Delta Tau PMAC2A-PC-104 User Manual

Name: Delta Tau PMAC2A-PC-104
Brand: Delta Tau
SKU: 1078096
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^1 HARDWARE REFERENCE MANUAL

^2 PMAC2

-PC/104

^3 PMAC2A-PC/104 Hardware Reference Manual

^4 4xx-603670-xHxx

^5 September 22, 2004

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

21314 Lassen Street Chatsworth, CA 91311 // Tel. (818) 998-2095 Fax. (818) 998-7807 // www.deltatau.com

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 exposed to hazardous or conductive materials and/or environments, we cannot guarantee their operation.

PMAC2A PC104 Hardware Reference Manual

Table of Contents

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

Board Configuration..................................................................................................................................................1

Base Version.........................................................................................................................................................1

Option 2A: PC/104 Bus Stack Interface ..............................................................................................................1

Option 5xF: CPU Speed Options.........................................................................................................................1

Option 6: Extended Firmware Algorithm............................................................................................................1

Option 6L: Multi-block Lookahead Firmware.....................................................................................................1

Option 10: Firmware Version Specification.........................................................................................................1

Option 12: Analog-to-Digital Converters.............................................................................................................2

Acc-1P: Axis Expansion Piggyback Board...........................................................................................................2

Acc-1P Option 1: I/O Ports .................................................................................................................................2

Acc-1P Option 2: Analog-to-Digital Converters.................................................................................................2

Acc-2P: Communications Board.........................................................................................................................3

Acc-2P Option 1A: USB Interface.......................................................................................................................3

Acc-2P Option 1B: Ethernet Interface.................................................................................................................3

Acc-2P Option 2: DPRAM Circuitry...................................................................................................................3

Acc-2P Option 3: I/O Ports .................................................................................................................................3

Acc-8TS Connections Board.................................................................................................................................3

Acc-8ES Four-Channel Dual-DAC Analog Stack Board......................................................................................3

Acc-8FS Four-Channel Direct PWM Stack Breakout Board................................................................................3

BASE BOARD HARDWARE SETUP...................................................................................................................... 5

Clock Configuration Jumpers....................................................................................................................................5

Board Reset Jumpers.................................................................................................................................................5

CPU Jumper Configuration.......................................................................................................................................6

Communication Jumpers...........................................................................................................................................6

I/O Configuration Jumpers........................................................................................................................................6

Resistor Packs Configuration....................................................................................................................................6

Differential or Single-Ended Encoder Selection...................................................................................................6

ACC-1P HARDWARE SETUP..................................................................................................................................9

I/O Configuration Jumpers........................................................................................................................................9

Reserved Configuration Jumpers ..............................................................................................................................9

Resistor Packs Configuration....................................................................................................................................9

Differential or Single-Ended Encoder Selection...................................................................................................9

Handwheel Encoder Termination Resistors.......................................................................................................10

ACC-2P HARDWARE SETUP................................................................................................................................11

I/O Configuration Jumpers......................................................................................................................................11

Communication Jumpers.........................................................................................................................................11

Resistor Packs Configuration..................................................................................................................................12

Differential or Single-Ended Handwheel Encoder Selection..............................................................................12

Handwheel Encoder Termination Resistors.......................................................................................................12

MACHINE CONNECTIONS...................................................................................................................................13

Mounting.................................................................................................................................................................13

Power Supplies........................................................................................................................................................13

Digital Power Supply..........................................................................................................................................13

DAC Outputs Power Supply ...............................................................................................................................13

Flags Power Supply............................................................................................................................................14

Overtravel Limits and Home Switches....................................................................................................................14

Types of Overtravel Limits..................................................................................................................................14

Home Switches....................................................................................................................................................14

Motor Signals Connections.....................................................................................................................................14

Incremental Encoder Connection.......................................................................................................................14

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PMAC2A PC104 Hardware Reference Manual

DAC Output Signals ...........................................................................................................................................15

Pulse and Direction (Stepper) Drivers...............................................................................................................15

Amplifier Enable Signal (AENAx/DIRn).............................................................................................................15

Amplifier Fault Signal (FAULT-).......................................................................................................................16

Acc-1P General-Purpose Digital Inputs and Outputs (J7 Port)...............................................................................16

Acc-2P General-Purpose Digital Inputs and Outputs (JOPT Port)..........................................................................17

Acc-1P Thumbwheel Multiplexer Port (J2 Port).....................................................................................................17

Acc-2P Thumbwheel Multiplexer Port (JTHW Port)..............................................................................................17

Acc-1P or Acc-2P Handwheel Port (JHW / PD Port).............................................................................................18

Optional Analog Inputs...........................................................................................................................................18

Compare Equal Outputs..........................................................................................................................................18

Serial Port (JRS232 Port)........................................................................................................................................19

Acc-2P Ethernet RJ45 Connector (J10 Port)...........................................................................................................19

Acc-2P USB Connector (J1 Port)............................................................................................................................19

