Axis 24E2 User Manual

1^ USER MANUAL
^2 Accessory 24E2
^3 Axis Expansion Board
^4 3Ax-603397-xUxx
^5 October 10, 2003
21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.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. 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 24E2
Table of Contents
INTRODUCTION.......................................................................................................................................................1
Overview...................................................................................................................................................................1
Features.....................................................................................................................................................................1
Board Configuration..................................................................................................................................................1
ACC-24E2 Power Supply Requirements ..................................................................................................................2
E-POINT JUMPER SETTINGS................................................................................................................................ 3
ACC-24E2 Base Board (Channels* 1 & 2)...............................................................................................................3
ACC-24E2 Option 1 Board (Channels 3 & 4)...........................................................................................................4
HARDWARE SETUP.................................................................................................................................................5
Position Compare Port Driver IC..............................................................................................................................5
Switch Configuration ................................................................................................................................................5
UMAC Address DIP Switch S1.............................................................................................................................5
MACRO Station Address DIP Switch S1..............................................................................................................5
ACC-24E2 Clock Settings.........................................................................................................................................6
Resistor Pack Configuration......................................................................................................................................6
Differential or Single-Ended Encoder Selection...................................................................................................6
Termination Resistors...........................................................................................................................................7
ACC-24E2 Limit and Flag Wiring............................................................................................................................7
Connecting Limits/Flags to the ACC-24E2..........................................................................................................8
Loss of Encoder Circuit.............................................................................................................................................8
ACC-24E2 Encoder Loss Detection with UMAC Turbo CPU..............................................................................8
ACC-24E2 Encoder Loss Detection with UMAC MACRO CPU..........................................................................9
CONNECTIONS.......................................................................................................................................................11
Mating Connectors..................................................................................................................................................12
Terminal Block Connectors................................................................................................................................12
DB15 Connector Option.....................................................................................................................................12
Indicators.................................................................................................................................................................12
Overall Wiring Diagram..........................................................................................................................................13
Sample Wiring Diagrams........................................................................................................................................14
TTL Level Inputs and Outputs ............................................................................................................................14
Position Limits, Home Flag, and User Flag.......................................................................................................15
ACC-24E2 Stepper Motor Outputs (TTL level)..................................................................................................15
Servo IC Configuration I-Variables ........................................................................................................................16
Servo IC Numbering...........................................................................................................................................16
Servo Channel Numbering..................................................................................................................................16
Multi-Channel I-Variables..................................................................................................................................16
Single-Channel I-Variables ................................................................................................................................17
Encoder Conversion Table I-Variables..............................................................................................................18
Motor Addressing I-Variables............................................................................................................................18
ULTRALITE/MACRO STATION SETUP............................................................................................................21
Hardware Setup for MACRO Station Use ..............................................................................................................21
Node-Specific Gate Array MI-Variables.............................................................................................................21
Encoder/Timer n Decode Control (MSn,MI910) ....................................................................................................21
Flag Capture Control (MSn,MI911-MI913)............................................................................................................22
Output Mode Select (MSn,MI916)..........................................................................................................................24
MACRO Station Encoder Conversion Table (MSn,MI120-MI151).......................................................................24
