Delta Tau Geo MACRO User manual

^1 USER MANUAL & REFERENCE
^2 Geo MACRO Drive
^3 Direct PWM Amplifier over MACRO
^4 500-603701-xUxx
^5 April 27, 2010
Single Source Machine Control Power // Flexibility // Ease of Use
21314 Lassen Street Chatsworth, CA 91311 // Tel. [phone] Fax. [phone] // www.deltatau.com

Copyright Information
© 2010 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: [phone]
Fax: [phone]
Email: [email protected]
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.
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:
IEC 364 resp. CENELEC HD 384 or DIN VDE 0100
IEC report 664 or DIN VDE 0110
National regulations for safety and accident prevention or VBG 4
Incorrect handling of products can result in injury and damage to persons and machinery. Strictly adhere
to the installation instructions. Electrical safety is provided through a low-resistance earth connection. It is
vital to ensure that all system components are connected to earth ground.
This product contains components that are sensitive to static electricity and can be damaged by incorrect
handling. Avoid contact with high insulating materials (artificial fabrics, plastic film, etc.). Place the
product on a conductive surface. Discharge any possible static electricity build-up by touching an
unpainted, metal, grounded surface before touching the equipment.
Keep all covers and cabinet doors shut during operation. Be aware that during operation, the product has
electrically charged components and hot surfaces. Control and power cables can carry a high voltage,
even when the motor is not rotating. Never disconnect or connect the product while the power source is
energized to avoid electric arcing.

After removing the power source from the equipment, wait at least 10 minutes before touching or
disconnecting sections of the equipment that normally carry electrical charges (e.g., capacitors, contacts,
screw connections). To be safe, measure the electrical contact points with a meter before touching the
equipment.
The following text formats are used in this manual to indicate a potential for personal injury or equipment
damage. Read the safety notices in this manual before attempting installation, operation, or maintenance
to avoid serious bodily injury, damage to the equipment, or operational difficulty.
WARNING
A Warning identifies hazards that could result in personal injury or death. It
precedes the discussion of interest.
Caution
A Caution identifies hazards that could result in equipment damage. It precedes
the discussion of interest
Note
A Note identifies information critical to the user’s understanding or use of the
equipment. It follows the discussion of interest.

REVISION HISTORY
REV. DESCRIPTION DATE CHG APPVD
1 UPDATED ENDAT SETUP INFO, P. 82 07/18/06 CP P.SHANTZ
2 UPDATED ERROR CODE EF GATE DRIVE INFO 09/21/06 CP P.SHANTZ
3 CORRECTED GP OUT INPUT FUNCTIONS, P. 39 06/11/08 CP K.ZHAO
4 CORRECTED RESET COMMAND, P. 138 10/30/08 CP S. MILICI
5 CORRECTED M-VARIABLE DEFINITIONS, P. 87 12/08/09 CP S. MILICI
6 CORRECTED ERRORS PPS. 85-87 02/25/10 CP S. MILICI
7 CORRECTED COVER PAGE FORMATTING 03/01/10 CP C. PERRY
8 ADDED SAFETY RELAY PN INFO, P. 108 04/27/10 CP S. MILICI

Geo MACRO Drive User and Reference Manual
Table of Contents i
Table of Contents
Copyright Information................................................................................................................................................i
Operating Conditions .................................................................................................................................................i
Safety Instructions......................................................................................................................................................i
INTRODUCTION .......................................................................................................................................................1
User Interface ............................................................................................................................................................1
Geo MACRO Drives .............................................................................................................................................1
Geo PMAC Drives ................................................................................................................................................2
Geo Direct-PWM Drives.......................................................................................................................................2
MACRO Defined ......................................................................................................................................................2
Feedback Devices......................................................................................................................................................3
Compatible Motors....................................................................................................................................................3
Maximum Speed....................................................................................................................................................3
Torque...................................................................................................................................................................3
Motor Poles ..........................................................................................................................................................4
Motor Inductance..................................................................................................................................................4
Motor Resistance ..................................................................................................................................................4
Motor Back EMF ..................................................................................................................................................4
Motor Torque Constant.........................................................................................................................................5
Motor Inertia ........................................................................................................................................................5
Motor Cabling.......................................................................................................................................................5
SPECIFICATIONS .....................................................................................................................................................7
Part Number ..............................................................................................................................................................7
Geo MACRO Feedback Options...............................................................................................................................8
Package Types...........................................................................................................................................................8
Electrical Specifications............................................................................................................................................9
230VAC Input Drives...........................................................................................................................................9
480VAC Input Drives..........................................................................................................................................11
Environmental Specifications..................................................................................................................................13
Recommended Fusing and Wire Gauge ..................................................................................................................13
RECEIVING AND UNPACKING...........................................................................................................................15
Use of Equipment....................................................................................................................................................15
MOUNTING ..............................................................................................................................................................17
Low Profile..............................................................................................................................................................18
Single Width............................................................................................................................................................19
Double Width ..........................................................................................................................................................20
CONNECTIONS .......................................................................................................................................................21
System (Power) Wiring...........................................................................................................................................21
Wiring AC Input, J1 ............................................................................................................................................23
Wiring Earth-Ground .........................................................................................................................................23
Wiring 24 V Logic Control, J4............................................................................................................................24
Wiring the Motors ...................................................................................................................................................24
J2: Motor 1 Output Connector Pinout...............................................................................................................24
J3: Motor 2 Output Connector Pinout...............................................................................................................24
Wiring the Motor Thermostats ................................................................................................................................25
Wiring the Regen (Shunt) Resistor, J5 ....................................................................................................................25
J5: External Shunt Connector Pinout ................................................................................................................26
Shunt Regulation.................................................................................................................................................27
Minimum Resistance Value.................................................................................................................................27
Maximum Resistance Value ................................................................................................................................27
Energy Transfer Equations .................................................................................................................................27
Bonding...................................................................................................................................................................29
Filtering...................................................................................................................................................................30