Machine Connections Example: Using Analog ±10V Amplifier............................................................................20

Machine Connections Example: Using Pulse and Direction Drivers......................................................................21

SOFTWARE SETUP ................................................................................................................................................23

Communications......................................................................................................................................................23

PMAC I-Variables...................................................................................................................................................23

Operational Frequency and Baud Rate Setup..........................................................................................................23

Filtered DAC Outputs Configuration......................................................................................................................24

Using Flag I/O as General-Purpose I/O...................................................................................................................25

General-Purpose Digital Inputs and Outputs...........................................................................................................25

Acc-1P with Jumper E6 on Position 1-2.............................................................................................................25

Acc-2P with Jumper E5 in Position 2-3..............................................................................................................26

Thumbwheel Port Digital Inputs and Outputs.........................................................................................................27

Acc-1P with Jumper E6 in Position 1-2..............................................................................................................27

Acc-2P with Jumper E5 in Position 2-3..............................................................................................................27

Analog Inputs Setup................................................................................................................................................28

Baseboard Analog Inputs....................................................................................................................................28

Acc-1P Analog Inputs.........................................................................................................................................28

BASE BOARD HARDWARE REFERENCE SUMMARY...................................................................................29

Board Dimensions...................................................................................................................................................29

Board Layout...........................................................................................................................................................30

Connectors and Indicators.......................................................................................................................................31

J3 - Machine Connector (JMACH1 Port)...........................................................................................................31

J4 - Machine Connector (JMACH2 Port)...........................................................................................................31

J8 - Serial Port (JRS232 Port)............................................................................................................................31

TB1 – Power Supply Terminal Block (JPWR Connector) ..................................................................................31

LED Indicators...................................................................................................................................................31

ACC-1P HARDWARE REFERENCE SUMMARY..............................................................................................33

Board Dimensions...................................................................................................................................................33

Board Layout...........................................................................................................................................................34

Connectors and Indicators.......................................................................................................................................35

J2 - Thumbwheel Multiplexer Port (JTHW Port) ...............................................................................................35

J3 - Machine Connector (JMACH1 Port)...........................................................................................................35

J4 - Machine Connector (JMACH2 Port)...........................................................................................................35

J7 - General-Purpose Digital Inputs and Outputs (JOPT Port).........................................................................35

J8 – Handwheel / Pulse and Direction Port (JHW / PD Port)...........................................................................35

TB1 – Power Supply Terminal Block (JPWR Connector) ..................................................................................35

ACC-2P HARDWARE REFERENCE SUMMARY..............................................................................................37

Board Dimensions...................................................................................................................................................37

Board Layout...........................................................................................................................................................38

Connectors and Indicators.......................................................................................................................................39

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PMAC2A PC104 Hardware Reference Manual

J1 – USB Communications Port.........................................................................................................................39

J2 - Thumbwheel Multiplexer Port (JTHW Port) ...............................................................................................39

J7 - General-Purpose Digital Inputs and Outputs (JOPT Port).........................................................................39

J8 – Handwheel/Pulse and Direction Port (JHW / PD Port)............................................................................. 39

J10 – Ethernet Communications Port.................................................................................................................39

TB1 – Power Supply Terminal Block (JPWR Connector) ..................................................................................39

LED Indicators...................................................................................................................................................39

BASE BOARD E-POINT JUMPER DESCRIPTIONS.........................................................................................41

E0: Forced Reset Control.......................................................................................................................................41

E1: Servo and Phase Clock Direction Control .......................................................................................................41

E2: CPU Frequency Select.....................................................................................................................................41

E3: Normal/Re-Initializing Power-Up/Reset..........................................................................................................41

E4: CPU Frequency Select.....................................................................................................................................42

E8: Phase Clock Lines Output Enable....................................................................................................................42

E9: Servo Clock Lines Output Enable....................................................................................................................42

E10 – E12: Power-Up State Jumpers ..................................................................................................................... 42

E13: Power-Up/Reset Load Source........................................................................................................................43

E14: Watchdog Disable Jumper.............................................................................................................................43

E15A, B, C: Flash Memory Bank Select................................................................................................................43

E16:.........................................................................................................................................................................43

ADC Inputs Enable .................................................................................................................................................43

E18 – E19: PC/104 Bus Address............................................................................................................................44

ACC-1P E-POINT JUMPER DESCRIPTIONS.....................................................................................................45

E0: Reserved for Future Use..................................................................................................................................45

E1 - E2: Machine Output Supply Voltage Configure.............................................................................................45

E3 – E4: JHW, PD Function Select........................................................................................................................45

E5: Servo Gate Address Select...............................................................................................................................46

E6: I/O Gate Address Select....................................................................................................................................46

E7: Machine Input Source/Sink Control ................................................................................................................46

E16: ADC Inputs Enable........................................................................................................................................46

ACC-2P E-POINT JUMPER DESCRIPTIONS.....................................................................................................47

