
Charge Pump Time (% of PWM
Period)
5
Geo Direct PWM Amplifier
Specifications 12
All values are at ambient temperature of 045°C (113 F) unless
otherwise stated.
Geo Direct PWM Amplifier
Specifications 13
480 VAC Drives Dual Axis
GxH012
GxH032
GxH052
GxH102
GxH152
Main Input Power
Main AC Input
[VAC
rms]
375-20% 480+10% (~300 525)
Rated Input Current @ 240VAC
3ɸ
[A rms]
1.98
3.96
6.6
13.2
19.8
Frequency
[Hz]
50/60 Hz
Rated Input Power
[Watts]
1646
3292
5487
10974
16461
Main Bus Capacitance
[µf]
845
1255
AC Input Phase Requirement
1Φ or 3Φ
Output
Continuous Current Output per
Axis
[A rms]
1.5
3
5
10
15
Peak Current Output per Axis @ 2
sec
[A rms]
4.5
9
10
20
30
Power Output per Axis
[Watts]
748
1496
2494
4988
7482
Bus Protection
Nominal DC Bus
[VDC]
678
Over-Voltage Trip Level
[VDC]
828
Under-Voltage Lockout Level
[VDC]
137
Shunt Resistor
Shunt Turn-On Voltage
[VDC]
784
Shunt Turn-Off Voltage
[VDC]
744
Shunt Resistor (300 W max)
GAR78
GAR48
Logic Power
Input Voltage
[VDC]
20 27
Input Current
[A rms]
2
Inrush Current
[A]
4
Current Feedback
Full Scale Reading
[A]
7.32
14.64
16.26
32.53
48.79
Resolution
[bits]
12
Transistor Control
Recommended PWM Frequency
[KHz]
12
10
8
Minimum Dead time
[µs]
1.6
Charge Pump Time (% of PWM
Period)
5
Geo Direct PWM Amplifier
Specifications 14
All values are at ambient temperature of 045°C (113 F) unless
otherwise stated.
Agency Approval and Safety
Item
Description
Flammability Class
UL 94V-0
KC
EMI: KN 11
EMS: KN 61000-6-2
기기는 업무용 환경에서 사용할 목적으로 합성평가를 받은 기로서 가정
환경에서 사용하는 경우 전파간섭의 려가 있습니.
한국 EMC용제품 준수사항
제품 전파(KC 규정) 준수합니. 제품 사용하려면 다음 사항
의하십시. 기기는 업무용 경에 용할 목적으로 적합성평가 받은
기기로서 가정 경에 용하 경우 파간섭의 우려가 있습니다.
력에 EMC 필터, 서지 보호기, 라이 코어 또는 1차측의 케이블에 이즈
필터 입력으로 사용하십시오.
Geo Direct PWM Amplifier
Receiving and Unpacking 15
RECEIVING AND UNPACKING
Delta Tau products are thoroughly tested at the factory and carefully packaged for shipment. When the
Geo Direct PWM Drive 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 drive.
Remove the drive from the shipping container and remove all packing materials. Check all shipping
material for connector kits, documentation, or other small pieces of equipment. Be aware that some
connector kits and other equipment pieces may be quite small and can be accidentally discarded if care
is not used when unpacking the equipment. The container and packing materials may be retained for
future shipment.
Verify that the part number of the drive received is the same as the part number listed on the purchase
order.
Inspect the drive for external physical damage that may have been sustained during shipment and report
any damage immediately to the commercial carrier that delivered the drive.
Electronic components in this product are design-hardened to reduce static sensitivity. However, use
proper procedures when handling the equipment.
If the Geo Direct PWM Drive is to be stored for several weeks before use, be sure that it is stored in a
location that conforms to published storage humidity and temperature specifications.
Use of Equipment
The following restrictions will ensure the proper use of the Geo Direct PWM Drive:
The components built into electrical equipment or machines can be used only as integral components
of such equipment.
The Geo Direct PWM Drive must not be operated on power supply networks without a ground or with
an asymmetrical ground.
If the Geo Direct PWM Drive is used in residential areas, or in business or commercial premises,
implement additional filtering measures.
The Geo Direct PWM Drive may be operated only in a closed switchgear cabinet, taking into account
the ambient conditions defined in the environmental specifications.
Delta Tau guarantees the conformance of the Geo Direct PWM Drives with the standards for industrial
areas stated in this manual, only if Delta Tau components (cables, controllers, etc.) are used.
Geo Direct PWM Amplifier
Mounting, Physical Layout 16
MOUNTING, PHYSICAL LAYOUT
The location of the Geo Direct PWM Drive 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:
For effective cooling and maintenance, the Geo Direct PWM Drive should be mounted on a smooth,
non- flammable vertical surface.
At least 76 mm (3 inches) top and bottom clearance must be provided for air flow. At least 10 mm
(0.4 inches) clearance is required between units (each side).
Temperature, humidity and Vibration specifications should also be taken in account.
Caution
Unit must be installed in an enclosure that meets the environmental
IP rating of the end product (ventilation or cooling may be necessary
to prevent enclosure ambient from exceeding 45° C [113° F]).
The Geo Direct PWM Drive can be mounted with a traditional 4-hole panel mount, two U shape/notches
on the bottom and two pear shaped holes on top.