Geo MACRO Drive User Manual
ii Table of Contents
CE Filtering ........................................................................................................................................................30
Input Power Filtering .........................................................................................................................................31
Motor Line Filtering ...........................................................................................................................................31
I/O Filtering........................................................................................................................................................31
Connecting Main Feedback Sensors (X1 & X2) .....................................................................................................32
Digital Quadrature Encoders .............................................................................................................................32
Digital Hall Commutation Sensors.....................................................................................................................33
SSI Encoders.......................................................................................................................................................33
Sinusoidal Encoders ...........................................................................................................................................34
Hiperface® Interface ..........................................................................................................................................35
EnDat Interface...................................................................................................................................................36
Resolvers.............................................................................................................................................................37
Connecting Secondary Quad. Encoders (X8 & X9)................................................................................................38
Connecting General Purpose I/O & Flags (X3).......................................................................................................39
Sample wiring the I/O .........................................................................................................................................39
Sample Wiring the Flags.....................................................................................................................................40
Connecting MACRO Ring ......................................................................................................................................41
Fiber Optic MACRO connections (X5)...............................................................................................................41
RJ-45 Copper MACRO connections (X10 &X11)...............................................................................................41
Connecting optional Analog Inputs (X6 & X7) ......................................................................................................42
SOFTWARE SETUP FOR GEO MACRO DRIVES .............................................................................................43
Introduction .............................................................................................................................................................43
Establishing MACRO Communications with Turbo PMAC ..................................................................................43
MACRO Ring Frequency Control Variables ......................................................................................................43
I7: Phase Cycle Extension ..................................................................................................................................43
I6840: MACRO IC 0 Master Configuration .......................................................................................................44
I6890/I6940/I6990: MACRO IC 1/2/3 Master Configuration ............................................................................44
I6841/I6891/I6941/I6991: MACRO IC 0/1/2/3 Node Activation Control...........................................................44
I70/I72/I74/I76: MACRO IC 0/1/2/3 Node Auxiliary Function Enable..............................................................45
I71/I73/I75/I77: MACRO IC 0/1/2/3 Node Protocol Type Control ....................................................................46
I78: MACRO Master/Slave Auxiliary Communications Timeout .......................................................................46
I79: MACRO Master/Master Auxiliary Communications Timeout.....................................................................46
I80, I81, I82: MACRO Ring Check Period and Limits .......................................................................................46
MACRO Node Addresses ....................................................................................................................................47
Using the Turbo PMAC Setup Program .............................................................................................................51
Using the PEWIN32PRO 2 MACRO Ring ASCII Feature..................................................................................58
PEWIN32PRO Suite 2 MACRO Status window..................................................................................................62
Ring Order Communications Method .................................................................................................................63
MACRO ASCII Communications........................................................................................................................64
How to Enable and Disable MACRO ASCII Communication Mode ..................................................................64
SETTING UP PRIMARY FEEDBACK..................................................................................................................67
Device Selection Control.........................................................................................................................................67
Setting up Digital Quadrature Encoders.................................................................................................................67
Setting up SSI Encoders..........................................................................................................................................67
Setting up Sinusoidal Encoders...............................................................................................................................69
Principle of PMAC Interpolation Operation ......................................................................................................69
Setting up Endat ......................................................................................................................................................72
Setting up Resolvers................................................................................................................................................72
Setting up the Phase Shift (MI941) Manually .....................................................................................................73
Setting up the Resolver for Power-On Absolute Position ...................................................................................73
Scaling the Feedback Units ................................................................................................................................74
SETTING UP SECONDARY ENCODERS............................................................................................................75
SETTING UP THE TURBO PMAC CONVERSION TABLE .............................................................................77

