User ManualTable of ContentsIntroduction12Documentation12Downloadable Turbo PMAC Script13Specifications14Part Number14Geo Brick Drive Options16CPU Options16Encoder Feedback16Axes Power Configuration16Encoder Inputs16Digital Inputs/Outputs16Analog Inputs, DAC Outputs, Brakes, and Relays16Communication16Fieldbus Connectivity16Environmental Specifications17Protection Specifications17Agency Approvals17Electrical Specifications18Receiving and Unpacking20Use of Equipment20Mounting21Connector Locations224-Axis Geo Brick Drive236-Axis Geo Brick Drive248-Axis Geo Brick Drive25Pinouts and Software Setup26J1: Main Bus Power Input26Power On/Off Sequence27Cycling Main Bus Power27Older Models of the Geo Brick Drive28Newer Models of the Geo Brick Drive28Recommended Main Bus Power Wiring/Protection29Grounding, Bonding29Transformers31Fuses31Magnetic Contactors32Line Filters32Voltage Suppressors32Bus Power Cables32J2: 24VDC Logic Power and Safe Torque Off (STO)33Older Models34Newer Models34Disabling the STO (Backward compatibility)35Wiring and Using the STO35J3: External Shunt Resistor36J4: Limits, Flags, EQU [Axis 1- 4]38J5: Limits, Flags, EQU [Axis 5- 8]39Wiring the Limits and Flags40Limits and Flags [Axis 1- 4] Suggested M-Variables41Limits and Flags [Axis 5- 8] Suggested M-Variables41J6: General Purpose Inputs/Outputs42J7: General Purpose Inputs/Outputs (Additional)43About the Digital Inputs and Outputs44Inputs44Outputs44Wiring the Digital Inputs and Outputs45General Purpose I/Os (J6) Suggested M-Variables46General Purpose I/Os Additional (J7) Suggested M-Variables46J8: PWM Amplifier Interface47J9: Handwheel and Analog I/O48Setting up the Analog Inputs (J9)49J9 Analog Inputs Suggested M-Variables50Testing The J9 Analog Inputs50Setting up the Analog Output (J9)51J9 Analog Output Suggested M-Variable52Testing the J9 Analog Output52Setting up Pulse And Direction Output PFM (J9)53Testing The J9 PFM Output54Setting up the Handwheel Port (J9)55X1-X8: Encoder Feedback, Digital A Quad B56Setting up Quadrature Encoders58Encoder Count Error (Mxx18)58Encoder Loss Detection, Quadrature59Encoder Loss Example PLC:60Step and Direction PFM Output (To External Stepper Amplifier)61X1-X8: Encoder Feedback, Sinusoidal64Setting up Sinusoidal Encoders65Counts Per User Units66Encoder Count Error (Mxx18)67Encoder Loss Detection, Sinusoidal68X1-X8: Encoder Feedback, Resolver69Setting up Resolvers69Resolver Excitation Magnitude70Resolver Excitation Frequency70Resolver Data Registers71Encoder Conversion Table Processing71Calculating The Tracking Filter Gains72Motors 1-8 Resolver Encoder Conversion Table Setup Example72Position, Velocity Feedback Pointers73Resolver Power-On PLC Example74X1-X8: Encoder Feedback, HiperFace75Setting up HiperFace On-Going Position76Counts Per Revolution:77Setting up HiperFace Absolute Power-On Position78Global Control Registers79Channel Control Registers80HiperFace Data Registers81Setting up HiperFace Encoders Example82Using The Absolute Position Read Example PLC84Encoder Count Error (Mxx18)87Encoder Loss Detection, HiperFace88X1-X8: Encoder Feedback, SSI89Configuring SSI89Global Control Registers90Channel Control Registers91SSI Data Registers92SSI Control Registers Setup Example93Global Control Register93Channel Control Register93Control Registers Power-On PLC94X1-X8: Encoder Feedback, EnDat 2.1/2.294Configuring EnDat95Global Control