Delta Tau 4AX-603625-XUXX User Manual

^1 HARDWARE REFERENCE MANUAL

^2 UMAC-CPCI

Turbo CPU Board

^3 Turbo CPU Board

^4 4Ax-603625-xUxx

^5 January 28, 2003

Single Source Machine Control Power // Flexibility // Ease of Use

21314 Lassen Street Chatsworth, CA 91311 // Tel. [phone] Fax. [phone] // 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: [phone]
Fax: [phone]
Email: [e-mail]
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 exposed to hazardous or conductive materials and/or
environments, we cannot guarantee their operation.

UMAC-CPCI Turbo CPU Board Hardware Reference Manual

Table of Contents

INTRODUCTION.......................................................................................................................................................1

Associated Manuals...................................................................................................................................................2

BOARD CONFIGURATION.....................................................................................................................................3

Option 1: Communications Interfaces.......................................................................................................................3

Option 2: Dual-Ported RAM.....................................................................................................................................3

Option 5: CPU and Memory Configurations.............................................................................................................3

Option 8: High-Accuracy Clock Crystal...................................................................................................................4

Option 9: Serial Port Configuration ..........................................................................................................................4

Option 10: Firmware Revision Specification............................................................................................................4

Option 16: Battery-Backed Parameter Memory........................................................................................................4

HARDWARE SETUP.................................................................................................................................................5

Clock-Source Jumpers...............................................................................................................................................5

Watchdog Timer Jumper...........................................................................................................................................5

Operation Mode Jumpers..........................................................................................................................................5

Firmware Reload Jumper..........................................................................................................................................5

Re-Initialization Jumper............................................................................................................................................5

Serial-Port Level Select Jumpers...............................................................................................................................6

DPRAM IC Select Jumper........................................................................................................................................6

Flash IC Firmware Bank Select Jumpers..................................................................................................................6

Flash IC Power Supply Select Jumper......................................................................................................................6

Power-Supply Check Select Jumper .........................................................................................................................6

Reset-Lock Jumper....................................................................................................................................................6

CONNECTIONS.........................................................................................................................................................7

Compact UBUS Connector.......................................................................................................................................7

Rear Field Wiring Connector....................................................................................................................................7

Front-Panel RS-232 Connector.................................................................................................................................7

Stack Connectors to Bridge Board............................................................................................................................7

Factory-Use Connectors............................................................................................................................................8

BOARD LAYOUT.......................................................................................................................................................9

JUMPER DESCRIPTIONS......................................................................................................................................11

E0: Reset-Lock Enable (Factory Use Only)............................................................................................................11

E1A: Servo and Phase Clock Direction Control......................................................................................................11

E1B: Servo/Phase Clock Source Control................................................................................................................11

E2: (Reserved for Future Use).................................................................................................................................11

E3: Re-Initialization on Reset Control....................................................................................................................12

E4: (Reserved for Future Use).................................................................................................................................12

E5: USB/Ethernet Communication Jumper.............................................................................................................12

E11: Power Supply Check Control..........................................................................................................................12

E17 – E18: Serial Port Select..................................................................................................................................12

E18A, B, C, D: Ethernet Communication Control..................................................................................................13

E19: Watchdog Disable Jumper..............................................................................................................................13

E20 – E22: Power-Up/Reset Load Source ..............................................................................................................13

E23: Firmware Reload Enable.................................................................................................................................13

E25A, B, C: Flash Memory Firmware Bank Select................................................................................................13

W1: Flash IC Power Supply Select Jumper.............................................................................................................14

CONNECTOR SUMMARY.....................................................................................................................................15

CONNECTOR PINOUTS.........................................................................................................................................17

Compact UBUS Connector (J1) Pin-Out.................................................................................................................17

UMAC-CPCI Turbo CPU Board Hardware Reference Manual

UMAC-CPCI Turbo CPU Board J2 Connector ......................................................................................................18

J4: RS-232 Serial Port Connector...........................................................................................................................19

ACCESSORIES.........................................................................................................................................................21

ACC-Cx Compact UBUS Backplane Boards..........................................................................................................21

ACC-8CR Test Breakout Board..............................................................................................................................21

ACC-11C Sinking I/O Board..................................................................................................................................21

