Delta Tau PMAC2A-PC/104 CPU Reference Manual

^1 HARDWARE REFERENCE MANUAL

PMAC2A-PC/104 CPU

^3 PMAC2A-PC/104 CPU Hardware Reference

^4 4xx-603670-xAxx

^5 July 29, 2008

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

21314 Lassen Street Chatsworth, CA 91311 // Tel. [phone] Fax. [phone] // www.deltatau.com

Copyright Information

© 2008 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.

REV. DESCRIPTION DATE CHG APPVD

1 UPDATED JUMPER DESCRIPTIONS PGS. 6 & 30 05/17/06 CP S. MILICI

2 REVS: J4, E20-23, CONNECTOR PINOUTS,

& BOARD DIAGRAMS

3 CORRECTED TYPO IN I-VARIABLE SETTINGS, P. 17 01/22/08 CP S.MILICI

4 CORRECTED USER FLAGS FOR PINS 25 & 26, P.36 07/29/08 CP C.COKER

REVISION HISTORY

10/04/06 CP P. SHANTZ

PMAC2A PC104 Hardware Reference Manual

Table of Contents

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

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

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

Board Options ...........................................................................................................................................................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.........................................................................................................2

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

Additional Accessories..............................................................................................................................................2

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

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

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

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

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

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

CPU Configuration Jumpers .....................................................................................................................................6

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

ADC Configuration Jumpers.....................................................................................................................................6

Encoder Configuration Jumpers................................................................................................................................6

Single-Ended Encoders.........................................................................................................................................6

Differential Encoders............................................................................................................................................6

MACHINE CONNECTIONS.....................................................................................................................................9

Mounting ...................................................................................................................................................................9

Power Supplies..........................................................................................................................................................9

Digital Power Supply............................................................................................................................................9

DAC Outputs Power Supply .................................................................................................................................9

Flags Power Supply............................................................................................................................................10

Overtravel Limits and Home Switches....................................................................................................................10

Types of Overtravel Limits..................................................................................................................................10

Home Switches....................................................................................................................................................10

Motor Signals Connections .....................................................................................................................................10

Incremental Encoder Connection .......................................................................................................................10

DAC Output Signals ...........................................................................................................................................11

Pulse and Direction (Stepper) Drivers ...............................................................................................................11

Amplifier Enable Signal (AENAx/DIRn).............................................................................................................11

Amplifier Fault Signal (FAULT-) .......................................................................................................................12

Optional Analog Inputs ...........................................................................................................................................12

Compare Equal Outputs ..........................................................................................................................................12

Serial Port (JRS232 Port) ........................................................................................................................................12

Machine Connections Example: Using Analog ±10V Amplifier............................................................................13

Machine Connections Example: Using Pulse and Direction Drivers......................................................................14

SOFTWARE SETUP ................................................................................................................................................15

PMAC I-Variables...................................................................................................................................................15

Communications......................................................................................................................................................15

Operational Frequency and Baud Rate Setup ....................................................................................................15

Filtered DAC Output Configuration........................................................................................................................16

Parameters to Set up Global Hardware Signals.................................................................................................17

Parameters to Set Up Per-Channel Hardware Signals ......................................................................................18

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PMAC2A PC104 Hardware Reference Manual

Effects of Changing I900 on the System .............................................................................................................18

How does changing I900 effect other settings in PMAC ....................................................................................20

Effects of Output Resolution and Servo Interrupt Frequency on Servo Gains....................................................21

Using Flag I/O as General-Purpose I/O...................................................................................................................22

Analog Inputs Setup................................................................................................................................................22

CPU Analog Inputs.............................................................................................................................................22

HARDWARE REFERENCE SUMMARY .............................................................................................................23

Board Dimensions...................................................................................................................................................23

From v106 to 107................................................................................................................................................23

From v107 to 108................................................................................................................................................24

From v108 to 109................................................................................................................................................25

Board Layout...........................................................................................................................................................26

Connectors and Indicators.......................................................................................................................................27

J3 - Machine Connector (JMACH1 Port)...........................................................................................................27

J4 - Machine Connector (JMACH2 Port)...........................................................................................................27

J8 - Serial Port (JRS232 Port)............................................................................................................................27

TB1 – Power Supply Terminal Block (JPWR Connector) ..................................................................................27

LED Indicators ...................................................................................................................................................27

E-POINT JUMPER DESCRIPTIONS ....................................................................................................................29

E0: Forced Reset Control .......................................................................................................................................29

E1: Servo and Phase Clock Direction Control .......................................................................................................29

E2: CPU Frequency Select.....................................................................................................................................29