Registers96Channel Control Registers97EnDat Data Registers98EnDat Control Registers Setup Example99Global Control Register99Channel Control Register99Control Registers Power-On PLC100X1-X8: Encoder Feedback, BiSS C/B101Configuring BiSS101Global Control Registers102Channel Control Registers103BiSS Data Registers104BiSS Control Registers Setup Example105Global Control Register105Channel Control Register105Control Registers Power-On PLC106Setting up SSI | EnDat | BiSS107Technique 1107Technique 2107Technique 3107Setup Summary108Encoder Conversion Table Processing:108Commutation Source And Type (for commutated motors, e.g. brushless)108Resolution Scale Factor (SF)109Commutation Cycle Size109Position And Velocity Scale Factors, Position Error Limit109Absolute Power-On Position And Phasing109Technique 1 Example110Encoder Conversion Table - for position (Technique 1)110Counts Per User Units (Technique 1)111Absolute Power-On Position Read (Technique 1)111Technique 2 Example113Encoder Conversion Table – for position (Technique 2)113Counts Per User Units (Technique 2)114Encoder Conversion Table - for commutation (Technique 2)115Absolute Power-On Position Read (Technique 2)116Technique 3 Example118Encoder Conversion Table - for position (Technique 3)118Counts Per User Units (Technique 3)119Encoder Conversion Table - for commutation (Technique 3)120Absolute Power-On Position Read (Technique 3)121X1-X8: Encoder Feedback, Yaskawa Sigma II & III123Global Control Registers125Channel Control Registers126Yaskawa Feedback Channel Control Power-On Example PLC (Motors 1-8)127Yaskawa Data Registers127Yaskawa Sigma II 16-Bit Absolute Encoder128Encoder Conversion Table Setup (Motors 1-8)128Position (Ixx03) and Velocity (Ixx04) Pointers129Motor Activation129Absolute Power-On Position Read (Yaskawa 16-bit)130Yaskawa Sigma II 17-Bit Absolute Encoder131Encoder Conversion Table Setup (Motors 1-8)132Position (Ixx03) and Velocity (Ixx04) Pointers132Motor Activation132Absolute Power-On Position Read (Yaskawa 17-bit)133Yaskawa Sigma III 20-Bit Absolute Encoder134Encoder Conversion Table Setup (Motors 1-8)135Position (Ixx03) and Velocity (Ixx04) Pointers135Motor Activation135Absolute Power-On Position Read (Yaskawa 20-bit)136Yaskawa Sigma II 13-Bit Incremental Encoder137Encoder Conversion Table Setup (Motors 1-8)138Position (Ixx03) and Velocity (Ixx04) Pointers138Motor Activation138Yaskawa Sigma II 17-Bit Incremental Encoder139Encoder Conversion Table Setup (Motors 1-8)140Position (Ixx03) and Velocity (Ixx04) Pointers140Motor Activation140Yaskawa Incremental Encoder Alarm Codes141Homing with Yaskawa Incremental Encoders142X9-X10: Analog Inputs/Outputs143X11-X12: Analog Inputs/Outputs143Setting up the Analog (ADC) Inputs144Analog Inputs Suggested M-Variables145Testing the Analog Inputs145Setting up the Analog (DAC) Outputs145Analog Outputs Suggested M-Variables:147Testing the Analog Outputs147Setting up the General Purpose Relay, Brake148General Purpose Relay Suggested M-Variables149Setting up the External Amplifier Fault Input150External Amplifier Fault Input, Suggested M-Variables:150X13: USB 2.0 Connection151X14: RJ45, Ethernet Connection151X15: Watchdog and ABORT (TB2)152Wiring the Abort Input152Wiring the Watchdog Output153RS232: Serial Communication Port154A1 - A8: Motor Wiring155Low (5/10A) – Medium (8/16A) power Axes:155High (15/30A) power Axes:155Motor Cable, Noise