Encoder Conversion Table for ACC-24E2 at MACRO Station ..........................................................................24
MLDT FEEDBACK FOR UMAC-TURBO & UMAC-MACRO.........................................................................25
MLDT Hardware Setup of the ACC-24E2..............................................................................................................25
MLDT Software Setup of the UMAC Turbo..........................................................................................................25
Hardware Setup I-Variables for Servo IC m ......................................................................................................25
Table of Contents i
Accessory 24E2
Conversion Table Processing I-Variables..........................................................................................................26
Motor I-Variables...............................................................................................................................................26
Pulse Output Frequency.....................................................................................................................................27
PMAC2/Turbo PMAC2 Conversion Table & Motor I-variables........................................................................28
MLDT Feedback for UMAC-MACRO...................................................................................................................28
MLDT Software Setup of the UMAC MACRO....................................................................................................29
Station Hardware Setup I-Variables for Servo IC..............................................................................................29
Station Conversion Table Processing I-Variables..............................................................................................29
Station Motor Node I-Variables .........................................................................................................................30
Power-On Feedback Address for PMAC2 Ultralite...........................................................................................30
MACRO Parallel Absolute Position Setup..........................................................................................................31
CONNECTOR & TERMINAL DESCRIPTION ...................................................................................................33
Direct PWM Amplifier Connector..........................................................................................................................33
J1- PWM AMP1 ..................................................................................................................................................33
J2- PWM AMP2 ..................................................................................................................................................34
Terminal Block Option for Encoders and EQU......................................................................................................35
Connector TB1 Top – Encoder 1........................................................................................................................35
Connector TB2 Top – Encoder 2........................................................................................................................35
Connector TB3 Top – EQU Outputs...................................................................................................................35
DB15 Connector Option for Encoders and EQU....................................................................................................36
Connector J1 Top - Encoder 1 / EQU ................................................................................................................36
Connector J2 Top - Encoder 2 / EQU ................................................................................................................36
Flag and User Flag Terminal Block Inputs .............................................................................................................37
Connector TB1 Front- Limits 1 ..........................................................................................................................37
Connector TB2 Front- Limits 2 ..........................................................................................................................37
SCHEMATICS..........................................................................................................................................................39
ii Table of Contents
Accessory 24E2
INTRODUCTION
Overview
The ACC-24E2 Axis Expansion Board provides two or four channels of PMAC2-style direct PWM servo interface circuitry for UMAC and Ultralite/MACRO Station controllers. The ACC-24E2 is part of the UMAC family of expansion cards and these accessory cards are designed to plug into an industrial 3U rack system. The information from these accessories is passed directly to either the UMAC or MACRO Station CPU via the high speed UBUS expansion bus. Other axis or feedback interface UBUS accessories include the following:
ACC-14E
ACC-24E2
ACC-24E2A
ACC-24E2S
ACC-28E ACC-51E ACC-53E
Up to eight ACC-24E2x boards can be connected to one UMAC providing up to 32 additional channels of servo interface circuitry. Because each MACRO Station CPU can service only eight channels of servo data, only two ACC24E2x boards can be connected to the MACRO-Station. The new MACRO 16-Axis CPU can support four ACC-24E2x cards.
The ACC-24E2 board contains no processor; it has one highly integrated 4-channel PMAC2-style Servo IC with the buffering circuitry and connectors around them. The two-axis ACC-24E2 plugs into the backplane and uses one slot in the Rack. If two more axes are needed, ACC-24E2 Option 1 can be plugged into the ACC-24E2 connectors. The ACC-24E2 with its Option 1 card takes up a total of two slots.
Parallel Feedback Inputs (absolute enc. or interferometers) Digital Amplifier Breakout w/ TTL encoder inputs Analog Amplifier Breakout w/ TTL encoder inputs Stepper Amplifier Breakout w/ TTL encoder inputs 16-bit A/D Converter Inputs (up to four per card) 4096 times interpolator for 1Vpp sinusoidal encoders SSI encoder interface (up to 8 channels)
Features
The ACC-24E2 board can be used with any UMAC or MACRO Station CPU, interfacing through the UBUS.
The ACC-24E2 supports both Direct PWM servo and PFM stepper interfaces:
Direct digital pulse-width modulated (PWM) phase voltage commands
Pulse-and-direction commands
Board Configuration
An ACC-24E2 comes standard with one Servo IC providing four servo interface channels, which are brought out on terminal blocks and mini D-Sub connectors. Two of these channels are brought out on the single-board base configuration.
Each channel of servo interface circuitry includes the following:
Two output command signal sets, configurable as either:
One pulse-and-direction
Three PWM top-and-bottom pairs
AB-Quadrature and Index pulse differential/single-ended encoder input
Nine input flags, two output flags
Interface to two external serial ADCs, 8 to 18 bits, for current loop feedback
Introduction 1
Accessory 24E2
Option 1D: If Option 1D Piggyback Board is ordered, the circuitry and input/output connectors are provided for the third and fourth channels associated with the Servo IC on the main ACC-24E2.