Geo MACRO Drive User and Reference Manual
Table of Contents iii
SETTING UP TURBO MOTOR OPERATION ....................................................................................................79
Turbo PMAC Basic Setup for Brushless Servo or Induction Motor .......................................................................79
Turbo PMAC Basic Setup for DC Brush Motors................................................................................................80
Instructions for Direct-PWM Control of Brush Motors ..........................................................................................85
PWM/ADC Phase Match ....................................................................................................................................85
Synchronous Motor Stepper Action ....................................................................................................................85
Current Loop Polarity Check..............................................................................................................................85
Troubleshooting..................................................................................................................................................86
Testing PWM and Current Feedback Operation .....................................................................................................86
Purpose...............................................................................................................................................................86
Preparation.........................................................................................................................................................87
Position Feedback and Polarity Test ..................................................................................................................87
Setting Up Hall Commutation Sensors....................................................................................................................88
Signal Format .....................................................................................................................................................88
Using Hall Effect Sensors for Phase Reference..................................................................................................89
Determining the Commutation Phase Angle.......................................................................................................89
Finding the Hall Effect Transition Points...........................................................................................................89
Calculating the Hall Effect Zero Point (HEZ) ....................................................................................................90
Determining the Polarity of the Hall Effects – Standard or Reversed................................................................92
Software Settings for Hall Effect Phasing...........................................................................................................92
Setting I2T Protection ..............................................................................................................................................96
Calculating Minimum PWM Frequency .................................................................................................................97
SETTING UP DISCRETE INPUTS AND OUTPUTS...........................................................................................99
Inputs and Outputs ..................................................................................................................................................99
Ring Break Output indicator MS{node},MI13 .....................................................................................................100
Setting up the Analog Inputs (X6 and X7)............................................................................................................100
Limit and Flag Circuit Wiring...............................................................................................................................102
Connecting Limits/Flags to the Geo Drive .......................................................................................................102
Setting up Position Compare (EQU) Outputs........................................................................................................103
Setting up for a Single Pulse Output.................................................................................................................103
Setting up for Multiple Pulse Outputs...............................................................................................................104
CONNECTORS.......................................................................................................................................................105
Connector Pinouts .................................................................................................................................................105
X1: Encoder Input 1.........................................................................................................................................105
X2: Encoder Input 2.........................................................................................................................................106
X3: General Purpose I/O..................................................................................................................................107
X4: Safety Relay (Optional) .............................................................................................................................108
X6: Analog IN 1 (Optional 3/4/5) ....................................................................................................................108
X7: Analog IN 2 (Optional 3/4/5) ....................................................................................................................108
X8: S. Encoder 1 ..............................................................................................................................................109
X9: S. Encoder 2 ..............................................................................................................................................109
X13: Discrete I/O.............................................................................................................................................109
J1: AC Input Connector Pinout .......................................................................................................................110
J2: Motor 1 Output Connector Pinout.............................................................................................................110
J3: Motor 2 Output Connector Pinout (Optional) ...........................................................................................110
J4: 24VDC Input Logic Supply Connector .......................................................................................................110
J5: External Shunt Connector Pinout ..............................................................................................................110
MACRO Link Connectors.....................................................................................................................................111
X5: MACRO I/O, MACRO Fiber Optic Transceiver (Optional).......................................................................111
X10 and X11 MACRO RJ-45 Copper Connectors ............................................................................................111
USB Connector .....................................................................................................................................................111
X12: USB Universal Serial Bus Port ...............................................................................................................112
TROUBLESHOOTING..........................................................................................................................................113
Error Codes ...........................................................................................................................................................113

Geo MACRO Drive User Manual
iv Table of Contents
D1: Geo MACRO Drive Status Display Codes.................................................................................................113
MACRO Network Errors...................................................................................................................................114
Status LEDs ......................................................................................................................................................115
Geo MACRO Drive Ring Status Error Codes.......................................................................................................116
MS{node},MI4 Geo MACRO Status Word (Read Only) ...............................................................................116
MS{node},MI6 Status Word Control.............................................................................................................117
Status Word.......................................................................................................................................................117
TURBO PMAC2 RELATED I-VARIABLE REFERENCE ...............................................................................119
Ixx10: Motor xx Power-On Servo Position Address............................................................................................119
Ixx25, Ixx24: Flag Address and Mode ..................................................................................................................121
Ixx70, Ixx71: Commutation Cycle Size ...............................................................................................................123
Ixx72: Commutation Phase Angle.........................................................................................................................123
Ixx75: Absolute Phase Position Offset.................................................................................................................123
Ixx81: Motor xx Power-On Phase Position Address and Mode...........................................................................124
Ixx82: Current Loop Feedback Address................................................................................................................125
Ixx83: Commutation Feedback Address ..............................................................................................................126
Ixx91: Motor xx Power-On Phase Position Format .............................................................................................126
Ixx95: Motor xx Power-On Servo Position Format .............................................................................................129
Ixx97 Motor xx Position Capture and Trigger Mode ...........................................................................................131
GEO MACRO DRIVE MI-VARIABLE REFERENCE......................................................................................133
Global MI-Variables .............................................................................................................................................133
MS{node},MI0 Geo MACRO drive Firmware Version (Read Only)............................................................133
MS{node},MI1 Geo MACRO drive Firmware Date (Read Only) ................................................................133
MS{node},MI2 and MI3 (Reserved for future use).......................................................................................133
MS{node},MI4 Geo MACRO drive Status Word (Read Only) ......................................................................134
MS{node},MI5 Ring Error Counter .............................................................................................................134
MS{node},MI6 Status Word Control............................................................................................................135
MS{node},MI7 Geo MACRO Error Counter ...............................................................................................135
MS{node},MI8 Geo MACRO Ring Check Period ........................................................................................135
MS{node},MI9 Geo MACRO Ring Error Shutdown Count..........................................................................135
MS{node},MI10 Geo MACRO Sync Packet Shutdown Count......................................................................136
MS{node},MI11 Station Order Number.......................................................................................................136
MS{node},MI12 Card Identification (Read Only)........................................................................................137
MS{node},MI13 Ring Break Output indicator .............................................................................................137
MS{node},MI100 Motor Activation Control word .......................................................................................138
MS{node},MI101-102 Primary Feedback Selection .....................................................................................138
MS{node},MI103 Sin Encoder/ Resolver #1 bias..........................................................................................139
MS{node},MI104 Sin Encoder/ Resolver #2 bias..........................................................................................139
MS{node},MI105 Cosine Encoder/ Resolver #1 bias....................................................................................139
MS{node},MI106 Cosine Encoder/ Resolver #2 bias....................................................................................139
MS{node},MI107 Motor 1 Encoder-Loss Mask ............................................................................................140
MS{node},MI108 Motor 2 Encoder-Loss Mask ............................................................................................140
Primary Channel Node-Specific Gate Array MI-variables....................................................................................142
MS{node},MI910 Primary Encoder/Timer n Decode Control ......................................................................142
MS{node},MI911 Primary Enc. Position Compare n Channel Select ..........................................................143
MS{node},MI912 Primary Encoder n Capture Control................................................................................143
MS{node},MI913 Primary Encoder Capture n Flag Select Control.............................................................144
MS{node},MI914 Primary Encoder n Gated Index Select ............................................................................144
MS{node},MI915 Primary Encoder Index Gate State/Demux Control.........................................................145
MS{node},MI910 Secondary Encoder Decode Control ................................................................................146
MS{node},MI911 Secondary Encoder counter Direction .............................................................................146
MS{node},MI912 Secondary Encoder Index Capture Control ....................................................................147
MS{node},MI913 Secondary Encoder Home Flag Capture Control ...........................................................147
MS{node},MI914 Secondary Encoder Filter Control ...................................................................................147
MS{node},MI915 Secondary Encoder Capture Flag Select Control ............................................................148