E1: USB/Ethernet Micro-Controller Firmware Reload Enable..............................................................................47

E3 – E4: JHW, PD Function Select........................................................................................................................47

E5: I/O Gate Address Select...................................................................................................................................47

E6: Communications Port Select............................................................................................................................47

E7- E10: Ports Direction Control............................................................................................................................48

BASE BOARD CONNECTOR PINOUTS..............................................................................................................49

TB1 (JPWR): Power Supply ..................................................................................................................................49

ACC-1P CONNECTOR PINOUTS.........................................................................................................................53

TB1 (JPWR): Power Supply ..................................................................................................................................53

J2 (JTHW): Multiplexer Port Connector.................................................................................................................54

J3 (JMACH1): Machine Port Connector (50-Pin Header).....................................................................................55

J4 (JMACH2): Machine Port Connector (34-Pin Header)......................................................................................57

J7 (JOPTO): I/O Port Connector.............................................................................................................................58

J8 (JHW) Handwheel Encoder Connector...............................................................................................................59

ACC-2P CONNECTOR PINOUTS.........................................................................................................................61

TB1 (JPWR): Power Supply ..................................................................................................................................61

J1 (USB) Universal Serial Bus Port (Optional).......................................................................................................61

J2 (JTHW): Multiplexer Port Connector.................................................................................................................62

J7 (JOPT): I/O Port Connector................................................................................................................................63

J8 (JHW) Handwheel Encoder Connector...............................................................................................................64

J10 Ethernet Port (Optional)....................................................................................................................................64

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PMAC2A PC104 Hardware Reference Manual

iv Table of Contents

PMAC2A PC104 Hardware Reference Manual

INTRODUCTION

The PMAC2A PC/104 motion controller is a compact, cost-effective version of the Delta Tau’s PMAC2 family of controllers. The PMAC2A PC/104 can be composed of three boards in a stack configuration.

The baseboard provides four channels of either DAC ±10V or pulse and direction command outputs. The optional axis expansion board provides a set of four additional servo channels and I/O ports. The optional communications board provides extra I/O ports and either the USB or Ethernet interface for faster communications.

Board Configuration

Base Version

The base version of the PMAC2A PC/104 ordered with no options provides a 90mm x 95mm board with:

• 40 MHz DSP563xx CPU (80 MHz 560xx equivalent)

• 128k x 24 internal zero-wait-state SRAM

• 512k x 8 flash memory for user backup and firmware

• Latest released firmware version

• RS-232 serial interface

• Four channels axis interface circuitry, each including:

• 12-bit ±10V analog output

• Pulse-and-direction digital outputs

• 3-channel differential/single-ended encoder input

• Four input flags, two output flags

• Three PWM top-and-bottom pairs (unbuffered)

• 50-pin IDC header for amplifier/encoder interface

• 34-pin IDC header for flag interface

• PID/notch/feedforward servo algorithms

• 1-year warranty from date of shipment

• One CD-ROM per set of one to four PMACs in shipment (Cables, mounting plates, mating

connectors not included)

PMAC2A-PC/104 Base Board shown

Option 2A: PC/104 Bus Stack Interface

Option 2A provides the PC/104 bus interface allowing bus communications between a PC/104 type computer and the PMAC2A PC/104 motion controller.

Option 5xF: CPU Speed Options

• Option 5CF: 80 MHz DSP563xx CPU (160 MHz 56002 equivalent)

• Option 5EF: 160 MHz DSP563xx CPU (320 MHz 56002 equivalent)

Option 6: Extended Firmware Algorithm

Option 6 provides an Extended (Pole-Placement) Servo Algorithm firmware instead of the regular servo algorithm firmware. This is required only in difficult-to-control systems (resonances, backlash, friction, disturbances, changing dynamics).

Option 6L: Multi-block Lookahead Firmware

Option 6L provides a special lookahead firmware for sophisticated acceleration and cornering profiles execution. With the lookahead firmware PMAC controls the speed along the path automatically (but without changing the path) to ensure that axis limits are not violated.

Option 10: Firmware Version Specification

Normally the PMAC PCI Lite is provided with the newest released firmware version. A label on the memory IC shows the firmware version loaded at the factory. Option 10 provides for a user-specified firmware version.

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PMAC2A PC104 Hardware Reference Manual

Option 12: Analog-to-Digital Converters

Option 12 permits the installation of two channels of on-board analog-to-digital converters with ±10V input range and 12-bits resolution. The key component installed with this option is U20.

Acc-1P: Axis Expansion Piggyback Board

Acc-1P provides four additional channels axis interface circuitry for a total of eight servo channels, each including:

• 12-bit ±10V analog output

• Pulse-and-direction digital outputs

• 3-channel differential/single-ended encoder input

• Four input flags, two output flags

• Three PWM top-and-bottom pairs (unbuffered)

Acc-1P Option 1: I/O Ports

Option 1 provides the following ports on the Acc-1P axes expansion board for digital I/O connections.

