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ACC-8K2_____________________________Intelligent

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2. Accessory 8K2 IA DELTA TAU Data Systems Inc NEW IDEAS IN MOTION Single Source Machine Control Power Flexibility Ease of Use 21314 Lassen Street Chatsworth CA 91311 Tel 318 998 2095 Fax 818 998 7807 www deliatau com 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 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
3. Amplifier fault ret signal Grounded on PMAC pin 16 used as signal 9 IPB_PHA Output Phase A bottom command 10 SHIELD BI Shield Phase B shield Jumper E3 connects to ground 11 IPB_PHB Output Phase B bottom command IPB Phase B is PMAC Phase C 12 SHIELD N C Place to land spare shield wire 13 IPB_PHC Output Phase C bottom command _ IPB Phase C is PMAC phase B 14 RST_SRC Output 5Vdc Supply for reset optos in amp 15 10UT3 Output Fault reset Taken low then high to reset amplifier after amplifier enable 16 FAULTI1 Input Amplifier fault signal Amplifier holds low when not in fault This connector provides the command outputs for the Ist axis 22 Connector Pinouts Accessory 8K2 P4 25 Pin Encoder and Hall Effect om Feedback DSUB Connector Option ENEE EES 1B only Top View Lu Si Pin Symbol Function Description Notes 1 Al Input Encoder CHAN A 2 Al Input Encoder CHAN A 3 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 4 Bl Input Encoder Channel B 5 B1 Input Encoder Channel B 6 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 7 ESV_RET Common Enc Supply return 8 ESV_RET Common Enc Supply return 9 HALL 11 Input For CHU flag 0 10 HALL12 Input For CHV flag 0 11 HALL13 Input For CHW flag 0 12 SHIELD Shield Not connected inside
4. phase wires will help to reduce noise generated by the phase switching If maximum noise reduction is desired a shielded cable may be used Always connect the chassis ground wires from the motor to the servo amplifier Also be sure that all servo amplifiers have a wire connected between their ground post and the equipment s earth ground Motor Wiring pal pl ACC 8K2 PMAC2 PC 4 8 Axis PMAC2 LITE 4 Axis IPB IPB Power Servo PMAC2 PWM IPB Phase Current Feedback Logic Supply Power Supply Une Phase A Power IN Phase B Ee Phase C Case GND Note Reduce Radiated noise by twisting Phase wires on motor Further reduce radiated noise by using Shielded wiring PMAC2 Encoder and Motor Interconnection 15 Accessory 8K2 Encoder When connecting the encoder to the ACC8 K2 interface be sure to use a wire which is multi paired with an overall shield such as Belden 8334 or equivalent The 5Vdc and ground supply conductors may be routed through a 4th pair in the same cable jacket as the encoder signals Note Shielding the power supply lines is not required Multi paired cable with individual shields is also acceptable for encoder wiring such as Belden 9728 or equivalent Always route the encoder wires back to the ACC8 K2 interface separately from the motor wires The motor cabling may emit extremely high levels of energy that could damage the
5. 3 N C No connect 4 N C No connect 5 CUR_AI Input Phase A current input Differential input with CUR_A1 O pos 6 CUR C1 Input Phase C current input Differential input with CUR CI 0 pos 7 N C No connect 8 N C No connect 9 SHIELD Shield connection Jumper E7 connects to ground 10 N C No connect 11 CUR Al Input Phase A current input Differential input with CUR_A1 O neg 12 CUR_CI Input Phase C current input Differential input with CUR_C1 0 neg This connector provides the current feedback for the 1st axis amplifier Maximum scaled input is 8 5 Vdc The Kollmorgen IPB servo driver amplifier returns current measurement for phase C ACC 8K2 swaps phase B and phase C i e PMAC2 s phase B output is connected to IPB s Phase C input P3 16 Pin Command Output Molex Connector Top View Pin Symbol Function Description Notes 1 IPB_PHA Output Phase A top command 2 SHIELD A1 Shield Phase A shield Jumper El connects to ground 3 IPB_PHB Output Phase B top command IPB Phase B is PMAC Phase C 4 SHIELD C1 Shield Phase C shield Jumper E connects to ground 5 IPB_PHC Output Phase C top command IPB Phase C is PMAC Phase B 6 N C No connect 7 AENAI Output Amplifier enable control line Low is enable 8 FAULT RET Ground