Geo MACRO Drive User and Reference Manual
Table of Contents v
MS{node},MI916 Output n Mode Select .......................................................................................................148
MS{node},MI917 Output n Invert Control....................................................................................................148
MS{node},MI918 Output n PFM Direction Signal Invert Control ...............................................................149
MS{node},MI919 Hardware 1/T ...................................................................................................................149
MS{node},MI921 Flag Capture Position (Read Only)..................................................................................150
MS{node},MI922 ADC A Input Value (Read Only) ......................................................................................150
MS{node},MI923 Compare Auto-Increment Value.......................................................................................150
MS{node},MI924 ADC B Input Value (Read Only) ......................................................................................150
MS{node},MI925 Compare A Position Value ...............................................................................................151
MS{node},MI926 Compare B Position Value ...............................................................................................151
MS{node},MI927 (Reserved for future use)......................................................................................................151
MS{node},MI928 Compare-State Write Enable............................................................................................151
MS{node},MI929 Compare-Output Initial State...........................................................................................151
General Hardware Setup MI-variables..................................................................................................................152
MS{anynode}, MI930 SSI Channel 1 Control Word .....................................................................................152
MS{anynode}, MI931 SSI Channel 2 Control Word ....................................................................................152
MS{anynode}, MI932 Resolver Excitation Frequency Divider....................................................................153
MS{anynode}, MI933 SSI Clock Frequency Divider ...................................................................................153
MS{anynode},MI934-MI939 (Reserved for future use)................................................................................153
MS{anynode}, MI940 Resolver Excitation Gain.........................................................................................153
MS{anynode}, MI941 Resolver Excitation Phase Offset.............................................................................154
MS{anynode},MI942 ADC Strobe Word Channel 1* & 2* ..........................................................................154
MS{node},MI943 Encoder Power control bit ...............................................................................................154
MS{node},MI944-MI949 (Reserved for future use) .....................................................................................154
Global & 2-Axis Board I-Variables ......................................................................................................................155
MS{node},MI992 MaxPhase Frequency Control..........................................................................................155
MS{node},MI993 Hardware Clock Control Handwheel Channels...............................................................155
MS{node},MI994 PWM Deadtime ...............................................................................................................157
MS{node},MI995 MACRO Ring Configuration/Status .................................................................................157
MS{node},MI996 MACRO Node Activate Control .......................................................................................158
MS{node},MI997 Phase Clock Frequency Control ......................................................................................160
MS{node},MI998 Servo Clock Frequency Control .......................................................................................160
ABSOLUTE POWER ON ONLINE COMMANDS.............................................................................................161
$$*.........................................................................................................................................................................161
$*...........................................................................................................................................................................161
APPENDIX A...........................................................................................................................................................166
Fiber Optic Cable Ordering Information...............................................................................................................166
Mating Connector and Cable Kits .........................................................................................................................166
Mating Connector and Cable Kits ....................................................................................................................166
Connector and pins Part numbers ....................................................................................................................168
Cable Drawings ................................................................................................................................................170
Regenerative Resistor: GAR78/48 .......................................................................................................................176
Type of Cable for Encoder Wiring........................................................................................................................177
APPENDIX B...........................................................................................................................................................180
Schematics.............................................................................................................................................................180
X3: Discrete I/O...............................................................................................................................................180
X6 and X7: Analog Inputs................................................................................................................................182
X8 and X9 Secondary Encoders (3 and 4) ........................................................................................................183
APPENDIX C...........................................................................................................................................................184
Communication to the Geo MACRO via the USB Port ........................................................................................184
APPENDIX D...........................................................................................................................................................186
MACRO Flag Transfer Location...........................................................................................................................186
Turbo PMAC2 Node Addresses............................................................................................................................187