•

Multiplexer Port: This connector provides eight input lines and eight output lines at TTL levels. When using the PMAC Acc-34x type boards these lines allow multiplexing large numbers of inputs and outputs on the port. Up to 32 of the multiplexed I/O boards may be daisy-chained on the port, in any combination.

• I/O Port: This port provides eight general-purpose digital inputs and eight general-purpose digital

outputs at 5 to 24Vdc levels. This 34-pin connector was designed for easy interface to OPTO-22 or equivalent optically isolated I/O modules when different voltage levels or opto-isolation to the PMAC2A PC/104 is necessary.

• Handwheel port: this port provides two extra channels, each jumper selectable between encoder input

or pulse output.

PMAC2A PC/104 Base Board shown

stacked with the Acc-1P axes

Acc-1P Option 2: Analog-to-Digital Converters

Option 2 permits the installation on the Acc-1P of two channels of analog-to-digital converters with ±10V input range and 12-bits resolution. The key component installed with this option is U20.

PMAC2A PC/104 Base Board shown stacked with the Option-1P and Option-2P boards

2 Introduction

PMAC2A PC104 Hardware Reference Manual

Acc-2P: Communications Board

Without any options, the PMAC2A PC/104 communicates through the RS-232 serial interface using the optional Acc-3L flat cable. Only one method of communication is allowed at a time.

Acc-2P Option 1A: USB Interface

Option 1A it provides a 12 Mbit/sec USB interface allowing USB communications with the PMAC2A PC/104 motion controller.

Acc-2P Option 1B: Ethernet Interface

Option 1B provides a 10 Mbit/sec Ethernet interface allowing Ethernet communications with the PMAC2A PC/104 motion controller.

Acc-2P Option 2: DPRAM Circuitry

Option 2 provides an 8K x 16 dual-ported RAM for USB, Ethernet or PC/104 ports on board of the Acc2P communications board. If using for USB or Ethernet communications, Acc-2P-Opt-1A or Acc-2POpt-1B must be ordered. If used for PC/104-bus communications, PMAC2A PC/104 Option-2A must be ordered. The key component installed with this option is U17.

Acc-2P Option 3: I/O Ports

Option 3 provides the following ports on the Acc-2P communications board for digital I/O connections.

• Multiplexer Port: this connector provides eight input lines and eight output lines at TTL levels. When

using the PMAC Acc-34x type boards these lines allow multiplexing large numbers of inputs and outputs on the port. Up to 32 of the multiplexed I/O boards may be daisy-chained on the port, in any combination.

• I/O Port: this port provides 16 general-purpose digital I/O lines at TTL levels and these can be

configured as all inputs, all outputs or eight inputs and eight outputs.

• Handwheel port: this port provides two extra channels, each jumper selectable between encoder input

or pulse output.

Acc-8TS Connections Board

Acc-8TS is a stack interface board to for the connection of either one or two Acc-28B A/D converter boards. When a digital amplifier with current feedback is used, the analog inputs provided by the Acc28B cannot be used.

Acc-8ES Four-Channel Dual-DAC Analog Stack Board

Acc-8ES provides four channels of 18-bit dual-DAC with four DB-9 connectors. This accessory is stacked to the PMAC2A PC/104 board and it is mostly used with amplifiers that require two ±10 V command signals for sinusoidal commutation.

Acc-8FS Four-Channel Direct PWM Stack Breakout Board

Acc-8FS it is a 4-channel direct PWM stack breakout board for PMAC2A PC/104. This is used for controlling digital amplifiers that require direct PWM control signals. When a digital amplifier with current feedback is used, the analog inputs provided by the Option 12 of the PMAC2A PC/104 (the Option 2 of the Acc-1P or the Acc-28B) could not be used.

Introduction 3

PMAC2A PC104 Hardware Reference Manual

4 Introduction

PMAC2A PC104 Hardware Reference Manual

BASE BOARD HARDWARE SETUP

On the PMAC2 PC/104 baseboard, there are many jumpers (pairs of metal prongs) called E-points or Wpoints. Some have been shorted together; others have been left open. These jumpers customize the hardware features of the baseboard for a given application and must be setup appropriately. The following is an overview of the several jumpers grouped in appropriate categories. For a complete description of the jumper setup configuration, refer to the E-Point Descriptions section.

Clock Configuration Jumpers

E1: Servo and Phase Clock Direction Control – Jumper E1 should be OFF if the board is to use its own internally generated phase and servo clock signals. In this case, these signals are output on spare pins on the J8 RS-232 serial-port connector, where they can be used by other PMAC controllers set up to take external phase and servo clock signals.

Jumper E1 should be ON if the board is to use externally generated phase and servo clock signals brought in on the J8 RS-232 serial port connector. In this case, typically the clock signals are generated by another PMAC controller and output on its serial port connector.

If E1 is ON for external phase and clock signals, and these clock signals are not brought in on the serial port connector, the watchdog timer will trip almost immediately and shut down the board.