ACC-24C2 PWM Axis Board.................................................................................................................................22

ACC-24C2A Analog Axis Board............................................................................................................................ 22

ACC-51C Analog Encoder Interpolator Board.......................................................................................................22

SCHEMATICS..........................................................................................................................................................23

Table of Contents

ii

UMAC-CPCI Turbo CPU Board Hardware Reference Manual

INTRODUCTION

Delta Tau’s UMAC-CPCI systems provide a compact and clean integration of motion and I/O control for
sophisticated automation equipment. The system consists of a modular set of 3U-size (100mm x 160mm)
boards in the “Compact PCI” format, implementing Turbo PMAC software and hardware functions,
communicating with each other over a common backplane (the “Compact UBUS”). All field wiring is
available on rear connectors, suitable for a user-designed distribution system to the machine. UMAC
(Universal Motion and Automation Controller) -CPCI systems provide integrated connectivity as well as
ease of assembly, diagnostics, and repair. UMAC-CPCI systems differ from “standard” UMAC systems
in that all field wiring comes to the back of the rack, behind the backplane, instead of direct top and
bottom access.

The UMAC-CPCI Turbo CPU board (Part number 3A0-603625-10x) implements a Turbo PMAC2 CPU
in the 3U CPCI form factor. Its software operation is completely identical to other Turbo PMAC2
controllers.

Note that a Compact PCI interface does not automatically come with a UMAC-CPCI system, nor is one
necessary to communicate to the system, given the other possible communications ports: RS-232, RS­422, USB, and Ethernet.

This picture shows the UMAC-CPCI Turbo CPU
board. The connectors on the right side plug into the
“Compact UBUS” backplane board, with the bottom
right connector being the bus connector, and the top
right connector containing the external “field wiring”
signals, which typically pass through the backplane
board. The connector at lower left is an RS-232 port
intended for setup and diagnostics; the stack
connectors top and bottom provide the link to a CPCI
“bridge board”.

This picture shows a sample configuration of a
UMAC-CPCI system, not installed in its rack. It
consists of the following components:

1. Rack power supply (not a Delta Tau product)

2. UMAC-CPCI CPU board

3. ACC-11C Sinking I/O board

4. ACC-24C2A analog axis interface board

5. ACC-C8 8-slot Compact UBUS backplane.
Note the “pass-through” connector on the
back for field-wiring distribution. In this
picture, alternate slots in the backplane have
been left open to make each board more
visible. This does not have to be done in
actual use.

Introduction 1

UMAC-CPCI Turbo CPU Board Hardware Reference Manual

Associated Manuals

This document is the Hardware Reference Manual for the UMAC-CPCI Turbo CPU board for an UMAC­CPCI system. It describes the hardware features and provides setup instructions.

You will need other manuals as well to use your UMAC-CPCI system. Each accessory to the UMAC­CPCI Turbo CPU board has its own manual, describing its operation and any required software setup of
the Turbo CPU.

You will also need the Software Reference Manual for the Turbo PMAC family, and the User Guide for
the PMAC or Turbo PMAC families.

2 Introduction

UMAC-CPCI Turbo CPU Board Hardware Reference Manual

BOARD CONFIGURATION

The base version of the UMAC-CPCI Turbo CPU board provides a 1-slot 3U-format Eurocard board
with:

• 80 MHz DSP56303 CPU (120 MHz PMAC equivalent)

• 128k x 24 SRAM compiled/assembled program memory (Opt. 5C0)

• 128k x 24 SRAM user data memory (Opt. 5C0)

• 1M x 8 flash memory for user backup & firmware (Opt. 5C0)

• Latest released firmware version

• RS-232/422 serial interface, available both on front-panel DB-9 connector and on backside field-

wiring connector

• Backplane Compact UBUS expansion connector for communication to servo and I/O accessory

boards

• Backside field-wiring connector

Option 1: Communications Interfaces

The UMAC-CPCI Turbo CPU board comes standard only with an RS-232/422 serial interface. The
Option 1 family provides faster interfaces for high-speed communications – Universal Serial Bus (USB),
Ethernet, or the link to the CPCI bus through a “bridge” daughter board.

• Option 1: On-board 10-Base-T TCP/IP Ethernet interface. The key added components are U67 and

U32.