Geo MACRO Drive User Manual
vi Table of Contents
ADC Register Table ..............................................................................................................................................189
Stepping through an Electrical Cycle ....................................................................................................................190
Manually Stepping through an Electrical Cycle at 30 degree increments........................................................190
Example 1 of Hall Effect Values .......................................................................................................................191
Example 2 of Hall Effect Values .......................................................................................................................192
USEFUL NOTES.....................................................................................................................................................193

Geo MACRO Drive User and Reference Manual
Introduction 1
INTRODUCTION
The Geo Drive family of “bookcase”-style servo amplifiers provides many new capabilities for users.
This family of 1- and 2-axis 3-phase amplifiers, built around a common core of highly integrated IGBT-
based power circuitry, supports a wide variety of motors, power ranges, and interfaces. The 2-axis
configurations share common power input, bus, and shunt for a very economical implementation.
Three command interfaces are provided: direct-PWM, MACRO-ring, and integrated PMAC controller,
each described in following sections. In all three cases, fully digital “direct PWM” control is used. Direct
PWM control eliminates D-to-A and A-to-D conversion delays and noise, allowing higher gains for more
robust and responsive tuning without sacrificing stability.
All configurations provide these power-stage features:
• Direct operation off AC power mains (100 – 240 or 300 – 480 VAC, 50/60 Hz) or optional DC
power input (24 – 350 or 24 – 700 VDC)
• Integrated bus power supply including soft start and shunt regulator (external resistor required)
• Separate 24VDC input to power logic circuitry
• Complete protection: over voltage, under voltage, over temperature, PWM frequency limit,
minimum dead time, motor over temperature, short circuit, over current, input line monitor
• Ability to drive brushed and brushless permanent-magnet servo motors, or AC induction motors
• Single-digit LED display and six discrete LEDs for status information
• Optional safety relay circuitry. Please contact factory for more details and pricing.
• Easy setup with Turbo PMAC and UMAC controllers.
User Interface
The Geo Drive family is available in different versions distinguished by their user interface styles.
Geo MACRO Drives
The Geo MACRO Drive interfaces to the controller through the 125 Mbit/sec MACRO ring, with
either a fiber-optic or Ethernet electrical medium, accepting numerical command values for direct
PWM voltages and returning numerical feedback values for phase current, motor position, and status.
It accepts many types of position feedback to the master controller, as well as axis flags (limits, home,
and user) and general-purpose analog and digital I/O. Typically, the Geo MACRO Drives are
commanded by either a PMAC2 Ultralite bus-expansion board, or a UMAC rack-mounted controller
with a MACRO-interface card. This provides a highly distributed hardware solution, greatly
simplifying system wiring, while maintaining a highly centralized software solution, keeping system
programming simple.
• Choices for main feedback for each axis: A/B quadrature encoder, sinusoidal encoder with
EnDatTM or HiperfaceTM, SSI encoder, resolver
• Secondary A/B quadrature encoder for each axis
• General-purpose isolated digital I/O: 4 in, 4 out at 24VDC
• 2 optional A/D converters, 12- or 16-bit resolution
Note:
Geo MACRO is not using the regular 8-axis or 16-axis MACRO station CPU.
A new MACRO CPU was developed for the Geo MACRO drive.

Geo MACRO Drive User Manual
2 Introduction
Geo PMAC Drives
The Geo PMAC Drive is a standalone-capable integrated controller/amplifier with a built-in full
PMAC2 controller having stored-program capability. It can be operated standalone, or commanded
from a host computer through USB2.0 or 100 Mbps Ethernet ports. The controller has the full
software capabilities of a PMAC (see descriptions), with an internal fully-digital connection to the
advanced Geo power-stage , providing a convenient, compact, and cost-effective installation for one
and two-axis systems, with easy synchronization to other drives and controls.
• Choices for main feedback for each axis: A/B quadrature encoder, sinusoidal encoder with
EnDatTM or HiperfaceTM, SSI encoder, resolver
• Secondary A/B quadrature encoder for each axis
• General-purpose isolated digital I/O: 8 in, 6 out at 24VDC
• 2 optional A/D converters 12- or 16-bit resolution
Geo Direct-PWM Drives
The direct-PWM interface versions accept the actual power-transistor on/off signals from the PMAC2
controller, while providing digital phase-current feedback and drive status to the controller for closed-
loop operation. Interface to the direct-PWM amplifier is through a standard 36-pin Mini-D style
cable. The drive performs no control functions but has protection features. Drive installation,
maintenance, and replacement are simplified because there is less wiring (position feedback and I/O
are not connected to the drive) and there are no variables to set or programs to install in the drive.
• Fully centralized control means that all gains and settings are made in the PMAC; no software
setup of drive is required
• No position feedback or axis flags required at the drive
MACRO Defined
MACRO defined is a digital interface for connection of multi–axis motion controllers, amplifiers and
other I/O devices on a fiber optic or twisted pair copper (RJ45 connector) ring.
MACRO operates in a ring topology. Data is transmitted serially. Each station on the ring has an in port
for receiving data and an out port for transmitting data. Nodes, residing at a station can be amplifier axes,
I/O banks, or communication interfaces to other devices. A station can have one or several nodes
allowing for multi-axis amplifiers with a single in and single out port. Data packets, (groups of 96 bits of
serial data) from the motion controller or master node are addressed to a specific amplifier or slave node.
If the data packet is not for an amplifier, it is passed on unchanged. If it is for the node, it copies the
contents of the data packet (typically commands), places feedback data into a packet, and transmits the
data packet.
MACRO’s Advantages are:
• Single–plug connections between controls and amplifiers: A single fiber optic strand can provide a
controller with: position feedback, flag status (limits, home flag), amplifier status and machine input
status. This same strand can communicate to the amplifier and other devices on the MACRO network
(Amplifier enable and amplifier command signals, machine outputs, commands to D/A converters; all
can be implemented with a single plug connection).
• Noise Immunity: Fiber–optic cable transmits light, not electricity. Unlike electricity light is immune
to electromagnetic noise, capacitive coupling, ground loops, and other wiring problems.
• Speed: MACRO’s operation is 125 Mbits/second. This is at least 25 times faster than other digital
motion control interfaces.