If multiple Geo Direct PWM Drives are used, they can be mounted side-by-side, leaving at least a 122
mm clearance between drives. This means a 122 mm center-to-center distance (0.4 inches) with the 4-
axis Drives. 8- and 6-axis Geo Direct PWM Drives can be mounted side by side at 214 mm center-to-
center distance (8.4 inches). It is extremely important that the airflow is not obstructed by the placement
of conduit tracks or other devices in the enclosure.
If the drive is mounted to a back panel, the back panel should be unpainted and electrically conductive to
allow for reduced electrical noise interference. The back panel should be machined to accept the
mounting bolt pattern of the drive.
The Geo Direct PWM Drive can be mounted to the back panel using four M4 screws and internal-tooth
lock washers. It is important that the teeth break through any anodization on the drive’s mounting gears
to provide a good electrically conductive path in as many places as possible. Mount the drive on the back
panel so there is airflow at both the top and bottom areas of the drive (at least three inches).
Geo Direct PWM Amplifier
Mounting, Physical Layout 17
GPx012
Width
Height
Depth
Weight
3.30 in. / 84 mm
11.00 in. / 280 mm
5.80 in. / 147 mm
4.2 lbs / 1.9 kgs
Low Profile, Single Width, No Fan
GATE ENABLE
DELTA TAU
Data Systems, Inc.
24VDC INPUT (J4)
L2
AC INPUT (J1)
L1
24VDC
+24VDC
RET
L3
DISCRETE I/O (X3)
Wait 5 minutes after
N/A
(X4)
SAFETY RELAY (X4)
before servicing unit.
removing power
WARNING:
HIGH VOLTAGE!
RELAY COMM
RELAY WB
RELAY WA
RELAY N/O
NOT USED
MTR1 PTC RET
MTR2 PTC RET
24V RET
MTR1 PTC
MTR2 PTC
Residual Voltage.
WARNING!
INPUT 1
DC BUS AMP
STATUS
(D1)
SHUNT
ENABLE 1
+5V
ENABLE 2
(X1)
PWM
INPUT 2
PWM
(X2)
EXT SHUNT (J5)
REGEN -
REGEN +
MOTOR 2 (J3)
W V U MOTOR 1 (J2)
W V U
10.625
(269.875 mm)
2.7
(68.6 mm)
9.875
(250.825 mm)
3.3
(83.82 mm)
5.79
(147.066 mm)
Geo Direct PWM Amplifier
Mounting, Physical Layout 18
GPL032
Width
Height
Depth
Weight
3.30 in./ 84 mm
11.00 in./ 280 mm
8.00 in./ 203 mm
5.4 lbs/ 2.45 kgs
Single Width, No Fan
L1
24VDC
+24VDC
24VDC INPUT (J4)
L2
AC INPUT (J1)
L3
RET
EXT SHUNT (J5)
REGEN +
REGEN -
MOTOR 2 (J3)
W V MOTOR 1 (J2)
U W UV
GATE ENABLE
DELTA TAU
Data Systems, Inc.
DISCRETE I/O (X3)
Wait 5 minutes after
N/A
(X4)
SAFETY RELAY (X4)
before servicing unit.
removing power
WARNING:
HIGH VOLTAGE!
RELAY COMM
RELAY WB
RELAY WA
RELAY N/O
NOT USED
MTR1 PTC RET
MTR2 PTC RET
24V RET
MTR1 PTC
MTR2 PTC
Residual Voltage.
WARNING!
INPUT 1
DC BUS AMP
STATUS
(D1)
SHUNT
ENABLE 1
+5V
ENABLE 2
(X1)
PWM
INPUT 2
PWM
(X2)
10.625
(269.875 mm)
2.7
(68.6 mm)
9.875
(250.825 mm)
3.3
(83.82 mm)
5.79
(147.066 mm)
Geo Direct PWM Amplifier
Mounting, Physical Layout 19
GPx05x, GPx102, GPL101, GPH032
Width
Height
Depth
Weight
3.30 in./ 84 mm
11.00 in./ 280 mm
8.00 in./ 203 mm
5.5 lbs/ 2.5 kgs
Single Width with Fan
AC INPUT (J1)
L2
L1
24VDC INPUT (J4)
+24VDC
RET
24VDC
L3
EXT SHUNT (J5)
REGEN -
REGEN +
MOTOR 2 (J3)
W V U MOTOR 1 (J2)
W V U
GATE ENABLE
DELTA TAU
Data Systems, Inc.
DISCRETE I/O (X3)
Wait 5 minutes after
N/A
(X4)
SAFETY RELAY (X4)
before servicing unit.
removing power
WARNING:
HIGH VOLTAGE!
RELAY COMM
RELAY WB
RELAY WA
RELAY N/O
NOT USED
MTR1 PTC RET
MTR2 PTC RET
24V RET
MTR1 PTC
MTR2 PTC
Residual Voltage.
WARNING!
INPUT 1
DC BUS AMP
STATUS
(D1)
SHUNT
ENABLE 1
+5V
ENABLE 2
(X1)
PWM
INPUT 2
PWM
(X2)
10.625
(269.875 mm)
2.7
(68.6 mm)
9.875
(250.825 mm)
3.3
(83.82 mm)
5.79
(147.066 mm)
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Delta Tau Geo Direct PWM Amplifier Owner's manual

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