• Option 1A: On-board 12 Mbit/sec USB interface. The key added component is U67.

• Option 1B: Solder-side stack connectors to CPCI-bridge daughter board. This option should only be

ordered when the bridge board is to be installed on the left side of the CPU board, so the CPU board
is in the leftmost slot of the Compact UBUS backplane, and the bridge board is in the rightmost slot
of the Compact PCI bus backplane.

Option 2: Dual-Ported RAM

With either the Option 1 Ethernet interface, or the Option 1A USB interface, communications throughput
can be increased through the use of dual-ported RAM, which provides a bank of memory that can be
directly accessed by both the UMAC-CPCI Turbo CPU and the communications microcontroller.

• Option 2: 32k x 16 bank of on-board dual-ported RAM (requires Option 1 or 1A) in component U56.

Option 5: CPU and Memory Configurations

The various versions of Option 5 provide different CPU speeds and main memory sizes on the piggyback
CPU board. Only one Option 5xx may be selected for the board.

The CPU is a DSP563xx IC as component U1. It is currently available only as an 80 MHz or 100 MHz
device (with computational power equivalent to a 120 MHz or 150 MHz non-Turbo PMAC, respectively),
but higher speed versions may become available.

The compiled/assembled-program (“P”) memory SRAM ICs are located in U14, U15, and U16. These
ICs form the active memory for the firmware, compiled PLCs, and user-written phase/servo algorithms.
These can be 128k x 8 ICs (for a 128k x 24 bank), fitting in the smaller footprint, or they can be the larger
512k x 8 ICs (for a 512k x 24 bank), fitting in the full footprint.

The user-data memory (“X/Y”) SRAM ICs are located in U11, U12, and U13. These ICs form the active
memory for user motion programs, uncompiled PLC programs, and user tables and buffers. These can be
128k x 8 ICs (for a 128k x 24 bank), fitting in the smaller footprint, or they can be the larger 512k x 8 ICs
(for a 512k x 24 bank), fitting in the full footprint.

Board Configuration 3

UMAC-CPCI Turbo CPU Board Hardware Reference Manual

The flash memory IC is located in U10. This IC forms the non-volatile memory for the board’s firmware,
the user setup variables, and for user programs, tables, and buffers. It can be 1M x 8, 2M x 8, or 4M x 8
in capacity.

• Option 5C0 is the standard CPU and memory configuration. It is provided automatically if no Option

5xx is specified. It provides an 80 MHz DSP56303 CPU (120 MHz PMAC equivalent) with 8k x 24
of internal memory, an external 128k x 24 of compiled/assembled program memory, an external 128k
x 24 of user data memory; and a 1M x 8 flash memory. Setup variable I52 should be set and saved at
7 for 80 MHz operation.

• Option 5C3 provides an 80 MHz DSP56303 CPU (120 MHz PMAC equivalent) with 8k x 24 of

internal memory, an expanded external 512k x 24 of compiled/assembled program memory, an
expanded external 512k x 24 of user data memory, and a 4M x 8 flash memory. Setup variable I52
should be set and saved at 7 for 80 MHz operation.

• Option 5D0 provides a 100 MHz DSP56309 CPU (150 MHz PMAC equivalent) with 34k x 24 of

internal memory, an external 128k x24 of compiled/assembled program memory, an external 128k x
24 of user data memory; and a 1M x 8 flash memory. Setup variable I52 should be set and saved at 9
for 100 MHz operation.

• Option 5D3 provides a 100 MHz DSP56309 CPU (150 MHz PMAC equivalent) with 34k x 24 of

internal memory, an expanded external 512k x 24 of compiled/assembled program memory, an
expanded external 512k x 24 of user data memory, and a 4M x 8 flash memory. Setup variable I52
should be set and saved at 9 for 100 MHz operation.

Option 8: High-Accuracy Clock Crystal

The UMAC-CPCI Turbo CPU board has a clock crystal (component Y1) of nominal frequency 19.6608
MHz (~20 MHz). The standard crystal’s accuracy specification is +/-100 ppm.

• Option 8A provides a nominal 19.6608 MHz crystal with a +/-15 ppm accuracy specification.