Geo MACRO Drive User and Reference Manual
Introduction 3
• One ring, multiple masters: In a ring network, several motion controllers (masters) can be on one
ring. Each controller controls several axes (up to 32 ea.).
• Simplicity: Transmission within the MACRO ring requires no software intervention. The
information sent to all nodes is written to a memory location and the MACRO hardware takes care of
the rest.
Feedback Devices
Many motors incorporate a position feedback device. Devices are incremental encoders, resolvers, and
sine encoder systems. The macro version of the Geo drive accepts feedback. In its standard form, it is set
up to accept incremental encoder feedback. With the appropriate feedback option, it is possible to use
either resolver or sinusoidal encoder feedback. Historically, the choice of a feedback device has been
guided largely by cost and robustness. Today, feedbacks are relatively constant for the cost and picked by
features such as size and feedback data. More feedback data or resolution provides the opportunity to
have higher gains in a servo system.
Geo MACRO drives have standard secondary quadrature encoder feedback. One secondary encoder (X8)
for one axis drive and two secondary encoders (X8 and X9) for dual axis drives (603542 rev-10A and
above). Earlier versions of the Geo MACRO drive cannot use the secondary encoders.
Compatible Motors
The Geo drive product line is capable of interfacing to a wide variety of motors. The Geo drive can
control almost any type of three-phase brushless motor, including DC brushless rotary, AC brushless
rotary, induction, and brushless linear motors. Permanent magnet DC brush motors can also be controlled
using two of the amplifiers three phases. Motor selection for an application is a science in itself and
cannot be covered in this manual. However, some basic considerations and guidelines are offered. Motor
manufacturers include a host of parameters to describe their motor.
Some basic equations can help guide an applications engineer to mate a proper drive with a motor. A
typical application accelerates a load to a speed, running the speed for a while and then decelerating the
load back into position.
Maximum Speed
The motor’s maximum rated speed is given. This speed may or may not be achievable in a given system.
The speed could be achieved if enough voltage and enough current loop gain are available. Also consider
the motor’s feedback adding limitations to achievable speeds. The load attached to the motor also limits
the maximum achievable speed. In addition, some manufacturers will provide motor data with their drive
controller, which is tweaked to extend the operation range that other controllers may be able to provide.
In general, the maximum speed can be determined by input voltage line-to-line divided by Kb (the
motor’s back EMF constant). It is wise to de-rate this a little for proper servo applications.
Torque
The torque required for the application can be viewed as both instantaneous and average. Typically, the
instantaneous or peak torque is calculated as a sum of machining forces or frictional forces plus the forces
required to accelerate the load inertia. The machining or frictional forces on a machine must be
determined by the actual application. The energy required to accelerate the inertia follows the equation:
T = JA, where T is the torque in Newton-meters or pound-feet required for the acceleration, J is the inertia
in kilogram-meters-squared or pound-feet-second squared, and A is in radians per second per second.
The required torque can be calculated if the desired acceleration rate and the load inertia reflected back to
the motor are known. The T=JA equation requires that the motor’s inertia be considered as part of the
inertia-requiring torque to accelerate.
Once the torque is determined, the motors specification sheet can be reviewed for its torque constant
parameter (Kt). The torque required at the application divided by the Kt of the motor provides the peak
current required by the amplifier. A little extra room should be given to this parameter to allow for good