ACC-24E2 Power Supply Requirements
The following table lists the power requirements for the entire ACC-24E2 family of products for the UMAC-Turbo and UMAC-MACRO. Because of the flexibility of these products, the power requirements for all ACC-24E products are listed.
Product 5V 12V for DACs -12V for DACs 12V-24V for Flag Circuits
ACC-24E2 700mA N/A N/A ACC-24E2 opt. 1 200mA N/A N/A ACC-24E2A 800mA 200mA 200mA ACC-24E2 opt. 1A 200mA 200mA 200mA ACC-24E2S 600mA N/A N/A
2 Introduction
Accessory 24E2
E-POINT JUMPER SETTINGS
ACC-24E2 Base Board (Channels* 1 & 2)
Jumper Configuration Description Default
E1A 1-2 No Jumper for TTL Level input for CHU1 flag
Jumper 1-2 for DIR1+ output in Stepper Mode
E1B 1-2 No Jumper for TTL Level input for CHV1 flag
Jumper 1-2 for DIR1- output in Stepper Mode
E1C 1-2 No Jumper for TTL Level input for CHW1 flag
Jumper 1-2 for PUL1+ output in Stepper Mode
E1D 1-2 No Jumper for TTL Level input for CHT1 flag
Jumper 1-2 for PUL1- output in Stepper Mode
E2A 1-2 No Jumper for TTL Level input for CHU2 flag
Jumper 1-2 for DIR2+ output in Stepper Mode
E2B 1-2 No Jumper for TTL Level input for CHV2 flag
Jumper 1-2 for DIR2- output in Stepper Mode
E2C 1-2 No Jumper for TTL Level input for CHW2 flag
Jumper 1-2 for PUL2+ output in Stepper Mode
E2D 1-2 No Jumper for TTL Level input for CHT2 flag
Jumper 1-2 for PUL2- output in Stepper Mode
E5 1-2-3 Jump 1-2 for Turbo 3U CPU and MACRO C P U
E7 1-2 No jumper to not tie D-shell to chassis ground
E8 1-2 No jumper to not tie D-shell to chassis ground
E10 1-2-3 Jump 1-2 for high true fault AMP1
E11 1-2-3 Jump 1-2 for high true fault AMP2
E13 1-2-3 Jump 1-2 to receive phase and servo clocks
E111 1-2 No jumper for direct PWM mode axis 1
E112 1-2 No jumper for direct PWM mode axis 2
* The channels refer to the Servo IC associated with the ACC-24E2 base board. For example, an 8-axis
application would have two ACC-24E2s wi t h opt ion 1. The first ACC-24E2 would have axes 1-4 and the second ACC-24E2 would contain axes 5-8.