6. ACC 8K2 Tied at other end only 13 THERM1 Input For CHT FLAG Motor Thermal Sensor 14 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 15 INDEX1 Input Encoder Channel C 16 INDEX1 Input Encoder Channel C 17 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 18 FAN SUPPLY Output Supply for encoder 19 FAN SUPPLY Output Supply for encoder 20 FAN SUPPLY Output Supply FOR encoder 21 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 22 HAIL 11 Input For CHU flag 0 23 HALL 12 Input For CHV flag 0 24 HALL 13 Input For CHW flag 9 25 THERM1 Input For CHT Flag Motor thermal sensor This connector provides the encoder and hall effect feedback for the 1st axis O A Negative signal can be used for differential line driver pair with SIP jumper installed in E10 position To select open collector operation move SIP jumper to E9 A Positive signal can be used for differential line driver pair with SIP jumper installed in E10 position When selected for open collector operation SIP jumper at E9 these inputs are not used Connector Pinouts 23 Accessory 8K2 P5 12 Pin Current Feedback Molex Top View JODA Connector Pin Symbol Function Description Notes 1 N C No connect 2 N C No connect 3 N C No connect 4 N C No connect 5 CUR_A2 Input Phase A current input Differential input with CUR_A2 O pos 6 CUR_
7. Encoder Channel C 16 INDEX2 Input Encoder Channel C 17 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 18 ESV_SUPPLY Output Supply for encoder 19 ESV_SUPPLY Output Supply for encoder 20 ESV SUPPLY Output Supply FOR encoder 21 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 22 HALL21 Input For CHU flag 23 HALL22 Input For CHV flag O 24 HALL23 Input For CHW flag 25 THERM2 Input For CHT Flag Motor thermal sensor This connector provides the encoder and hall effect feedback for the 2nd axis A Negative signal can be used for differential line driver pair with SIP jumper installed in E12 position To select open collector operation move SIP jumper to E11 A Positive signal can be used for differential line driver pair with SIP jumper installed in E12 position When selected for open collector operation SIP jumper at E11 these inputs are not used Connector Pinouts 25 Accessory 8K2 P8 14 Pin Sub Count Input E Header PERERA Top View Pin Symbol Function Description Notes 1 CHT1 Diff Input For 1 CHT flag 2 CHTI Diff Input For 1 CHT flag 3 CHUI Input For 1 CHU flag 4 CHVIz Input For 1 CHV flag 5 CHW 1 Input For 1 CHW flag 6 USER1 Input For 1 user flag H CHT2 Diff input For 2 CHT flag 8 CHT2 Diff input For 2 CHT flag 9 CHU2 Input For 2 CHT
8. NGGA KAKANIN AGA GG KANA 11 Motor L Variables caca ca an ba eebe see 12 PMAC2 ENCODER AND MOTOR INTERCONNECTION u ccssccssscssssscssccssssssssscsssescssscsssssenss 15 Motor EE 15 NOT AN 16 IRESOIV GR anan NA NN a NAA 17 SETTING UP COMMUTATION osicsssscsssscsnsssssonsssansseccssntsescoestinaceconssnstssecesedsassocvesnecesossssstessnscesenssonasseas 19 Testing PWM amp Current Feedback Operatton ceeeescecsseceeseeceseeeenceceeeesaeeceaeeeeneeceaeeeeneeceaeeeeneeeses 19 Digital Current Loop Tuning for PMAC2 0 0 0 ee ceccesececeeseesseeeeecesecesecaeceaecsaecseecaeeeneeeseeeneeeeeeerenerenaees 19 PMAC2 Commutation Phase Retferencmg nono nono n cnn nr nn nr nn nono non non nrnnn nn nnnnnnno 19 Ru S10 KNOW E 19 CONNECTOR PINOUTS E 21 Headers Terminal Blocks Molex and DSUB Connectors aaa 21 JMACH 100 Pin Header 21 P1 8 Pin Power Supply Input Molex Connechor mma anna pna wanawanawanawaaswssnwasansawnsanasanasunssnnas 21 P2 12 Pin Current Feedback Molex Connector 0 maaaaaaawaasasanaaaaasasanasanasasasassaasasasassasasana 22 P3 16 Pin Command Output Molex Connechor cone nonnnc canon ron nc canenronccnnns 22 P4 25 Pin Encoder and Hall Effect Feedback DSUB Connector Option 1B onl y 23 PS 12 Pin Current Feedback Molex Connector maaaaaaawaasasanaaaaanasanaaanasanasasssasasasassasasana 24 P6 16 Pin Command Output Molex Connechor cane n ron nc cane n
9. 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 Accessory 8K2 Table of Contents INN SAA vst Csok sst vv tott k dokon e sK oop NESES ESEVE SSES er K sieren esik ints oes ets 1 OPTIONS EE E CN 3 INIA ICAA A A 5 Watehdop Paulinas did BANDED RANA 5 INTI 5 EE 5 AMPZENA araceli 5 AMP PE KEE 5 AAA A GENEE 7 A oe cute ee EEr AEn r cose s eanee eed EE E sense IE RESES TEE EAE E 7 Le WEE T E eebe T AA AA AA AA AA AA AA AA AA AA AA AA H P4 Option Bi T Paanan E E TE Mana MEG NAG E T I AA AN T PO EE H PIO TB WE H ER Eeer 7 JA EE 7 d BEE 7 TB3 Option TA iia tirada 8 TB4 Option VA paa NABIBINGI NIAN NAN PAIRED RANG 8 TBICO DO TAN nan Ban NA NANG NAN ANAN ANG 8 TB6 Option IA 8 TB7 Assys 602655 102 and Later ME 8 LAYOUT DIA GRAMS wissssssecissssssssssesdevsocsesntsessienssssssessnsncsecabensehsnossduesd nnsecbncessesiessesstonsnsversbosesetsesessecsass 9 TEVARIABLE ASSIGNMENTS wissscscsscccstssssstoeccssassssosssessossecsteadsesnsssosssessesessessesssesdsesnessosssseoasesnssoesstand 11 Global Gate Array Variables ironia Seegen Eed Eege EEN 11 Channel Specific Gate Array Varlables i1 sa NANA ANA