Geo MACRO Drive User Manual
4 Introduction
servo control.
Most applications have a duty cycle in which the acceleration profile occurs repetitively over time.
Calculating the average value of this profile gives the continuous rating required by the amplifier.
Applications also concern themselves with the ability to achieve a speed. The requirements can be
reviewed by either defining what the input voltage is to the drive, or defining what the voltage
requirements are at the motor. Typically, a system is designed at a 230 or 480V input line. The motor
must be able to achieve the desired speed with this voltage limitation. This can be determined by using
the voltage constant of the motor (Kb), usually specified in volts-per-thousand rpm. The application
speed is divided by 1000 and multiplied by the motor's Kb. This is the required voltage to drive the motor
to the desired velocity. Headroom of 20% is suggested to allow for good servo control.
Peak Torque
The peak torque rating of a motor is the maximum achievable output torque. It requires that the amplifier
driving it be able to output enough current to achieve this. Many drive systems offer a 3:1 peak-to-
continuous rating on the motor, while the amplifier has a 2:1 rating. To achieve the peak torque, the drive
must be sized to be able to deliver the current to the motor. The required current is often stated on the
datasheet as the peak current through the motor. In some sense, it can also be determined by dividing the
peak amplifier's output rating by the motor's torque constant (Kt).
Continuous Torque
The continuous torque rating of the motor is defined by a thermal limit. If more torque is consumed from
the motor than this on average, the motor overheats. Again, the continuous torque output of the motor is
subject to the drive amplifier’s ability to deliver that current. The current is determined by the
manufacturer’s datasheets stating the continuous RMS current rating of the motor and can also be
determined by using the motor’s Kt parameter, usually specified in torque output per amp of input current.
Motor Poles
Usually, the number of poles in the motor is not a concern to the actual application. However, it should
be noted that each pole-pair of the motor requires an electrical cycle. High-speed motors with high motor
pole counts can require high fundamental drive frequencies that a drive amplifier may or may not be able
to output. In general, drive manufacturers with PWM switching frequencies (16kHz or below) would like
to see commutation frequencies less than 400 Hz. The commutation frequency is directly related to the
number of poles in the motor.
Motor Inductance
PWM outputs require significant motor inductance to turn the on-off voltage signals into relatively
smooth current flow with small ripple. Typically, motor inductance of servomotors is 1 to 15 mH. The
Geo drive product series can drive this range easily. On lower-inductance motors (below 1mH), problems
occur due to PWM switching where large ripple currents flow through the motor, causing excessive
energy waste and heating. If an application requires a motor of less than 1mH, external inductors are
recommended to increase that inductance. Motors with inductance in excess of 15mH can still be driven,
but are slow to react and typically are out of the range of high performance servomotors.
Motor Resistance
Motor resistance is not really a factor in determining the drive performance, but rather, comes into play
more with the achievable torque or output horsepower from the motor. The basic resistance shows up in
the manufacturer's motor horsepower curve.
Motor Back EMF
The back EMF of the motor is the voltage that it generates as it rotates. This voltage subtracts from the
bus voltage of the drive and reduces the ability to push current through the motor. Typical back EMF

Geo MACRO Drive User and Reference Manual
Introduction 5
ratings for servomotors are in the area of 8 to 200 volts-per-thousand rpm. The Geo drive product series
can drive any range of back EMF motor, but the back EMF is highly related to the other parameters of the
motor such as the motor inductance and the motor Kt. It is the back EMF of the motor that limits the
maximum achievable speed and the maximum horsepower capability of the motor.
Motor Torque Constant
Motor torque constant is referred to as Kt and usually it is specified in torque-per-amp. It is this number
that is most important for motor sizing. When the load that the motor will see and knowing the motor’s
torque constant is known, the drive amplifier requirements can be calculated to effectively size a drive
amplifier for a given motor. Some motor designs allow Kt to be non-linear, in which Kt will actually
produce less torque per unit of current at higher output speeds. It is wise to de-rate the systems torque
producing capability by 20% to allow headroom for servo control.
Motor Inertia
Motor inertia comes into play with motor sizing because torque to accelerate the inertia of the motor is
effectively wasted energy. Low inertia motors allow for quicker acceleration. However, consider the
reflected inertia from the load back to the motor shaft when choosing the motor’s inertia. A high ratio of
load-to-motor inertia can limit the achievable gains in an application if there is compliance in the
transmission system such as belt-drive systems or rubber-based couplings to the systems. The closer the
rotor inertia matches the load’s reflected inertia to the motor shaft, the higher the achievable gains will be
for a given system. In general, the higher the motor inertia, the more stable the system will be inherently.
Mechanical gearing is often placed between the load and the motor simply to reduce the reflected inertia
back to the motor shaft.
Motor Cabling
Motor cables are an integral part of a motor drive system. Several factors should be considered when
selecting motor cables. First, the PWM frequency of the drive emits electrical noise. Motor cables must
have a good-quality shield around them. The motor frame must also have a separate conductor to bring
back to the drive amplifier to help quench current flows from the motor due to the PWM switching noise.
Both motor drain wire and the cable shield should be tied at both ends to the motor and to the drive
amplifier.
Another consideration in selecting motor cables is the conductor-to-conductor capacitance rating of the
cable. Small capacitance is desirable. Longer runs of motor cable can add motor capacitance loading to
the drive amplifier causing undesired spikes of current. It can also cause couplings of the PWM noise
into the earth grounds, causing excessive noise as well. Typical motor cable ratings would be 50 pf per
foot maximum cable capacitance.
Another factor in picking motor cables is the actual conductor cross-sectional area. This refers to the
conductors ability to carry the required current to and from the motor. When calculating the required
cable dimensions, consider agency requirements, safety requirements, maximum temperature that the
cable will be exposed to, the continuous current flow through the motor, and the peak current flow
through the motor. Typically, it is not suggested that any motor cable be less than 14 AWG.
The motor cable’s length must be considered as part of the application. Motor cable length affects the
system in two ways. First, additional length results in additional capacitive loading to the drive. The
drive’s capacitive loading should be kept to no more than 1000pf. Additionally, the length sets up
standing waves in the cable, which can cause excessive voltage at the motor terminals. Typical motor
cable length runs of up to 60 meters (200 feet) for 230V systems and 15 meters (50 feet) for 480V
systems are acceptable. Exceeding these lengths may put other system requirements in place for either a
snubber at the motor end or a series inductor at the drive end. The series inductor at the drive end
provides capacitance loading isolation from the drive and slows the rise time of the PWM signal into the
cable, resulting in less voltage overshoot at the motor.