E2 and E4: CPU Frequency Control Jumpers – When the PMAC I46 I- variable is set to zero jumpers E2 and E4 on the base PMAC2A PC/104 board control the frequency at which the CPU will operate (or attempt to operate). Generally, this will be the highest frequency at which the CPU is rated to operate. Note that it is always possible to operate a CPU at a frequency lower than its maximum rating. While it may be possible to operate an individual processor at a frequency higher than its maximum rating, particularly at low ambient temperatures, performance cannot be guaranteed at such a setting, and this operation is done completely at the user’s own risk.

• If jumpers E2 and E4 are both OFF, the CPU will operate at a 40 MHz frequency.

• If E2 is ON and E4 is OFF, the CPU will operate at a 60 MHz frequency.

• If E2 is OFF and E4 is ON, the CPU will operate at an 80 MHz frequency.

If I46 is set to a value greater than 0, the operational frequency is set to 10MHz * (I46 + 1), regardless of the jumper setting. See the Software Setup section for details on this.

E8: Phase Clock Lines Output Enable – Jump pin 1 to 2 to enable the Phase clock line on the J8 connector. Remove jumper to disconnect the Phase clock line on the J8 connector.

E9: Servo Clock Lines Output Enable – Jump pin 1 to 2 to enable the Servo clock line on the J8 connector. Remove jumper to disconnect the Servo clock line on the J8 connector.

Board Reset Jumpers

E0: Forced Reset Control – Remove E0 for normal operation. Installing E0 forces PMAC to a reset state, and this configuration is for factory use only; the board will not operate with E0 installed.

E3: Re-Initialization on Reset Control – If E3 is OFF (default), PMAC executes a normal reset, loading active memory from the last saved configuration in non-volatile flash memory. If E3 is ON, PMAC re-initializes on reset, loading active memory with the factory default values.

E13: Firmware Load Jumper – If jumper E13 is ON during power-up/reset, the board comes up in bootstrap mode which permits the loading of new firmware into the flash-memory IC on the board. When the PMAC Executive program tries to establish communications with a board in this mode, it will detect automatically that the board is in bootstrap mode and ask what file to download as the new firmware.

Jumper E13 must be OFF during power-up/reset for the board to come up in normal operational mode.

Baseboard Hardware Setup 5

PMAC2A PC104 Hardware Reference Manual

CPU Jumper Configuration

E15A-E15C: Flash Memory Bank Select Jumpers – The flash-memory IC in location U10 on the PMAC2A PC/104 base board has the capacity for eight separate banks of firmware, only one of which can be used at any given time. The eight combinations of settings for jumpers E15A, E15B, and E15C select which bank of the flash memory is used. In the factory production process, firmware is loaded only into Bank 0, which is selected by having all of these jumpers OFF.

E10-E12: Power-Up State Jumpers – Jumper E10 must be OFF, jumper E11 must be ON, and jumper E12 must be ON, in order for the CPU to copy the firmware from flash memory into active RAM on powerup/reset. This is necessary for normal operation of the card. (Other settings are for factory use only.)

E14: Watchdog Timer Jumper – Jumper E14 must be OFF for the watchdog timer to operate. This is a very important safety feature, so it is vital that this jumper be OFF in normal operation. E14 should only be put ON to debug problems with the watchdog timer circuit.

W1: Flash chip select – Jumper W1 in position 1-2 selects a 28F320J3A part for the U10 flash chip. Jumper W1 in position 2-3 selects a 28F320J5A part for the U10 flash chip. This jumper is installed in the factory and must not be changed from its default state.

Communication Jumpers

E18-E19: PC/104 Bus Base Address Control – Jumpers E18 and E19 on the PMAC2A PC/104 baseboard determine the base address of the card in the I/O space of the host PC’s bus. Together, they specify four consecutive addresses on the bus where the card can be found. The jumpers form the base address in the following fashion:

E18 E19 Address (hex) Address (dec)

OFF OFF $200 512 OFF ON $210 528

ON OFF $220 544 ON ON $230 560

The default base address is 528 ($210) formed with jumper E18 removed and E19 installed. This configuration is necessary for using the USB or Ethernet ports of the Acc-2P communications board.

I/O Configuration Jumpers

E16: ADC Enable Jumper – Install E16 to enable the analog-to-digital converter circuitry ordered through Option-12. Remove this jumper to disable this option, which might be necessary to control motor 1 through a digital amplifier with current feedback.

Resistor Packs 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 kΩ pull-up resistor to +5V. This cannot be changed.

The ‘-‘ inputs of each differential pair each have a hard-wired 2.2 kΩ resistor to +5V; each also has another 2.2 kΩ 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.

6 Baseboard Hardware Setup

PMAC2A PC104 Hardware Reference Manual

If this socketed resistor is configured as a pull-up resistor (by reversing the SIP pack in the socket), the two parallel 2.2 kΩ resistors act as a single 1.1 kΩ pull-up resistor, holding the line at +5V in the absence of an external signal. This configuration is required if complementary open-collector drivers are used; it is permissible for differential line-driver inputs.