10. flag 10 CHV2 Input For 2 CHV flag 11 CHW2 Input For 2 CHW flag 12 USER2 Input For 2 user flag 13 GND IPB amp PMAC2 ground 14 5VRG From IPB power supply This connector provides access to the T U V W and User flags for sub count resolver inputs When inputs are used at this connector corresponding inputs are not used at encoder inputs TB1 6 Pin Input Flag Terminal P a Block O A bd la ad ki H yp View La Pin Symbol Function Description Notes 1 USER1 Input General capture flag Sinking or sourcing 2 PLIM1 Input Positive limit flag Sinking or sourcing 3 MLIM1 Input Negative limit flag Sinking or sourcing 4 HOME1 Input Home flag Sinking or sourcing 5 FLG 1 RET Common Return for all flags V 12 to 24V or OV 6 FLG_1_RET Common Return for all flags Connected to pin 5 This terminal block provides the connection for the standard machine input flags for the 1st axis For flag sensors that use sinking outputs open collector connect the Flag Return lines to V 12 24Vdc power For sourcing output flag sensors the Flag Return lines should be connected to V ground or power supply return on the flag sensors power supply TB2 6 Pin Input Flag Terminal Block SE Top View La Pin Symbol Function Description Notes 1 USER2 Input General capture flag Sinking or sourcing 2 PLIM2 Input Positive limit flag Sinking or sourcin
11. pins Note On the ACC 8K2 all channels are numbered 1 or 2 However if the ACC 8K2 is connected to PMAC2 s JMACH2 it represents PMAC2 channels 3 4 JMACH3 represents channels 5 6 JMACH4 represents channels 7 8 P1 8 Pin Power Supply Input Molex Connector Top View Pin Symbol Function Description Notes 1 A 18V Input Positive supply voltage Generates 12Vdc supply on ACC 8K2 14 5V to 26 5V 2 A 18V Input Negative supply voltage Generates 12Vdc supply on ACC 8K2 14 5V to 6 5V 3 A COM Common Power supply return Connects to PMAC2 GND 4 A 10V Input Positive supply voltage Generates 5Vdc supply on ACC 8K2 6 5V to 14V 5 A 18V Input Positive supply voltage Generates 12Vdc supply on ACC 8K2 14 5V to 26 5V 6 A 18V Input Negative supply voltage Generates a 12Vdc supply on ACC 8K2 14 5V to 26 5V 7 A COM Common Power supply return Connects to PMAC2 GND 8 A 10V Input Positive supply voltage Generates 5Vdc supply on ACC 8K2 6 5V to 14V This Molex connector provides the input for the power supply for the circuits on the board It is designed to be directly compatible with the Kollmorgen IPB power supply cable 21 Connector Pinouts Accessory 8K2 P2 12 Pin Current Feedback Molex Connector eg AG DEER lop View Pin Symbol Function Description Notes 1 N C No connect 2 N C No connect
12. run if the flags are enabled with nothing connected to the flag inputs When reset the PMAC2 default values are acceptable for typical axis assignments except that flags are enabled The Ix66 parameter is used to limit the maximum drive PWM allowed into the motor phase coils This value must be non zero to perform the motor setup procedures Ix66 is scaled in units to 1900 or 1906 When Ix66 is set to the same value as 1900 or 1906 the voltage applied to a motor will approach the maximum that the servo driver can supply The Ix66 value should take into account the ratio between the motor s maximum line to line voltage and the actual bus voltage that the servo amplifier may deliver The value of Ix66 should be set to 1900 10 2401 when the bus voltage on the servo amplifier is close to the voltage rating of the motor When the motor s maximum voltage rating is less than the amplifier s maximum output Ix66 must be scaled to prevent excess current from damaging the motor If a motor is used that has a current rating that exceeds the amplifier Ix66 might be reduced to prevent overcurrent faults in the amplifier The Ix69 parameter is used to scale how much current is applied to the motor phase coils The Ix69 parameter has a maximum value of 32 767 The ratio of 1x69 to 32 767 will scale how much current is provided to the motor coils Use the peak current of both the motor and the amplifier to determine the Ix69 parameter 12 I Variable Assi
13. 0 2 e e e e e e e Option 1A Pin Symbol Function Description Notes 1 HALL 11 4 Input For CHU flag O 2 HALL11 Input For CHU flag o 3 HALL12 Input For CHV flag 4 HALL12 Input For CHV flag o 5 HALL13 Input For CHW flag 6 HALL13 Input For CHW flag 0 H THERMI1 Input For CHT FLAG Thermal Sensor 8 THERM1 Input For CHT FLAG Thermal Sensor 9 ENC 5V Output Digital supply 10 GND Common Digital ground This terminal block provides the interface to the set of hall effect flags for the 1st axis O A Negative signal can be used for differential line driver pair with SIP jumper installed in E10 position To select open collector operation move SIP jumper to E9 A Positive signal can be used for differential line driver pair with SIP jumper installed in E10 position When selected for open collector operation SIP jumper at E9 these inputs are not used view 21212 j0 0 0 o Top View La Notes TB5 8 Pin Encoder Interface Terminal Block Option 1A only Pin 1 Also Pulse input Also Pulse input Also direction input Also direction input Enc 2 pos c Chan Index channel Index channel 100mA max 8 This terminal block provides the interface to a quadrature encoder or the signals of a simulated encoder for the 2nd axis SI DA Nn B Oo bo Connector Pinouts 27 Accessory 8K2 1 Nao A MI BRIO to 10 TB6 10 Pin Hall Effect Interface Terminal Bl