E3: Normal/Re-Initializing Power-Up/Reset..........................................................................................................29

E4: CPU Frequency Select.....................................................................................................................................30

E8: Phase Clock Lines Output Enable....................................................................................................................30

E9: Servo Clock Lines Output Enable....................................................................................................................30

E10 – E12: Power-Up State Jumpers .....................................................................................................................30

E13: Power-Up/Reset Load Source........................................................................................................................31

E14: Watchdog Disable Jumper.............................................................................................................................31

E15A, B, C: Flash Memory Bank Select................................................................................................................31

E16: ADC Inputs Enable.........................................................................................................................................31

E18 – E19: PC/104 Bus Address............................................................................................................................32

E20-E23: ENCODER SINGLE ENDED/DIFFERENTIAL SELECT (Note: v107 and above only) ..............32

CONNECTOR PINOUTS.........................................................................................................................................33

TB1 (JPWR): Power Supply ..................................................................................................................................33

J4 (JRS232) Serial Port Connector..........................................................................................................................33

J3 (JMACH1): Machine Port Connector.................................................................................................................34

J3 JMACH1 (50-Pin Header)..................................................................................................................................35

J4 (JMACH2): Machine Port CPU Connector ........................................................................................................36

SCHEMATICS ..........................................................................................................................................................38

ii Table of Contents

PMAC2A PC104 Hardware Reference Manual

INTRODUCTION

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

The CPU 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/feed forward 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

Board Options

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.

Introduction 1

PMAC2A PC104 Hardware Reference Manual

Option 10: Firmware Version Specification

Normally the PMAC2A PC/104 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.

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.

Additional Accessories

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.

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.

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) or PC/104 bus. This board provides added communication and I/O features.

Acc-2P Option 1A: USB Interface

Option 1A it provides a 480 Mbit/sec USB 2.0 interface.

Acc-2P Option 1B: Ethernet Interface

Option 1B provides a 100 Mbit/sec Ethernet.

Acc-2P Option 2: DPRAM Circuitry

Option 2 provides an 8K x 16 dual-ported RAM used with USB, Ethernet or PC/104 bus applications. If
using for USB or Ethernet communications, Acc-2P-Opt-1A or Acc-2P-Opt-1B must be ordered. If used

2 Introduction

PMAC2A PC104 Hardware Reference Manual

for PC/104-bus communications, PMAC2A PC/104 Option-2A must be ordered. The key component
installed with this option is U17. USB/Ethernet and PC/104 bus communications cannot be made
simultaneously it is jumper selectable.

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

HARDWARE SETUP

On the PMAC2 PC/104 CPU, there are a number of jumpers called E-points or W-points. That customize
the hardware features of the CPU for a given application and must be setup appropriately. The following
is an overview grouped in appropriate categories. For an itemized 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.

Reset Jumpers

E0: Forced Reset Control – Remove E0 for normal operation. Installing E0 forces PMAC to a reset
state, 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 loading of firmware into the flash-memory IC. 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.

Hardware Setup 5

PMAC2A PC104 Hardware Reference Manual

6

CPU Configuration Jumpers

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 for 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 CPU
determine the base address of the card in the I/O space of the host PC. 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 setting
is necessary when using the USB or Ethernet ports of the Acc-2P communications board.

ADC 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.

Encoder Configuration Jumpers

E20-E23: Encoder Single Ended/Differential Select – PMAC has differential line receivers for each
encoder channel, but can accept either single-ended (one signal line per channel) or differential (two
signal lines, main and complementary, per channel). A jumper for each encoder permits customized
configurations, as described below.

Single-Ended Encoders

With the jumper for an encoder set for single-ended, the differential input lines for that encoder are tied to

2.5V; the single signal line for each channel is then compared to this reference as it changes between 0
and 5V.

When using single-ended TTL-level digital encoders, the differential line input should be left open, not
grounded or tied high; this is required for The PMAC differential line receivers to work properly.

Differential Encoders

Differential encoder signals can enhance noise immunity by providing common-mode noise rejection.
Modern design standards virtually mandate their use for industrial systems, especially in the presence of
PWM power amplifiers, which generate a great deal of electromagnetic interference.

Hardware Setup

PMAC2A PC104 Hardware Reference Manual

Connect pin 1 to 2 to tie differential line to +2.5V

• Tie to +2.5V when no connection

• Tie to +2.5V for single-ended encoders

Connect pin 2 to 3 to tie differential line to +5V

• Don’t care for differential line driver encoders

• Tie to +5V for complementary open-collector encoders (obsolete)

Hardware Setup 7

PMAC2A PC104 Hardware Reference Manual

Hardware Setup

8