If Pin 1 of the resistor pack, marked by a dot on the pack, matches Pin 1 of the socket, labeled by a white square, 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:

Device Resistor Pack Pack Size

Encoder 1 RP30 6-pin Encoder 2 RP31 6-pin Encoder 3 RP36 6-pin Encoder 4 RP37 6-pin

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PMAC2A PC104 Hardware Reference Manual

8 Baseboard Hardware Setup

PMAC2A PC104 Hardware Reference Manual

ACC-1P HARDWARE SETUP

On the Acc-1P, you will see many jumpers (pairs of metal prongs), called E-points. Some have been shorted together; others have been left open. These jumpers customize the hardware features of the Acc1P for a given application and must be setup appropriately. The following is an overview of the several jumpers grouped in appropriate categories. For a complete description of the jumper setup configuration, refer to the Acc-1P E-Point Description section.

I/O Configuration Jumpers

E1-E2: Machine Output Supply Configure – With the default sinking output driver IC (ULN2803A or equivalent) in U7 for the J7 JOPT port outputs, these jumpers must connect pins 1 and 2 to supply the IC correctly. If this IC is replaced with a sourcing output driver IC (UDN2981A or equivalent), these jumpers must be changed to connect pins 2 and 3 to supply the new IC correctly. A wrong setting of these jumpers will damage the associated output IC.

E3-E4: JHW, PD Function Select – When jumper E3 connects pins 2 and 3, a set of pulse and direction signals can be output on channel 1 (pins 2 to 5) of the JHW, PD port. If E3 connects pins 1 and 2, then channel 1 is configured as a handwheel encoder input. When jumper E4 connects pins 2 and 3, a set of pulse and direction signals can be output on channel 2 (pins 6 to 9) of the JHW, PD port. If E4 connects pins 1 and 2, then channel 2 is configured as a handwheel encoder input.

E5: Servo Gate address select – If jumper E5 connects pins 1 and 2 (default) the servo channels on the Acc-1P will be accessed at the regular addresses for motors 5 to 8. When E5 connects pins 2 and 3 the servo channels on the Acc-1P board will be accessed at the regular addresses for motors 5 to 8 plus $40, and this is useful only when two Acc-1Ps are used with the same PMAC2A PC/104 baseboard.

E6: I/O Gate address select – If jumper E6 connects pins 1 and 2 (default) the I/O features on the Acc1P will be accessed at the regular addresses and the JTHW port can be used as a multiplexer port. When E6 connects pins 2 and 3 the I/O features on the Acc-1P board will be accessed at the regular addresses plus $40, and this is useful only when two Acc-1P are used with the same PMAC2A PC/104 baseboard.

E7: Machine Input Source/Sink Control – With this jumper connecting pins 1 and 2 (default) the machine input lines on the J7 JOPT port are pulled up to +5V or the externally provided supply voltage for the port. This configuration is suitable for sinking drivers. If the jumper is changes to connect pins 2 and 3, these lines are pulled down to GND – this configuration is suitable for sourcing drivers.

E16: ADC Enable Jumper – Install E16 to enable the analog-to-digital converter circuitry ordered through Option-2. Remove this jumper to disable this option, which might be necessary to control motor 5 through a digital amplifier with current feedback.

Reserved Configuration Jumpers

E0: Reserved for future use

Resistor Packs Configuration

Differential or Single-Ended Encoder Selection

The ‘+’ inputs of each differential pair each have a hard-wired 1 kΩ pull-up resistor to +5V. This cannot be changed.

Acc-1P Hardware Setup 9

PMAC2A PC104 Hardware Reference Manual

Device Resistor Pack Pack Size

Encoder 1 RP30 6-pin Encoder 2 RP31 6-pin Encoder 3 RP36 6-pin Encoder 4 RP37 6-pin

Handwheel Encoder RP55 6-pin

Handwheel Encoder Termination Resistors

The PMAC provides a socket for termination resistors on the handwheel encoder differential input pairs coming into the board. As shipped, there is no resistor pack in the RP56 socket. If these signals are brought long distances into the PMAC board and ringing at signal transitions is a problem, a SIP resistor pack may be mounted on the RP56 socket to reduce or eliminate the ringing. The 6-pin termination resistor pack is the type that has independent resistors (no common connection) with each resistor using 2 adjacent pins.

Acc-1P Hardware Setup

PMAC2A PC104 Hardware Reference Manual

ACC-2P HARDWARE SETUP

On the Acc-2P, there are many jumpers (pairs of metal prongs), called E-points. Some have been shorted together; others have been left open. These jumpers customize the hardware features of the Acc-2P for a given application and must be setup appropriately. The following is an overview of the several jumpers grouped in appropriate categories. For a complete description of the jumper setup configuration, refer to the Acc-2P E-Point Descriptions chapter.