14. A Optional Hall Effects IPB SC Drive 2 Shielded Cable PWM amp Phase Current Signals Motor Phase Leads The PMAC2 can drive the commutation of a motor through a 3 phase servo amplifier accurately and efficiently using the two current sensors that are provided in the amplifier Since the IPB product line provides these signals to PMAC2 then the current in a 3 phase permanent magnet brushless servomotor or AC induction motor may be monitored for precise commutation resulting in precise control of each motor on a per axis basis ACC 8K2 is one of a series of I O accessories for PMAC2 The interface to the PMAC2 is made using the JMACH connector cable This 24inch 61cm cable is supplied with the board The ACC 8K2 has 16 pin Molex connectors for the amplifier command signals 12 pin Molex connectors for the amplifier feedback signals and an 8 pin Molex connector for power All of these connectors match the pinout at the IPB amp and power supply end so straight across cables can be used The ACC 8K2 Option 1B has two DB 25 connectors for the encoder and Hall Effect input signals These connectors match the Kollmorgen quadrature encoder specification Option 1A provides terminal connectors for alternate interconnection requirements When used with the ACC 8K2 the PMAC2 provides three pairs of pulse trains which have constant frequency and variable pulse width This scheme is known as Pulse Width Modulation PWM Introduct
15. C2 Input Phase C current input Differential input with CUR_C2 0 pos 7 N C No connect 8 N C No connect 9 SHIELD Shield Connection Jumper e8 connects to ground 10 N C No connect 11 CUR_A2 Input Phase A current input Differential input with CUR_A2 O neg 12 CUR_C2 Input Phase C current input Differential input with CUR_C2 0 neg This connector provides the current feedback for the 2nd axis Maximum scaled input is 8 5 Vdc The Kollmorgen IPB servo driver amplifier returns current measurement for phase C ACC 8K2 swaps phase B and phase C i e PMAC2 s phase B output is connected to IPB s Phase C input P6 16 Pin Command Output Molex Connector Top View ee Pin Symbol Function Description Notes 1 IPB_PHA _ Output Phase A top command 2 SHIELD A2 Shield Phase A shield Jumper E4 connects to ground 3 IPB_PHB Output Phase B top command IPB Phase B is PMAC Phase C 4 SHIELD C2 Shield Phase C shield Jumper ES connects to ground 5 IPB_PHC Output Phase C top command IPB Phase C is PMAC Phase B 6 N C No connect 7 AENA2 Output Amplifier enable control Low is enable line 8 FAULT RET Ground Amplifier fault ret signal Grounded on PMAC pin 16 used as signal 9 IPB_PHA Output Phase A bottom command 10 SHIELD B2 Shield Phase B shield Jumper
16. DAD DDA DAAAADANAD boooooodoooon KOO 5 Ma 1 PB NASHI MADE IN THE USA PET O Eng 734547 wT D CAGES 5 a a O 000000000000 o0 00o ajo ojopy GEI 200000000000 e ili iti O Q Q o o E 15 pg rez eil ooooooOol pappoocaa SA e 1 Ty oy KOG lbi O Moy COooooooooti Ooooooot O Q LAYOUT DIAGRAM ACC 8K2 OPTION 1B CONNECTORS JUMPERS AND LEDs Layout Diagrams 9 10 Accessory 8K2 Layout Diagrams Accessory 8K2 I VARIABLE ASSIGNMENTS There are a group of I variables that should be set to perform proper PWM motor control functions using the ACC 8K2 interface Refer to the PMAC2 Hardware Software Reference for more complete details on I variable assignments The following I variables are important to be set properly for PWM interface between the PMAC2 and Kollmorgen IPB Global Gate Array Variables I Var Value Description Notes 27 kHz Maxphase 1901 9 kHz 1902 2 25 kHz 1903 See Software Reference 1904 PWM Deadtime CH1 4 x2 Sec 1906 2183 Maxphase and PWM CH5 8 Freq 13 5 kHz PWM 27 kHz Maxphase 1907 2258 Hardware Clock Control CH5 8 See Software Reference T908 15 PWM Deadtime CH5 8 x2 uSec Channel Specific Gate Array Variables I Var Value Description Notes 19n0 3 Encoder Timer n Decode Control X4 Quadrature Decode CW 19n6 2 Output n Mode Select _ Outputs A B C are PWM 19n7 Output n Invert Control Default I Variable Assignme