Option 9: Serial Port Configuration

The UMAC-CPCI Turbo CPU board comes standard with a single RS-232/422 serial port, a second serial
port can be added.

• Option 9T adds an auxiliary RS-232 port on the CPU board. The key components added are ICs U28

and U43.

Option 10: Firmware Revision Specification

Normally the UMAC-CPCI Turbo CPU board is provided with the newest released firmware revision.
Some users may wish to “freeze” their designs on an older revision. A label on the U10 flash memory IC
shows the firmware revision loaded at the factory. The VERSION command can be used to report what
firmware revision is currently installed.

• Option 10 provides for a user-specified firmware version.

Option 16: Battery-Backed Parameter Memory

The contents of the standard memory are not retained through a power-down or reset unless they have
been saved to flash memory first. Option 16 provides supplemental battery-backed RAM for real-time
parameter storage that is ideal for holding machine state parameters in case of an unexpected power­down.

• Option 16A provides a 32k x 24 bank of battery-backed parameter RAM in components U17, U18,

and U19 and a “can-stack” lithium battery in component BT1. While the average expected battery
life is over five years, a yearly replacement schedule is recommended. Replacement batteries can be
ordered from Delta Tau as Acc-1LS (Part # 100-0QTC85-000).

4 Board Configuration

UMAC-CPCI Turbo CPU Board Hardware Reference Manual

HARDWARE SETUP

Clock-Source Jumpers

In order to operate properly, the Turbo CPU board must receive servo and phase clock signals from a
source external to the board. These clock signals can be brought into the board from one of three possible
ports: the stack connector, the UBUS backplane connector, or the front-side main serial-port connector.
Jumpers E1A and E1B must be configured properly for the clock source used.

(Note: If the UMAC-CPCI Turbo CPU board cannot find the clock signal from the source specified by
these jumpers, it will generate its own 2.26kHz servo clock and its own 9.04kHz phase clock so it will
stay in operation.)

To receive the clock signals over the Compact-UBUS backplane, usually from an ACC-24C2x axis­interface board, E1A must connect pins 1 and 2, and E1B must connect pins 2 and 3. This configuration
is typical for an UMAC-CPCI system. The clock signals are output on the main serial port.

To receive the clock signals through the stack connectors, usually from the MACRO IC on the CPCI
“bridge” board, E1A must connect pins 1 and 2, and the E1B jumper must be removed. The clock signals
are output on the main serial port.

To receive the clock signals through the main serial port, usually from another UMAC system or a
reference signal generator, E1A must connect pins 2 and 3, and E1B must connect pins 1 and 2. This
configuration is rarely used, but permits complete synchronization to the system that is generating the
clock signals.

Watchdog Timer Jumper

Jumper E19 should be OFF for normal operation, leaving the watchdog timer circuit active and prepared
to shut down the card in case of a severe problem. Putting jumper E19 ON disables the watchdog timer
circuit. This should only be used for test purposes, in trying to track down the source of watchdog timer
trips. Normal operation of a system with this jumper ON should never be attempted, as an important
safety feature is disabled.

Operation Mode Jumpers

Jumpers E20, E21, and E22 control the operational mode of the UMAC-CPCI Turbo CPU. For normal
operation, E20 must be OFF, E21 must be ON, and E22 must be ON. Other settings of these jumpers are
for factory use only.

Firmware Reload Jumper

Jumper E23 should be OFF for normal operation. If you want to load new firmware into the flash­memory IC on the CPU, E23 should be ON when the card is powered up. This puts the card in “bootstrap
mode”, ready to accept new firmware. If you then try to establish communications to the card with the
Executive program, either over the main serial port or the optional USB or Ethernet ports, the Executive
program will automatically recognize that the card is in bootstrap mode, and prompt you for the firmware
file to download.

Re-Initialization Jumper

Jumper E3 should be OFF for normal operation, where the last saved I-variable values are loaded from
flash memory into active memory at power-up/reset. If E3 is ON during power-up/reset, the factory
default I-variable values are instead loaded into active memory at power-up/reset. The last saved values
are not lost when this happens. This jumper is typically only used when the system’s set up has a
problem severe enough that communications does not work – otherwise, a $$$*** command can be
used for re-initialization.

Board Configuration 5