** For legacy MACRO Stations (part number 602804-100 thru 602804-104)
** Jump 2-3 for legacy MACRO CPU (before 6/00)
Jump 1-2 to tie J1 D-Shell to chassis ground
Jump 1-2 to ground J2 D-Shell to Chassis Ground
Jump 2-3 for low true fault AMP1
Jump 2-3 for low true fault AMP2
Jump 2-3 to transmit phase and servo clocks
Jump 1-2 for pulse and direction mode axis 1
Jump 1-2 for pulse and direction mode axis 2
No jumper
No jumper
No jumper
No jumper
No jumper
No jumper
No jumper
No jumper
Jump 1-2
No Jumper
No Jumper
Jump 2-3
Jump 2-3
Factory set
No jumper
No jumper
E-Point Jumper Settings 3
Accessory 24E2
ACC-24E2 Option 1 Board (Channels 3 & 4)
Jumper Configuration Description Default
E1A 1-2 No Jumper for TTL Level input for CHU3 flag
Jumper 1-2 for DIR3+ output in Stepper Mode
E1B 1-2 No Jumper for TTL Level input for CHV3 flag
Jumper 1-2 for DIR3- output in Stepper Mode
E1C 1-2 No Jumper for TTL Level input for CHW3 flag
Jumper 1-2 for PUL3+ output in Stepper Mode
E1D 1-2 No Jumper for TTL Level input for CHT3 flag
Jumper 1-2 for PUL3- output in Stepper Mode
E2A 1-2 No Jumper for TTL Level input for CHU4 flag
Jumper 1-2 for DIR4+ output in Stepper Mode
E2B 1-2 No Jumper for TTL Level input for CHV4 flag
Jumper 1-2 for DIR4- output in Stepper Mode
E2C 1-2 No Jumper for TTL Level input for CHW4 flag
Jumper 1-2 for PUL4+ output in Stepper Mode
E2D 1-2 No Jumper for TTL Level input for CHT4 flag
Jumper 1-2 for PUL4- output in Stepper Mode
E7 1-2 No jumper to not tie D-shell to chassis ground
Jump 1-2 to tie J1 D-Shell to chassis ground
E8 1-2 No jumper to not tie D-shell to chassis ground
Jump 1-2 to ground J2 D-Shell to Chassis Ground
E10 1-2-3 Jump 1-2 for high true fault AMP3
Jump 2-3 for low true fault AMP3
E11 1-2-3 Jump 1-2 for high true fault AMP4
Jump 2-3 for low true fault AMP4
E111 1-2 No jumper for direct PWM mode axis 3
Jump 1-2 for pulse and direction mode axis 3
E112 1-2 No jumper for direct PWM mode axis 4
Jump 1-2 for pulse and direction mode axis 4
No jumper
No jumper
No jumper
No jumper
No jumper
No jumper
No jumper
No jumper
No Jumper
No Jumper
Jump 2-3
Jump 2-3
No jumper
No jumper
4 E-Point Jumper Settings
Accessory 24E2
HARDWARE SETUP
Position Compare Port Driver IC
As with the other PMAC controllers, the UMAC has the high speed compare outputs which allows firing an output based on position. This circuit will fire within 100 nsec of reaching the desired position. The position compare output port on the ACC-24E2 and its Option 1 daughter card has a socketed driver IC in a 8-pin DIP socket at component U27. This IC gives a fast CMOS driver.
The following table lists the properties of each driver IC:
Part # of
Pins
DS75451N 8 5V, 10 mA Totem-Pole
Max Voltage &
Current
Output Type Max
Frequency
5 MHz 1-2
(CMOS)
E11, E12
Setting
Switch Configuration
UMAC Address DIP Switch S1
S1, S1-3, S1-4 are used to address the ACC-24E2 as shown in the table below.
S1-1 S1-3 S1-4 Board No. IC No. I-Var. Range Base Address
ON ON ON 1 2 I7200 $078200
OFF ON ON 2 3 I7300 $078300
ON OFF ON 3 4 I7400 $079200
OFF OFF ON 4 5 I7500 $079300
ON ON OFF 5 6 I7600 $07A200
OFF ON OFF 6 7 I7700 $07A300
ON OFF OFF 7 8 I7800 $07B200
OFF OFF OFF 8 9 I7900 $07B300
S1-2, S1-5, and S1-6 are used to determine whether the ACC-24E2 is communicating to a Turbo 3U PMAC or a MACRO Station CPU.
S1-2 S1-5 S1-6 Function
ON ON ON 3U Turbo PMAC Use
MACRO Station Address DIP Switch S1
S1-1, S1-2, S1-3, S1-4 are used to address the ACC-24E2 as shown in the table below.
S1-1 S1-2* S1-3 S1-4 Board No. IC No. Base Address
ON ON OFF OFF 1 2 $00C040
OFF OFF OFF OFF 2 3 $00C060
* Always set to OFF for legacy MACRO Stations (part number 602804-100 through 602804-104)
S1-5 and S1-6 are used to determine whether the ACC-24E2 is communicating to a Turbo 3U PMAC or a MACRO Station CPU.