17. E6 connects to ground 11 IPB_PHB Output Phase B bottom command IPB Phase B is PMAC Phase C 12 SHIELD N C Place to land spare shield wire 13 IPB_PHC Output Phase C bottom command IPB Phase C is PMAC Phase B 14 RST_SRC Output 5Vdc Supply for reset optos in amp 15 20UT3 Output Fault reset Taken low then high to reset amplifier after amplifier enable 16 FAULT2 Input Amplifier fault signal Amplifier holds low when not in fault This connector provides the command outputs for the 2nd axis 24 Connector Pinouts Accessory 8K2 P7 25 Pin Encoder and Hall Effect DSUB oe Connector Option 1B only RENE Bech ip ki NG mi Pin Symbol Function Description Notes 1 A2 Input Encoder CHAN A 2 A2 Input Encoder CHAN A 3 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 4 B2 Input Encoder Channel B 5 B2 Input Encoder Channel B 6 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only H E5V REI Common Enc Supply return 8 E5V REI Common Enc Supply return 9 HALL21 Input For CHU flag o 10 HALL22 Input For CHV flag o 11 HALL23 Input For CHW flag 0 12 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 13 THERM2 Input For CHT FLAG Motor thermal sensor 14 SHIELD Shield Not connected inside ACC 8K2 Tied at other end only 15 INDEX2 Input
18. MAC2 with needed parameters to perform phase current drive These adjustments help establish the response of the PMAC2 Servo amp Motor system PMAC2 Commutation Phase Referencing Commutation is a position dependent process that aligns the motor poles to the commutation algorithm A register in the PMAC2 receives encoder inputs from the motor shaft To maintain synchronization between the commutation algorithm and the actual motor position a ring counter is established which maintains the number of counts per commutation cycle The counts per commutation cycle is derived from the ratio of Ix71 to Ix70 Encoder counts rev Number of Pole Pairs When the proper phase biasing is provided to the motor the ring counter gets reset to 0 This will align the commutation calculations to the actual motor position This process allows the motor to achieve maximum torque Things to Know When tuning the motor parameters and making the motor spin for the first time the motor should be disconnected from the load After tuning is completed but before connecting the load to a motor be sure that limit switches are in place Also be sure that the I variable which corresponds to its LIMIT HOME FLAG ADDRESS Ix25 has been enabled by removing the prefix that has been inserted in the setup procedures above After enabling the flags if the axis appears not to work the limit switches should be checked for proper polarity and direction input S
19. ble at this connector attaches between the ACC 8K2 and the IPB servo amplifier P4 Option 1B This 25 pin DSUB connector is used for encoder and Hall effect inputs at axis 1 This connector also provides the input signal for an overtemp sensor The cable at this connector attaches between the ACC 8K2 and the motor at its encoder connection P5 This 12 pin connector is the interface for the current feedback for axis 2 The cable at this connector attaches between the ACC 8K2 and the IPB servo amplifier P6 This is a 16 pin connector that provides the PWM drive outputs for the servo amplifier at axis 2 The cable at this connector attaches between the ACC 8K2 and the IPB servo amplifier P7 Option 1B This 25 pin DSUB connector is used for encoder and Hall Effect inputs at axis 2 This connector also provides the input signal for an overtemp sensor The cable at this connector attaches between the ACC 8K2 and the motor at its encoder connection P8 This 14 pin header provides an alternate input for Hall Effect inputs or TUVW flags and USER flag This header provides connections for both axes and is used by Delta Tau s sub count interpolation board TB1 This 6 pin connector strip provides the input for user flags on axis 1 These inputs are designed for 12 24 Vdc operation TB2 This 6 pin connector strip provides the input for user flags on axis 2 These inputs are designed for 12 24 Vdc operati
20. d Motor Interconnection 17 18 Accessory 8K2 PMAC2 Encoder and Motor Interconnection Accessory 8K2 SETTING UP COMMUTATION A detailed description for how to set up commutation is provided in the PMAC2 User s Manual There are three processes that must be followed when setting up the IPB servo amplifiers for the first time 1 Testing PWM amp Current Feedback Operation 2 Digital Current Loop Tuning For PMAC2 3 PMAC2 Commutation Phase Referencing Testing PWM amp Current Feedback Operation This process guarantees that when the motor is wired to the IPB servo amplifier that polarities for encoder UP DN counting and motor phasing have proper correlation Since the PMAC2 commutation algorithm uses the encoder input for establishing the phase angle for commutation it is important to ensure that the motor turns the encoder in the proper direction When wired per the IPB instruction manual and the I Variables are set at the values listed in the table above this procedure will verify the motor connections Digital Current Loop Tuning for PMAC2 The commutation process for a motor involves calculating and providing the current path that causes magnetic fields to be developed in the coils of the motor The total amount of current flowing into each phase coil of a motor must be equal to zero if Norton loop current laws are to be maintained There are several parameters that are set up in this process They provide the P