Elimination156Motor Selection158Motor Inductance158Motor Resistance158Motor Inertia158Motor Speed158Motor Torque158Required Bus Voltage for Speed and Torque159+5V ENC PWR (Alternate Encoder Power)160Wiring the Alternate (+5V) Encoder Power161Functionality, Safety Measures162Motor Setup163Motor Setup Flow Chart163Dominant Clock Settings164Minimum PWM Frequency164Recommended clock Frequencies164Clock Calculations166ADC Strobe Word (I7m06)166AC/DC Brushless (Rotary/Linear) Motor Setup167Before you start167Commutation Angle, Current Mask: Ixx72, Ixx84167PWM Scale Factor: Ixx66167Current Feedback Address: Ixx82167Commutation Position Address, Commutation Enable: Ixx83, Ixx01168Quadrature / Sinusoidal / HiperFace168SSI / EnDat / BiSS168Resolver169Yaskawa169I2T Protection: Ixx57, Ixx58, Ixx69170Commutation Cycle Size: Ixx70, Ixx71171Ixx71 Saturation172ADC Offsets: Ixx29, Ixx79172Current-Loop Tuning: Ixx61, Ixx62, Ixx76173Motor Phasing, Power-On Mode: Ixx73, Ixx74, Ixx80, Ixx81, Ixx91174Manual | Custom Phasing1752-Guess Phasing Method177Stepper Phasing Method177Hall Effect Phasing: Digital quadrature encoders178Fine Phasing181Hall Effect Phasing: Yaskawa Incremental encoders182Absolute Power-On Phasing: HiperFace185Using The Absolute Power-On Phasing Example PLC185Absolute Power-On Phasing: EnDat | SSI | BiSS188Absolute Power-On Phasing: Yaskawa absolute encoders192Open-Loop Test, Encoder Decode: I7mn0194Position-Loop PID Tuning: Ixx30…Ixx39196High Speed Motors197AC Induction (Asynchronous) Motor Setup – With Encoder198Before you start198Commutation Angle, Current Mask: Ixx72, Ixx84198PWM Scale Factor: Ixx66198Current Feedback Address: Ixx82198Commutation Position Address, Commutation Enable: Ixx83, Ixx01199Magnetization Current, Slip Gain: Ixx77199Motor Slip Gain: Ixx78199Calculating Slip Gain From Name Plate Data:199Calculating Slip Gain From Rotor Time Constant. Example:199I2T Protection: Ixx57, Ixx58, Ixx69200Commutation Cycle Size: Ixx70, Ixx71201ADC Offsets: Ixx29, Ixx79201Current-Loop Tuning: Ixx61, Ixx62, Ixx76201Open-Loop Test, Encoder Decode: I7mn0202Position-Loop PID Tuning: Ixx30…Ixx39204Optimizing Magnetization Current Ixx77, Slip Gain Ixx78205Magnetization current205Slip Gain206Correcting I2T Settings207Closed-Loop vs. Open-Loop Operation207Field Weakening208High Speed Spindles209AC Induction (Asynchronous) Motor Setup – Without Encoder, Direct Micro-Stepping210Before you start210Encoder Conversion Table Setup210Motor Activation, Position, Velocity Pointers: Ixx03, Ixx04211Commutation Angle, Current Mask, Flag Mode Control: Ixx72, Ixx84, Ixx24211PWM Scale Factor: Ixx66211Current Feedback Address: Ixx82211Commutation Position Address, Commutation Enable: Ixx83, Ixx01211Commutation Cycle size: Ixx70, Ixx71211Maximum Achievable Motor Speed, Output Command Limit: Ixx69212Theoretical Ixx69212Calculated Ixx69212I2T Protection, Magnetization Current: Ixx57, Ixx58, Ixx69, Ixx77213Magnetization Current: Ixx77213Motor Slip Gain: Ixx78214Calculating Slip Gain From Name Plate Data. Example:214Calculating Slip Gain From Rotor Time Constant. Example:214ADC Offsets: Ixx29, Ixx79214Current-Loop Tuning: Ixx61, Ixx62, Ixx76215Position-Loop PID Tuning: Ixx30…Ixx39215Moving the Motor216Counts per Revolution216DC Brush Motor Setup217Before you start217Phasing Search Error Bit, Current-Loop Integrator Output (Ixx96)217Commutation Enable, Phase