I/O Configuration Jumpers

E5: I/O Gate address select – If jumper E5 connects pins 1 and 2 the I/O features on the Acc-2P will be accessed at the regular addresses and the JTHW port can be used as a multiplexer port. When E5 connects pins 2 and 3 the I/O features on the Acc-2P board will be accessed at the regular addresses plus $40, and this is necessary only when both Acc-2P and Acc-1P are used with the same PMAC2A PC/104 baseboard.

E7-E10: Ports Direction Control – These jumpers select the I/O lines direction of the JTHW and the JOPT connectors. This allows configuring these ports as all inputs, all outputs or half inputs and half outputs according to the following tables:

JTHW Connector

E7 E8

OFF OFF Output Output OFF OFF Output Output OFF ON Output Input OFF ON Output Input

ON OFF Input Output ON OFF Input Output ON ON Input Input ON ON Input Input

If E7 is removed or E8 is installed then the multiplexing feature if the JTHW port cannot be used.

DATx

lines

SELx

lines

E9 E10

JOPT Connector

MOx

lines

MIx

Lines

Communication Jumpers

E1: USB/Ethernet Micro Controller Firmware reload enable – This jumper was added on revision – 103 and above of the Acc-2P. Factory default position is ON, and it should remain ON. If the firmware was corrupted due to a previous firmware download, the card firmware may be reloaded by powering on the card with the jumper off, installing the jumper without powering off, then downloading firmware with out powering off. Under normal circumstances, this jumper should be on even when upgrading firmware.

E6: Communications Port Selection – When jumper E6 connects pins 1 and 2 the PC/104 communications port is enabled. If E6 connects pins 2 and 3 the Ethernet or USB ports are enabled. Only one port can be used at a time. If either the Ethernet or USB ports are used then jumper E19 on the base board must be installed and jumper E18 on the base board must be removed. In order to communicate through the RS-232 serial port jumper E6 must be installed, either in position 1-2 or 2-3.

Acc-2P Hardware Setup 11

PMAC2A PC104 Hardware Reference Manual

Resistor Packs Configuration

Differential or Single-Ended Handwheel Encoder Selection

The handwheel encoder differential input signal pairs to the PMAC have user-configurable pull-up/pulldown 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 kΩ pull-up resistor to +5V. This cannot be changed.

RP22 is the 6-pin pull-up/pull-down resistor pack for the handwheel encoder input.

Handwheel Encoder Termination Resistors

The PMAC provides a socket for termination resistors on the handwheel encoder differential input pairs coming into the board. As shipped, there is no resistor pack in the RP23 socket. If these signals are brought long distances into the PMAC board and ringing at signal transitions is a problem, a SIP resistor pack may be mounted on the RP23 socket to reduce or eliminate the ringing. The 6-pin termination resistor pack is the type that has independent resistors (no common connection) with each resistor using two adjacent pins.

Acc-2P Hardware Setup

PMAC2A PC104 Hardware Reference Manual

MACHINE CONNECTIONS

Typically, the user connections are actually made to terminal blocks that are attached to the JMACH connectors by a flat cable. The following are the terminal blocks recommended for connections:

• 34-Pin IDC header to terminal block breakouts (Phoenix part number 2281063) Delta Tau part

number 100-FLKM34-000

• 50-Pin IDC header to terminal block breakouts (Phoenix part number 2281089) Delta Tau part

number 100-FLKM50-000

Mounting

The PMAC2A PC/104 is always installed either using standoffs, when it is stacked to a PC/104 computer or used as a stand-alone controller. At each of the four corners of the PMAC2A PC/104 board, there are mounting holes that can be used to mount the board on standoffs.

The PMAC2A PC/104 baseboard is placed always at the bottom of the stack. The order of the Acc-1P or Acc-2P with respect to the baseboard does not matter.

Power Supplies

Baseboard mounted at the bottom of the stack

Digital Power Supply

3A @ +5V (±5%) (15 W) (Eight-channel configuration, with a typical load of encoders) The PMAC2A PC/104, the Acc-1P and the Acc-2P each require a 1A @ 5VDC power supply for

operation. Therefore, a 3A @ 5VDC power supply is recommended for a PMAC2A PC/104 board stack with Acc-1P and Acc-2P boards.

• The host computer provides the 5 Volts power supply in the case PMAC is installed in the PC/104

bus. With the board stack into the bus, it will automatically pull +5V power from the bus and it cannot be disconnected. In this case, there must be no external +5V supply, or the two supplies will "fight" each other, possibly causing damage. This voltage could be measured on the TB1 terminal block or the JMACH1 connector.

• In a stand-alone configuration, when PMAC is not plugged in a computer bus, it will need an external

5V supply to power its digital circuits. The 5V power supply can be brought in either from the TB1 terminal block or from the JMACH1 connector.