21. encoder or the ACC8 K2 interface card Encoder Wiring ACC 8K2 SHIELD B IN J C C 5V GND PMAC2 PC 4 8 Axis igi PMAC2 LITE 4 Axis d i A a Bia Note Shield wire is only connected at one end Conductors are twisted pairs 16 PMAC2 Encoder and Motor Interconnection Accessory 8K2 Resolver When connecting a resolver follow the installation instructions for the ACC 8D Option 7 Note The wire is multi paired cable with an overall shield such as Belden 8333 or equivalent The ACC 8D Opt 7 typically uses a ribbon cable or short lead wires to connect to the ACC 8K2 Multi paired cable with individual shields Belden 9730 or equivalent is also acceptable for resolver wiring Always route the resolver wires back to the ACC 8D Option 7 separately from the motor wires The motor cabling may emit extremely high levels of energy that could damage the Resolver to Digital Converter adapter card Resolver Wiring ACC 8K2 naa w naco a Axis Interface gt PMAC2 PC 4 8 Axis PMAC2 LITE 4 Axis ACC 8D Opt 7 Resolver to Encoder Converter EEES y A B B amp C Interface SHIELD A Ref Hi Resolver 8 f Ref Lo Drive Decode Z Sin Hi Logic amp Analog Sin Lo Supply Input gt y N Cos Hi fy Cos Lo 4 Note Shield wire is only connected at one end Conductors are twisted pairs PMAC2 Encoder an
22. etting Up Commutation 19 Accessory 8K2 Maximum speed and acceleration are determined for a motor system after the load has been connected Note The amplifier bus voltage may limit the maximum speed that the motor may be allowed to spin The bus voltage on the IPB is less when it is connected to 120Vac than when it is connected to 3 phase 240Vac This will have an effect on the maximum speed that the motor will spin PMAC2 maintains an encoder count input for each axis to accommodate motor commutation Encoder reliability must be ensured for commutation reliability On assemblies 602655 101 TB7 is not included for external encoder power When E STOP switches are used to remove supply power from the IPB Servo amplifier it should be noted that the encoders would lose power also This creates the need for re phasing each time after power is applied In machines that use this kind of circuit that have ASSY 602655 101 you should provide external power to the encoders to maintain count integrity when the amplifier power is removed 20 Setting Up Commutation Accessory 8K2 CONNECTOR PINOUTS Headers Terminal Blocks Molex and DSUB Connectors JMACH 100 Pin Header This header provides the connection to the matching 100 pin header on the PMAC2 It contains all the input and output signals between this board and the PMAC2 Refer to the PMAC2 Hardware Software Reference for a complete listing of JMACH connector
23. g 3 MLIM2 Input Negative limit flag Sinking or sourcing 4 HOME2 Input Home flag Sinking or sourcing 5 FLG 2 RET Common Return for all flags V 12 to 24V or OV 6 FLG 2 RET Common Return for all flags Connected to pin 5 This terminal block provides the connection for the standard machine input flags for the 2nd axis For flag sensors that use sinking outputs open collector connect the Flag Return lines to V 12 24V dc power For sourcing output flag sensors the Flag Return lines should be connected to V ground or power supply return on the flag sensors power supply 26 Connector Pinouts Accessory 8K2 TB3 8 Pin Encoder Interface Terminal la e Block Option 1A only Top View 2lele elelelele Pin Symbol Function Description Notes 1 CHA1 Input Enc 1 pos A Chan Also Pulse input 2 CHA1 Input Enc 1 neg A Chan Also Pulse input 3 CHB1 Input Enc 1 pos B Chan Also direction input 4 CHBI Input Enc 1 neg B Chan Also direction input 5 CHC1 Input Enc 1 pos C Chan Index channel 6 CHC1 Input Enc 1 neg C Chan Index channel 7 ENC 5 Output Digital supply 100mA max V 8 GND Common Digital ground This terminal block provides the interface to a quadrature encoder or the signals of a simulated encoder for the Ist axis TB4 10 Pin Hall Effect Interface Terminal Block Top i 1