S1-5 S1-6 Function
OFF OFF 3U MACRO Station use
Hardware Setup 5
Accessory 24E2
ACC-24E2 Clock Settings
The Phase Clock and Servo Clock must be configured on each ACC-24E2x base board. Each system can have only one source for the servo and phase clocks and jumpers must be set appropriately to avoid a timing conflict or a watchdog condition.
Starting in UMAC-Turbo firmware version 1.937, the firmware will set the clock settings automatically for the ACC-24E2 cards in the UBUS. To enable this feature, set jumper E13 from 2 to 3 for all of the ACC-24E2s plugged into the UMAC. At re-initialization (either $$$*** command or power up with E3 jumpered on UMAC), the firmware will know that all of the cards are in the auto configuration setup and will assign the card with the lowest base address setting (usually $78200) the task of sourcing the clocks by setting variable I19 to the appropriate register. The clocks will be set initially to the factory default servo update cycle and phase clock cycle. For a better understanding of this feature, refer to description of I19 in the Turbo Software Reference Manual.
For UMAC Turbo systems with firmware older than version 1.937, set one of the ACC-24E2s to transmit (E13 set 2-3) the phase and servo clock (usually the card at the lowest base address setting) and the rest of the ACC-24E2s to receive (E13 set 1-2) the phase and servo clocks.
For MACRO systems, the clock select jumper should be set to receive servo and phase clocks. For the ACC-24E2, E13 should be set 1-2.
Resistor Pack Configuration
Differential or Single-Ended Encoder Selection
The differential input signal pairs to the PMAC have user-configurable pull-up/pull-down resistor networks to permit the acceptance of either single-ended or differential signals in one setting, or the detection of lost differential signals in another setting.
The ‘+’ inputs of each differential pair each have a hard-wired 1 k pull-up resistor to +5V. This cannot be changed.
The ‘-’ inputs of each differential pair each have a hard-wired 2.2 k resistor to +5V; also each has another 2.2 k resistor as part of a socketed resistor pack that can be configured as a pull-up resistor to +5V, or a pull-down resistor to GND.
If this socketed resistor is configured as a pull-down resistor (the default configuration), the combination of pull-up and pull-down resistors on this line acts as a voltage divider, holding the line at +2.5V in the absence of an external signal. This configuration is required for single-ended inputs using the ‘+’ lines alone; it is desirable for unconnected inputs to prevent the pick-up of spurious noise; it is permissible for differential line-driver inputs.
If this socketed resistor is configured as a pull-up resistor (by reversing the SIP pack in the socket), the two parallel 2.2 k resistors act as a single 1.1 k pull-up resistor, holding the line at +5V in the absence of an external signal. This configuration is required if encoder-loss detection is desired; it is required if complementary open-collector drivers are used; it is permissible for differential line-driver inputs even without encoder loss detection.
If Pin 1 of the resistor pack (marked by a dot on the pack) matches Pin 1 of the socket (marked by a wide white square solder pin on the front side of the board), then the pack is configured as a bank of pull-down resistors. If the pack is reversed in the socket, it is configured as a bank of pull-up resistors.
The following table lists the pull-up/pull-down resistor pack for each input device:
6 Hardware Setup
Device Resistor Pack Pack Size
Encoder 1 RP22 6-pin
Accessory 24E2
Encoder 2 RP24 6-pin Encoder 3 RP22 6-pin Encoder 4 RP24 6-pin
Termination Resistors
The ACC-24E2A provides sockets for termination resistors on differential input pairs coming into the board. As shipped, there are no resistor packs in these sockets. If these signals are brought long distances into the ACC-24E2A board and ringing at signal transitions is a problem, SIP resistor packs may be mounted in these sockets to reduce or eliminate the ringing.
All termination resistor packs have independent resistors (no common connection) with each resistor using two adjacent pins.
Channel Specific Resistor Packs
Channel 1 Channel 2 SIP Description
RP22 RP24 2.2KΩ Reverse resistor pack for encoder loss feature (for differential
encoders only) RP23 RP25 RP45 RP46
220
1K
UBUS Specific Resistor Packs
Termination resistor to reduce ringing (not installed by default).