Angle, Current Mask: Ixx01, Ixx72, Ixx84217PWM Scale Factor: Ixx66218Current Feedback Address: Ixx82218Commutation Cycle Size: Ixx70, Ixx71218I2T Protection: Ixx57, Ixx58, Ixx69219ADC Offsets: Ixx29, Ixx79220Current-Loop Gains, Open-Loop/Enc. Decode: Ixx61, Ixx62, Ixx76, I7mn0220Position-Loop PID Gains: Ixx30…Ixx39221Macro Connectivity222Introduction to MACRO222MACRO Configuration Examples223Review: MACRO Nodes and Addressing224Review: MACRO Auxiliary Commands225Configuration Example 1: Brick - Brick226Setting up the Slave in Torque Mode227Slave Handshaking PLC Example: Phase then kill Motor #1:229Note about Slave Motors’ I2T229Setting up the Master in Torque Mode230Setting up the Slave in PWM Mode233Setting up the Master in PWM Mode234Configuration Example 2: Brick – Geo MACRO Drive240Brick – Brick MACRO I/O Data Transfer248Transferring the Digital (Discrete) Input and Outputs249Slave Digital I/Os Transfer Example251Master Digital I/Os Transfer Example252Bitwise Assignments (downloaded onto the master)253Transferring the X9-X12 Analog Inputs/Outputs254Transferring the J9 Analog Inputs256MACRO Limits, Flags and Homing257Limits and Flags257Homing from Master257Homing from Slave257MACRO Suggested M-Variables258Absolute Position Reporting over MACRO260MACRO Configuration Power-Up Sequence260Drive Structure and Troubleshooting261Geo Brick Drive Structure261Serial Number and Board Revisions Identification262Default Mode, Strobe Word (I7m06) Setting263Enhanced Mode (Reading IGBT Temperature and Bus Voltage)264Error Codes265Axis Faults (n = 1 - 8)265Global Faults266Reading IGBT Temperature and Bus Voltage267Calculating Motor Current Output Example268LED Status269Error 18 (Erro18)270Watchdog Timer Trip271Geo Brick Drive Specific Online Commands271Type272Ampversion273Ampmod273Ampsid274Ampclrf274Boot Switch SW (Firmware Reload) – Write-Protect Disable275Reloading PMAC firmware276Changing IP Address, Gateway IP, Gateway Mask278Enabling ModBus279Reloading Boot and Communication Firmware280Reset Switch SW (Factory Reset)281List of Changes and Updates282AMPVER Command, December 2007282Example:282Quick Verification:282External Encoder Power Supply Connector, April 2010283EEPROM Write-Protect Enable. April 2010283AMPVER Fail-Safe Mechanism. Configuration Error, May 2010284Modifications and Improvements, October 2012285Control board285Power board(s)285Appendix A286Schematic Samples286Watchdog: X15286Inputs: J6 & J7286Outputs: J6 & J7 (603793 – 109 and earlier)287Outputs: J6 & J7 (603793 – 10A and later)287Limits & Flags: J4288Appendix B289DB Connector Spacing Specifications289X1-8: DB-15 Connectors for encoder feedback289X9-12: DB-9 Connectors for Analog I/O289Screw Lock Size for all DB-connectors289Appendix C290Control Board Jumpers (For Internal Use)290E6 – E9: AENA/GPIO Selection Jumper290E10 – E12: Power-up/Reset Load Source290E13: Firmware Reload Enable (BOOT SW)291E14: Watchdog Disable Jumper291E25-28: Select Encoder Index input or AENA output (channels 1-4)291E35-38: Select Encoder Index input or AENA output (channels 5-8)291E40: USB/Ethernet Communication Firmware Load Enable291Appendix D292Absolute Serial Encoders Limitation With Turbo PMAC292Quick Comparison292Resolution Scale Factor (SF)292Maximum “Actual” Open-Loop Velocity293Maximum “Commanded” Closed-Loop Velocity294Maximum Motor Travel294Size: 9.44 MBPages: 294Language: EnglishOpen manual