24. gnments Accessory 8K2 Ipk motor The equation for Ix69 is Ix69 _ 32 767 Ipk amp For most applications Ix69 should be left at the default value of 20480 Each pole pair represents a commutation cycle If a bias were placed on 1 phase of the motor the pole pair count would be the number of magnetic stops that would be encountered in 1 rotation of the motor shaft The number of encoder counts per revolution is divided by the number of commutation cycles per revolution to determine how many encoder counts to use for each commutation cycle The value of 4096 is used in Ix71 because that is the number of counts per revolution that the resolver puts out in a Delta Tau ACC 8D Option 7 Resolver to Digital Converter Card This number will probably need to be different if a quadrature encoder is used Typical values are 1182 C006 1282 COOE 1382 C016 1482 C01E 1582 C026 1682 C02E 1782 C036 1882 C03E O When using encoder inputs typical values are 1183 C001 1283 C009 1383 C011 1483 C019 1583 C021 1683 C029 1783 C031 1883 C039 I Variable Assignments 13 14 Accessory 8K2 I Variable Assignments Accessory 8K2 PMAC2 ENCODER AND MOTOR INTERCONNECTION Motor When connecting the motor to the IPB amplifier be sure to use a wire which has a suitable thickness for carrying the currents necessary to run the motor at its peak current Twisting the 3
25. ignal for axis 2 is active This LED is D3 on the circuit board AMP2 FLT This amber LED will illuminate when the FAULT input to the ACC 8K2 card has been activated on axis 2 When the servo amplifier is indicating a fault state this LED will illuminate If the fault state in the amplifier is reset this LED will cease to be lit This may occur even if the PMAC2 has not been reset from its fault action This LED is D5 on the circuit board If there is no connection to the fault line from the external servo amplifier this line will indicate a fault condition LED Indicators 5 Accessory 8K2 LED Indicators Accessory 8K2 CONNECTORS Refer to the layout diagram of ACC 8K2 for the location of the connectors on the board A pin definition listing for each connector begins on page 21 of this manual JMACH1 This is the 100 pin connector that attaches the ACC 8K2 to the PMAC2 P1 This is an 8 pin terminal block that provides the connection for an external power supply This connector matches the connector on the IPB family of servo power supplies and ACC 8K2 receives its power from the daisy chained cable that interconnects IPB family products P2 This 12 pin connector is the interface for the current feedback for axis 1 The cable at this connector attaches between the ACC 8K2 and the IPB servo amplifier P3 This 16 pin connector provides the PWM drive outputs for the servo amplifier at axis 1 The ca
26. ion 1 Accessory 8K2 Introductions Accessory 8K2 OPTIONS One of the following options must be selected when ordering the ACC 8K2 Option 1A Encoder and Hall Effect inputs use terminals TB3 TB4 TB5 TB6 Option 1B Encoder and Hall Effect inputs use DSUB connectors P4 P7 Options Accessory 8K2 Options Accessory 8K2 LED INDICATORS Refer to the layout diagram of ACC 8K2 for the location of the LED indicators on the board Watchdog Fault This red LED will illuminate when there is a watchdog fault This LED is identical in function to the red LED on PMAC2 s processor board Refer to the PMAC User Manual for more information on the watchdog operation This LED is DI on the circuit card AMP1 ENA This green LED illuminates when the amplifier enable output signal for axis 1 is active This LED is D2 on the circuit board AMP1 FLT This amber LED will illuminate when the FAULT input to the ACC 8K2 card has been activated on axis 1 When the servo amplifier is indicating a fault state this LED will illuminate If the fault state in the amplifier is reset this LED will cease to be lit This may occur even if the PMAC2 has not been reset from its fault action This LED is D4 on the circuit board If there is no connection to the fault line from the external servo amplifier this line will indicate a fault condition AMP2 ENA This green LED illuminates when the amplifier enable output s
27. nts 11 Accessory 8K2 Motor I Variables WARNING Always disconnect motors from the driven load when running with flags disabled I Var Ix00 k01 1x02 Ix03 1x04 1x08 Ix09 Ix25 Ix29 k61 1x62 1x66 1x69 Ix70 1x71 1x72 Ix76 Ix77 Ix78 Ix79 1x82 Ix83 1x84 Value Description Notes Enable motor calculations Enable commutate calculations See PMAC Software Reference See Software Reference See Software Reference 96 Positive Loop Scale Factor See Software Reference 96 Positive Velocity Scale Daer See Software Reference Defeat limit flags 0 OupuVFirstPhaseOffset O Luet Loop Integral Gain LW Be Set During Current Loop Tuning LO Current Loop Prop Gain Forward Will Be Set During Current Loop Tuning Voltage Output Scaling Max Current Level Limit Number of Pole Pairs S Set for IPB value LO Current Loop Proportional Gain Backpath Will Be Set During Current Loop Tuning LO Induction Motor Mag Cur Will be Set After Current Loop Tuning LO Induction Motor Slip Gain Will be Set After Current Loop Tuning Lo Output Second Phase Offset See PMAC2 Software Reference O See PMAC2 Software Reference SFFF000 Current Loop Feedback Mask Word Bit mask for 12 bit A D converter O The 2 will defeat limit switches when added to the Limit Home Flag Amp Flag address This is put in the table to remind the user that motors will not