DAC Outputs Power Supply

0.3A @ +12 to +15V (4.5W)

0.25A @ -12 to -15V (3.8W) (Eight-channel configuration)

• The host computer provides the ±12 Volts power supply in the case PMAC is installed in the PC/104

bus. With the board stack into the bus, it will pull ±12V power from the bus automatically and it cannot be disconnected. In this case, there must be no external ±12V supply, or the two supplies will fight each other, possibly causing damage. This voltage could be measured on the TB1 terminal block.

• In a stand-alone configuration, when PMAC is not plugged in a computer bus, it will need an external

±12V supply only when the digital-to-analog converter (DAC) outputs are used. The ±12V lines from the supply, including the ground reference, can be brought in either from the TB1 terminal block or from the JMACH1 connector.

Machine Connections 13

PMAC2A PC104 Hardware Reference Manual

Flags Power Supply

Each channel of PMAC has five dedicated digital inputs on the machine connector: PLIMn, MLIMn (overtravel limits), HOMEn (home flag), FAULTn (amplifier fault), and USERn. A power supply from 5 to 24V must be used to power the circuits related to these inputs. This power supply can be the same used to power PMAC and can be connected from the TB1 terminal block or the JMACH1 connector.

Overtravel Limits and Home Switches

When assigned for the dedicated uses, these signals provide important safety and accuracy functions. PLIMn and MLIMn are direction-sensitive over-travel limits that must conduct current to permit motion in that direction. If no over-travel switches will be connected to a particular motor, this feature must be disabled in the software setup through the PMAC Ix25 variable.

Types of Overtravel Limits

PMAC expects a closed-to-ground connection for the limits to not be considered on fault. This arrangement provides a failsafe condition. Usually, a passive normally close switch is used. If a proximity switch is needed instead, use a 5 to 24V normally closed to ground NPN sinking type sensor.

Home Switches

While normally closed-to-ground switches are required for the overtravel limits inputs, the home switches could be either normally close or normally open types. The polarity is determined by the home sequence setup, through the I-variables I9n2. However, for the following reasons, the same type of switches used for over-travel limits are recommended:

• Normally closed switches are proven to have greater electrical noise rejection than normally open types.

• Using the same type of switches for every input flag simplifies maintenance stock and replacements.

Motor Signals Connections

Incremental Encoder Connection

Each JMACH1 connector provides two +5V outputs and two logic grounds for powering encoders and other devices. The +5V outputs are on pins 1 and 2; the grounds are on pins 3 and 4. The encoder signal pins are grouped by number: all those numbered 1 (CHA1+, CHA1-, CHB1+, CHC1+, etc.) belong to encoder #1. The encoder number does not have to match the motor number, but usually does. Connect the A and B (quadrature) encoder channels to the appropriate terminal block pins. For encoder 1, the CHA1+ is pin 5 and CHB1+ is pin 9. If there is a single-ended signal, leave the complementary signal pins floating – do not ground them. However, if single-ended encoders are used, check the settings of the resistor packs (see the Hardware Setup section for details). For a differential encoder, connect the complementary signal lines – CHA1- is pin 7, and CHB1- is pin 11. The third channel (index pulse) is optional; for encoder 1, CHC1+ is pin 13, and CHC1- is pin 15.

Example: differential quadrature encoder connected to channel #1:

Machine Connections

PMAC2A PC104 Hardware Reference Manual

DAC Output Signals

If PMAC is not performing the commutation for the motor, only one analog output channel is required to command the motor. This output channel can be either single-ended or differential, depending on what the amplifier is expecting. For a single-ended command using PMAC channel 1, connect DAC1+ (pin

29) to the command input on the amplifier. Connect the amplifier’s command signal return line to PMAC’s GND line (pin 48). In this setup, leave the DAC1- pin floating; do not ground it.

For a differential command using PMAC channel 1, connect DAC1 (pin 29) to the plus-command input on the amplifier. Connect DAC1- (pin 31) to the minus-command input on the amplifier. PMAC’s GND should still be connected to the amplifier common.

To limit the range of each signal to ±5V, use parameter Ix69. Any analog output not used for dedicated servo purposes may be utilized as a general-purpose analog output. Usually this is done by defining an M-variable to the digital-to-analog-converter register (suggested M-variable definitions M102, M202, etc.), then writing values to the M-variable. The analog outputs are intended to drive high-impedance inputs with no significant current draw. The 220Ω output resistors will keep the current draw lower than 50 mA in all cases and prevent damage to the output circuitry, but any current draw above 10 mA can result in noticeable signal distortion.

Example:

Pulse and Direction (Stepper) Drivers

The channels provided by the PMAC2A PC/104 board or the Acc-1P board can output pulse and direction signals for controlling stepper drivers or hybrid amplifiers. These signals are at TTL levels.

Amplifier Enable Signal (AENAx/DIRn)

Most amplifiers have an enable/disable input that permits complete shutdown of the amplifier regardless of the voltage of the command signal. PMAC’s AENA line is meant for this purpose. AENA1- is pin 33. This signal is an open-collector output and an external 3.3 kΩ pull-up resistor can be used if necessary.

Machine Connections 15

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