Geo MACRO Drive User Manual
6 Introduction

Geo MACRO Drive User and Reference Manual
Specifications 7
SPECIFICATIONS
Part Number
Geo MACRO Drive
Model Number Definition
GL03 1 0
Continuous/Peak Current Rating
(Sinusoidal RMS )
01 = 1.5/4.5 Amp (one or 3
φ operation )
03 = 3/9 Amp (one or 3
φ operation )
05 = 5/10 Amp (3
φ input, for single φneed to derate 20%)
10 = 10/20 Amp (3
φ input*)
15 = 15/30 Amp (3
φ input*)
20 = 20/40 Amp (3
φ input*)
30 = 30/60 Amp (3
φ input*)
*For single phase input, need to derate 30%
Voltage Rating (Direct Mains )
L = 110 - 240 VAC
H = 300 - 480 VAC
Number of Axes
1 = Single Axis
2 = Dual Axis
Note: Any available method can be used for
feedback but only one method can be used at
any time . Feedback method is selected by
wiring.
MACRO Link Options:
F = Fiber Optic
R = RJ/45 (Default)
RM
Feedback Options
0 = No options, Default; Standard feedback
per axis is quadrature differential
encoder with hall effect inputs or SSI
absolute encoder .
1 = Analog Feedback including :
• Option 0 Standard Feedback
• 4096x Sin/Cos interpolator
• Resolver Interface
2 = Absolute Feedback including :
• Option 1 Analog Feedback
• Endat™
• Hiperface™
3, 4, 5 = Same as Options 0, 1 and 2
described above but with two 16-bit
analog-to-digital converter inputs
Product Width According to Ratings
Single-Width Units : Double-Width Units:
1.5/4.5 Dual Axis 10/20 Dual Axis (480VAC)
3/9 Dual Axis 15/30 Dual Axis
5/10 Single and Dual Axis 20/40 Single Axis
10/20 Single Axis and Dual Axis (240VAC) 30/60 Single Axis
15/30 Single Axis
GMx012xx GMx051xx GMx101xx GMx151xx GMx032xx GMx052xx GML102xx GMx201xx GMx301xx GMH102xx GMx152xx
Single axis √√√√√
Dual Axis √√√√√√
Single Width √* √√√√√√
Size Axis
Double width √√√√
* Low Profile Unit, No heatsink, no Fan

Geo MACRO Drive User Manual
8 Specifications
Geo MACRO Feedback Options
Model Default Configuration:
Quadrature Encoders
Or SSI Absolute Encoders
And Hall Effect inputs
Analog (Sin/Cos) Encoders:
x4096 Interpolator
Resolver to Digital
Converters
Absolute Encoder
Interfaces:
EnDat
Hiperface
Addition of two
channels of 16-bit
A/D converters with
each feedback option
GMxxxxx0 √
GMxxxxx1 √
GMxxxxx2 √
GMxxxxx3 √√
GMxxxxx4 √√
GMxxxxx5 √√
Package Types
Geo package types provide various power levels and one or two axis capability with three different
package types.
The Geo Drive has a basic package size of 3.3"W x 11"H x 8.0"D(84mm W x 280mm H x 203mm D).
This size includes the heat sink and fan. In this package size, Single Width, the Geo can handle one or
two low-to-medium power axes or only a single axis for medium to high power.
The mechanical design of the Geo drive is such that it allows two heat sinks to be easily attached together
to provide two high power axes in a double width configuration. This double package size is 6.5" W x
11" H x 8.0" D (165 mm W x 280 mm H x 203 mm D). It provides a highly efficient package size
containing two axes of up to about 10kW each thus driving nearly 24kW of power, but using a single
interface card. This results in a highly cost effective package.
There is also one more package type only for the low power (1.5A/4.5A) single width Geo drive, model
Gxx012xx. This package substitutes the heatsink and the fan with a smaller plate which has the same
mounting pattern as the regular single width drive, making the units depth 2.2inches (56mm) less than the
single width drive, 5.8" D (148mm D).
• Low Profile: GMx012xx (only)
3.3" wide (84 mm) (no heatsink, no fan), Maximum Power Handling ~1200 watts
Package Dimensions: 3.3" W x 11" H x 5.8" D (84 mm W x 280 mm H x 148 mm D)
Weight: 4.3 lbs. (1.95kgs)
• Single Width: GMx051xx, GMx101xx, GMx151xx, GMH032xx, GMx052xx and GML102xx.
3.3" wide (84 mm)(with heatsink and fan), Maximum Power Handling ~12000 watts
GML032xx Single Width, with heatsink, no Fan (Weight 5.4lbs/2.45kgs)
Package Dimensions: 3.3" W x 11" H x 8.0" D (84 mm W x 280 mm H x 203 mm D)
Weight: 5.5 lbs. (2.50kgs)
• Double Width: GMx201xx, GMx301xx, GMH102xx and GMx152xx.
6.5” wide (164mm)(with heatsink and fan), Maximum Power Handling ~24,000 watts
Package Dimensions: 6.5" W x 11" H x 8.0" D (164 mm W x 280 mm H x 203 mm D)
Weight: 11.6lbs (5.3kgs)