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3. Key Technical Specifications
| Parameter | Value |
|---|---|
| Part Number | 602804-109 (4Ax-602804-xHxx family) |
| Manufacturer | Delta Tau Data Systems (now Omron) |
| Form Factor | 3U Eurocard (100 mm × 160 mm) |
| Processor | 80 MHz DSP56303 |
| Memory | 512 k × 8 flash (firmware + user backup) |
| Power Requirement | 1.5 A @ +5 V (±5 %) ≈ 7.5 W (typical 8-channel load) |
| MACRO Interface Options | Fiber (Opt A, SC transceiver) or Copper (Opt C, RJ-45) |
| Communication Ports | RS-232 serial, JTHW multiplexed I/O, UBUS backplane |
| Stack / Backplane | Piggyback stack connectors + UBUS for axis/I/O boards |
| Operating Temperature | 0 °C to 60 °C (32 °F to 140 °F) |
| Storage Temperature | −12 °C to 82 °C |
| Humidity | 10 % to 95 % non-condensing |
| Weight | ≈ 0.5 lb (≈ 227 g) |
| Dimensions | ≈ 16 cm × 10 cm × 3.6 cm |
4. Product Introduction
The Delta Tau 602804-109 is a 3U MACRO-CPU board that serves as the processor and MACRO ring interface for UMAC MACRO and MACRO Stack remote stations. It connects to a PMAC2 Ultralite or Turbo PMAC2 master over the MACRO fiber or copper ring and provides local interfaces for encoders, flags, digital/analog drives, and I/O boards.
This board is the core of distributed motion systems where axes and I/O must sit up to several kilometers from the main controller. Engineers use it when a compact, deterministic remote station is required without placing a full Turbo PMAC2 at every machine location. The 602804-109 belongs to the later revision family of the 602804 series and is now obsolete; verified new-surplus units remain the practical replacement path for existing UMAC MACRO installations.
602804-109
5. Troubleshooting Quick Reference
| Symptom | Possible Cause | Relevance to this Part | Quick Check Method | Recommendation |
|---|---|---|---|---|
| Station not recognized on MACRO ring | Wrong master number or ring break | ✅ High | Verify SW2 setting matches PMAC I996 / I6840 master number; check fiber/RJ-45 link LEDs | Match SW2 to master IC number; reseat fiber or copper connectors |
| No response / watchdog timeout | Watchdog disabled or firmware fault | ✅ High | Confirm E1 is OFF (watchdog enabled); observe character display | Enable watchdog; power-cycle and re-initialize if needed |
| Axes not responding or wrong node | SW1 node configuration mismatch | ✅ High | Record SW1 setting; compare to expected servo nodes and base addresses | Set SW1 to correct node count/address per system map |
| Serial port inaccessible | Baud-rate jumper or bootstrap mode | ✅ Medium | Check E2 (must be pins 2-3 for normal mode) and E3 | Return E2 to normal mode; verify baud rate |
| Power-related faults or resets | +5 V supply out of tolerance or missing ±15 V | ✅ High | Measure +5 V, +15 V, −15 V at TB1 under load | Correct power supply; leave 20 % current margin |
| Intermittent MACRO errors | Fiber contamination or copper EQ setting | ✅ Medium | Clean SC fiber ends; verify E40 and EQ jumpers | Clean optics; confirm input select (fiber vs copper) |
If the station still fails after these checks, capture the character display codes, SW1/SW2 settings, jumper positions, and clear photos of the board and ring connections before contacting support.
6. Frequently Asked Questions (FAQ)
Q: Is the 602804-109 still manufactured by Delta Tau / Omron?
No. This is an obsolete part. Available units are new surplus or carefully tested inventory. Quantities are limited.
Q: What is the difference between the 300-602804 and 3R0-602804 versions?
300-602804 has no front plate (preferred for stack assemblies). 3R0-602804 includes a front plate for UMAC rack mounting. Functionally they are the same board family; the -109 is a specific revision within that family.
Q: Can this board talk to a Turbo PMAC2 or only non-Turbo PMAC2?
It works with both. Match the SW2 master-number setting to the appropriate I-variable on the master (I996 for non-Turbo, I6840 / I6890 / etc. for Turbo).
Q: Do I need Option A (fiber) or Option C (copper)?
One of the two MACRO interface options must be present. Many boards carry both. Set jumper E40 to select which input is active. Fiber supports longer distances (up to ~3 km); copper is limited to ~100 m.
Q: Will my existing axis and I/O accessory boards still work?
Yes, provided the UBUS addressing and SW1 settings are correct. Note that older accessory boards may have address limitations relative to later high-speed cards when used with certain 602804 revisions. Verify the hardware address map before installation.
Q: Why is a new-surplus unit priced lower than original list?
The part is discontinued. Genuine new-surplus stock is original Delta Tau product that has never been installed in a machine, but it no longer carries a factory warranty. Reputable suppliers test the boards and provide their own warranty (typically 12 months).
Q: What should I document before removing the old board?
Photograph SW1 and SW2 switch positions, all jumper settings (especially E1, E2, E40), the character display, and the physical orientation in the rack or stack. Note the exact firmware revision if available. This prevents the majority of post-swap configuration errors.