Install for 5V limits
Resistor Pack SIP Description
RP5 RP6
220
2.2K
Terminator (not installed, only used for non-UBUS) Pull Down for Old MACRO CPU
Pull Up for UMAC Turbo & MACRO
ACC-24E2 Limit and Flag Wiring
The ACC-24E2 allows the use of sinking or sourcing position limits and flags to the controller. The opto­isolator IC used is a PS2705-4NEC-ND quad photo-transistor output type. This IC allows the current to flow from return to flag (sinking) or from flag to return (sourcing).
A sample of the positive limit circuit is shown below. The 4.7K resistor packs used will allow 12-24V flag inputs. If 0-5V flags are used, then a 1K resistor pack (RP) can be placed in either RP45 or RP46 (refer to the Resistor Pack Configuration section of this manual). If these resistor packs are not added, all flags (±Limits, Home, User, and amplifier fault) will be referenced from 0-5V.
Hardware Setup 7
Accessory 24E2
Connecting Limits/Flags to the ACC-24E2
The following diagram illustrates the sinking and sourcing connections to an ACC-24E2. this example uses 12-24V flags.
Sinking,
Separate
Supply
Sourcing,
Separate
Supply
Loss of Encoder Circuit
The encoder-loss detection circuitry works for differential incremental encoders only. In proper operation, the digital states of the complementary inputs for a channel (e.g. A and A/) should always be opposite: when one is high, the other is low. If for some reason, such as a cable connection coming undone, one or more of the signal lines is no longer driven, pull-up resistors on the input line pull and hold the signal high.
The encoder-loss detection circuitry uses exclusive-or (XOR) gates on each complementary pair to detect whether the signals are in the same or opposite states. These results are combined to produce a single encoder-loss status bit that the processor can read.
This technique requires that both signal lines of the pair have pull-up resistors. Note that this is not the default configuration of a PMAC as it is shipped. The complementary lines (A/ and B/) are pulled to
2.5V in a voltage-divider configuration as shipped to be able to accept both single-ended and normal differential inputs. This must be changed to a pull-up configuration which involves reversing a socketed resistor pack on the ACC-24E2A.
ACC-24E2 Encoder Loss Detection with UMAC Turbo CPU
Channel Resistor
Pack
1 RP22 Y:$07xF08,5 Y:$07xF0C,5 QL_1- 0 2 RP24 Y:$07xF09,5 Y:$07xF0D,5 QL_2- 0 3 RP22** Y:$07xF0A,5 Y:$07xF0E,5 QL_3- 0
4 RP24** Y:$07xF0B,5 Y:$07xF0F,5 QL_4- 0 *The x digit in this hex address matches the value (8, 9, A, or B) in the fourth digit from the right in the board’s own base address (e.g. $079200). If alternate addressing of Servo ICs is used (e.g. Servo IC 2*), add $20 to these addresses. **These resistor packs are on the Option 1A piggyback board (if present) of the module, not on the baseboard.
Status Bit Address
(Even-Numbered
Servo IC)*
Status Bit Address
(Odd-Numbered
Servo IC)*
Status Bit
Name
Bit Error
State
8 Hardware Setup
Accessory 24E2
ACC-24E2 Encoder Loss Detection with UMAC MACRO CPU
Channel Resistor
Pack
Status Bit
Address (First-
Status Bit Address
(Second Servo IC)*
Status Bit
“Name”
Servo IC)*
1 RP22 Y:$B8C8,5 Y:$B8CC,5 QL_1- 0 2 RP24 Y:$B8C9,5 Y:$B8CD,5 QL_2- 0 3 RP22** Y:$B8CA,5 Y:$B8CE,5 QL_3- 0
4 RP24** Y:$B8CB,5 Y:$B8CF,5 QL_4- 0 *First Servo IC has base address $C040; second Servo IC has base address $C060 **These resistor packs are on the Option 1A piggyback board (if present) of the module, not on the base board.
Bit Error
State
Hardware Setup 9
Accessory 24E2
10 Hardware Setup
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