28. ock Option 1A only Pin Symbol Top View g o o o o o THERM2 For CHT flag Thermal sensor THERM2 For CHT flag ENC 5V Digital supply Digital ground This terminal block provides the interface to the set of hall effect flags for the 2nd axis O A Negative signal can be used for differential line driver pair with SIP jumper installed in E12 position To select open collector operation move SIP jumper to E11 A Positive signal can be used for differential line driver pair with SIP jumper installed in E12 position When selected for open collector operation SIP jumper at E11 these inputs are not used Thermal sensor 200000000F 1 Notes TB7 2 Pin Encoder Power Terminal Block Assys 602655 102 and later ele Top View 1 Pin Symbol Function Description Notes 1 5Vdc Input Encoder power 2 GND Common Encoder return This terminal block is where the user provides power for encoders 28 Connector Pinouts Accessory 8K2 JUMPERS Jumper Description Notes Default El Not Installed O E2 Not Installed E3 Not Installed E4 Not Installed O ES Not Installed O E6 Not Installed E7 Not Installed E8 CUR2 shield Not Installed O EFFECT Input select E10 selects differential input EFFECT Input select E12 selects differential input E13 Encoder Power 1 2 User supplies encoder 5Vdc 1 2 User supplied encoder 2 3 PMAC
29. on Connectors Accessory 8K2 TB3 Option 1A This connector strip is provided for encoder inputs on axis 1 Fight pins are used to connect a quadrature encoder 5Vdc is provided for encoder power 100mA max TB4 Option 1A Hall Effect inputs are connected here for axis 1 5Vdc is provided at this connector TB5 Option 1A This connector strip is provided for encoder inputs on axis 1 Eight pins are used to connect a quadrature encoder 5Vdc is provided for encoder power 100mA max TB6 Option 1A Hall Effect inputs are connected here for axis 1 5Vdc is provided at this connector TB7 Assys 602655 102 and Later The user provides 5 Vdc power here for encoders By providing an external power supply for the encoders PMAC can track the motor s position while the amplifier is shut off This may occur if an E stop switch removes power from the amplifier 8 Connectors Accessory 8K2 LAYOUT DIAGRAMS Oc ooog 5 O 50500050 ao
30. ranncnnns 24 Table of Contents Accessory 8K2 P7 25 Pin Encoder and Hall Effect DSUB Connector Option 1B only nsec 23 P8 14 Pin Sub Count Input Header 26 TBI 6 Pin Input Flag Terminal Block 26 TB2 6 Pin Input Flag Terminal Block 26 TB3 8 Pin Encoder Interface Terminal Block Option LA oni 27 TB4 10 Pin Hall Effect Interface Terminal Block Option JA 27 TB5 8 Pin Encoder Interface Terminal Block Option LA oni 27 TB6 10 Pin Hall Effect Interface Terminal Block Option IA oni 28 TB7 2 Pin Encoder Power Terminal Block Assys 602655 102 and Jorer 28 JUMPERS AAA NT 29 li Table of Contents Accessory 8K2 INTRODUCTION PMAC2 s Accessory 8K2 ACC 8K2 is a 2 axis board designed for easy connection to the Kollmorgen Industrial Drives Power Block product line The ACC 8K2 allows the Industrial Drives Power Block IPB family of servo drivers using IPB mode 1 to interface with the PMAC2 controller to provide the drive for 3 phasecommutated motors The ACC 8K2 interface card provides the 3 phase outputs analog phase current inputs encoder and flag signals for each of the two axes The drawing below shows the interconnection of the ACC 8K2 PMAC2 Motors and servo amplifiers Shielded Cable Motor Phase Gees PWM S Phase Leads Current Signals IPB Drive 1 Fe Af Encoder Resolver N Optional Hall Effects ara JMACH Flaos PMAC2 100 pin 3 g O Flags a e Encoder Resolver N
31. supplies encoder 4 5 Vdc power O Jumpers El E8 are used to connect the differential input shields to PMAC2 s gnd Typically the ground connection is provided by the IPB at the amplifier end Placing a jumper at these locations may result in ground loop noise problems or excessive current between the IPB and the PMAC2 system The jumpers used for E9 E10 and E11 E12 consist of a SIP resistor pack Place the resistor pack into either E9 or E10 E11 or E12 You should provide uninterrupted power to the encoders TB7 allows the user to do so when jumpered in the default position Jumpers 29

ACC-8K2_____________________________Intelligent

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